Fuel Cell Separator Transfer Coating for Low Contact Resistance
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Solution Overview
Problem
The existing fuel cell separators exhibit high contact resistance between the separator and the power generation portion, which hinders the performance of the fuel cell.
Innovation Solution
A method for producing a fuel cell separator using a metal base with conductive carbon materials and particles dispersed in a thermosetting resin, applied as a conductive layer on the projections of the separator to reduce contact resistance, involving the formation of a thermal transfer sheet and thermal transfer of the conductive paint to the separator's surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional conductive layer is applied to the separator surface, then the separator provides basic conductivity, but the contact resistance between the separator and power generation portion remains high
Solution Approach 1:
The conductive paint is applied to a film in advance to create a thermal transfer sheet, which is then transferred to the separator surface through heating and pressurizing. This preliminary preparation allows for uniform conductive layer formation and reduces manufacturing complexity by separating the paint application and transfer steps.
Solution Approach 2:
The conductive paint contains conductive carbon materials and conductive particles dispersed in resin, which undergo parameter changes during thermal transfer. The heating process causes the resin to soften and the conductive materials to form a low-resistance pathway on the separator surface, achieving contact resistance below 10^-3 cm².
2Reliability
If the contact resistance is reduced to improve fuel cell performance, then the conductivity increases, but the manufacturing process becomes more complex
Solution Approach 1:
The conductive layer is formed as a composite material containing conductive carbon materials, conductive particles, and resin. This composite structure provides both the necessary conductivity for fuel cell performance and a manufacturable form through the thermal transfer process, achieving high conductivity without excessive structural complexity.
3Reliability
If a thick conductive layer is applied to ensure low contact resistance, then the conductivity improves, but the manufacturing precision and uniformity decrease
Solution Approach 1:
The conductive paint is applied to a flexible film to create a thin, uniform thermal transfer sheet. This film-based approach allows for precise control of the conductive layer thickness and uniform distribution of conductive materials, achieving both low contact resistance and high manufacturing precision through the thermal transfer process.
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 method significantly reduces contact resistance between the separator and the power generation portion, enhancing the fuel cell's performance by ensuring better conductivity and preventing ion elution.
Implementation Method 1
pressurizing the thermal transfer sheet against the base and heating the thermal transfer sheet with the thermal transfer sheet in contact with each of the top surfaces of the projections, thereby thermally transferring the conductive paint to the each of the top surfaces of the projections
Data Source
AI summary
A separator includes a base including projections. The base is made of a metal plate. The separator includes a conductive layer arranged on a top surface of each of the projections of the base. The conductive layer includes conductive carbon materials, conductive particles, and a thermosetting resin. The conductive carbon materials and the conductive particles are dispersed in the resin and are in contact with each other over an entirety of the conductive layer in a thickness direction of the conductive layer.