Separator Conductive Coating for Durable Electrochemical Cells

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Solution Overview

Problem

Existing electrochemical devices, such as fuel cells and electrolyzers, face challenges in durability and reliability due to decreased adhesion and void generation between layers in multilayer separators, which affects their performance and cost-effectiveness.

Innovation Solution

The electrochemical device incorporates a conductive layer with metal oxide and metal hydroxide on a metal substrate sheet, reducing the number of layers and enhancing adhesion, using chromium oxide and chromium hydroxide to improve conductivity and corrosion resistance, and employing stainless steel substrates like SUS316 or SUS316L for cost-effectiveness.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a multilayer separator structure is used to improve conductivity and corrosion resistance, then the functional performance is enhanced, but the adhesion between layers deteriorates and voids are generated

Engineering Contradiction:

ImprovedurabilityVSAvoidadhesion between layers

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent combines multiple functional layers (conductive layer and protective layer) into a single integrated coating on the separator. This merging approach eliminates the adhesion problems between separate layers while maintaining the desired conductivity and corrosion resistance properties through the combined functional design of the coating system.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs composite material structures within the coating layers, combining conductive materials with protective materials to achieve both electrical conductivity and corrosion resistance in a single integrated layer system, avoiding the need for multiple separate layers that would suffer from adhesion issues.

Inventive Principle:

Principle #40Composite materials

2Reliability

If multiple layers are stacked to achieve desired properties, then the functional performance improves, but the device complexity increases

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidnumber of layers

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the functions of multiple layers into a single integrated coating structure that provides both conductivity and corrosion protection simultaneously, thereby reducing the total number of layers while maintaining the desired reliability and functional performance.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The coating layers are designed to perform multiple functions simultaneously - providing electrical conductivity, corrosion resistance, and mechanical protection in a single integrated structure, eliminating the need for separate specialized layers for each function.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If conventional separator structures are used to maintain simplicity, then the device complexity is low, but the durability and reliability are insufficient

Engineering Contradiction:

Improveseparator structureVSAvoiddurability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent applies composite material coatings on the separator that provide enhanced durability and corrosion resistance while maintaining a relatively simple overall structure. The composite nature of the coating allows it to deliver multiple protective functions without requiring a complex multi-layer construction.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent modifies the chemical and physical parameters of the separator surface through coating application, changing properties such as surface composition, conductivity, and corrosion resistance without fundamentally altering the basic separator structure, thereby improving reliability while keeping the device complexity low.

Inventive Principle:

Principle #35Parameter changes

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

This configuration enhances the durability and reliability of the electrochemical device by reducing layer separation and void formation, leading to improved performance and lower production costs while maintaining corrosion resistance.

Implementation Method 1

a conductive layer disposed on the metal substrate sheet and containing a metal oxide and a metal hydroxide

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

containing a metal oxide and a metal hydroxide... improve conductivity and corrosion resistance

Methodology Applied

Scientific EffectPassivation:

Data Source

PatentUS12148935B2Electrochemical device

Publication Date: 2024.11.19 PANASONIC INTELLECTUAL PROPERTY MANAGEMENT CO LTD

AI summary

An electrochemical device includes an electrolyte membrane, an anode disposed on a first main surface of the electrolyte membrane, a cathode disposed on a second main surface of the electrolyte membrane, an anode separator disposed on the anode, and a cathode separator disposed on the cathode. At least one of the anode separator or the cathode separator includes a metal substrate sheet and a conductive layer disposed on the metal substrate sheet and containing a metal oxide and a metal hydroxide.