Fuel Cell Separator Edge Coating Adhesion Treatment
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Solution Overview
Problem
Fuel cell separators face corrosion issues at peripheral edge portions due to incomplete coating, leading to reduced adhesion and potential leaks, and existing solutions like precious metal coatings either fail to protect the seal portion or compromise adhesion.
Innovation Solution
A fuel cell separator with a metal substrate and film coating member where the peripheral edge portion of the open manifold is adhesion treated using methods like heat welding, high-frequency welding, or adhesives, employing materials such as resin or elastomers, and surface treatments like gold or chrome, with a thermo-compression bonding process for improved corrosion resistance and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a fluorocarbon resin coating layer is formed on the end surface of the manifold using spraying, then corrosion resistance is improved, but the peripheral edge portion remains uncoated and susceptible to corrosion
Solution Approach 1:
The patent applies preliminary action by forming a protrusion at the peripheral edge portion of the manifold opening before the spraying process. This protrusion structure ensures that the coating material can be applied more effectively to the edge area, preventing the incomplete coating problem that occurs with conventional spraying methods alone.
2Object-affected harmful factors
If a precious metal coating is applied to the metal separator substrate, then corrosion resistance is improved, but adhesion of the seal portion is reduced
Solution Approach 1:
The patent applies local quality by differentiating the treatment of different regions: the peripheral edge portion receives a protrusion structure with coating for corrosion protection, while the seal portion maintains metal-to-metal contact without additional coating, preserving adhesion strength where sealing is critical.
Solution Approach 2:
The patent segments the manifold surface into distinct functional zones: the peripheral edge portion with protrusion and coating for corrosion resistance, and the seal portion without coating for optimal adhesion, allowing each region to be optimized for its specific function.
3Object-affected harmful factors
If the seal portion is coated with precious metal to prevent corrosion, then corrosion resistance is improved, but adhesion between seal and substrate is compromised
Solution Approach 1:
The patent applies local quality by restricting the protrusion and coating structure specifically to the peripheral edge portion, deliberately excluding the seal portion from this treatment. This ensures the seal portion maintains its metal-to-metal adhesion while the peripheral edges gain enhanced corrosion protection.
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 provides enhanced corrosion resistance and adhesion between the film and substrate, preventing corrosion at the peripheral edge and ensuring reliable fuel cell performance without leaks, resulting in improved durability for fuel cell vehicles.
Implementation Method 1
a portion of the film coating member that corresponds to at least a peripheral edge portion of the open portion is adhesion treated
Implementation Method 2
adhesion treated by heat welding
Implementation Method 3
adhesion treated by high-frequency welding
Implementation Method 4
employing materials such as resin or elastomers, and surface treatments like gold or chrome, with a thermo-compression bonding process for improved corrosion resistance and adhesion
Data Source
AI summary
A fuel cell separator is provided with a separator substrate made of metal which has at least one open portion through which a fluid can pass provided in a predetermined position, and a film coating member that coats a predetermined area including the open portion of the separator substrate. A portion of the film coating member that corresponds to at least a peripheral edge portion of the open portion is adhesion treated.