Porous Metal Separator Surface Layer for Conductivity and Corrosion Resistance
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Solution Overview
Problem
Existing metal separators for fuel cells face challenges in achieving both excellent electrical conductivity and corrosion resistance, particularly due to issues with exposed porous bodies leading to corrosion resistance deficiencies.
Innovation Solution
A metal separator comprising a first base material with a porous body stacked on its surface, where the porous body has holes with surface-modified layers formed on the upper surface of the surface layer parts and inner surfaces of the holes, containing specific compositions and treated with surface-modified layers to enhance conductivity and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a porous body is attached to the metal separator to enhance flow channel function, then gas permeability and flow distribution are improved, but exposed parts of the porous body occur leading to reduced corrosion resistance
Solution Approach 1:
A surface-modified layer is introduced as an intermediary between the porous body and the corrosive environment. This layer acts as a protective barrier that prevents direct contact between the porous metal surface and corrosive agents, thereby maintaining corrosion resistance while preserving the flow channel enhancement benefits of the porous structure.
Solution Approach 2:
The metal separator is constructed as a composite structure combining the base metal separator material with an attached porous body, and further composite with a surface-modified layer. This multi-layer composite approach allows each layer to contribute its specific properties: structural integrity from the base material, flow enhancement from the porous body, and corrosion protection from the surface-modified layer.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution results in a metal separator with improved electrical conductivity and corrosion resistance, ensuring seamless electrochemical reactions and preventing rust formation.
Implementation Method 1
a surface-modified layer is formed, respectively, on an upper surface of the surface layer parts and an inner surface of the holes
Implementation Method 2
the surface-modified layer formed on the upper surface of the surface layer parts may contain chromium at 20 at% to 28 at% in a region from a surface exposed to the outside to a depth of 1.0 nm
Implementation Method 3
the surface-modified layer formed on the upper surface of the surface layer parts may contain iron at 15 at% to 25 at% in a region from a surface exposed to the outside to a depth of 1.0 nm
Implementation Method 4
flow channels that guide the flow of hydrogen, oxygen, and cooling water may be formed
Implementation Method 5
distribute and supply them uniformly over the entire surface of the membrane electrode assembly
Implementation Method 6
a metal separator that is excellent not only in electrical conductivity but also in corrosion resistance
Data Source
Figure 1~2
AI summary
The present application relates to a metal separator and a manufacturing method therefor, the metal separator comprising: a first base material; and a porous body laminated on the upper surface of the first base material, wherein the porous body has a plurality of holes and surface portions present between the plurality of holes, and the upper surfaces of the surface portions and the inner surfaces of the holes each have a surface-modified layer. According to the metal separator and the manufacturing method therefor of the present application, not only electrical conductivity but also corrosion resistance can be excellent.