Titanium Gas Diffusion Layer Microporous Coating
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Solution Overview
Problem
The challenge lies in achieving both rigidity and gas diffusivity in a gas diffusion layer made of carbon, as adding a microporous layer increases electrical resistance when using titanium-based materials.
Innovation Solution
A method involving coating a titanium-based gas diffusion layer with a precursor containing electroconductive material, water-repellent resin, and polyethylene oxide, followed by heating in a non-oxidation atmosphere with low oxygen concentration to form a microporous layer, which suppresses the increase in electrical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a microporous layer is provided on a gas diffusion layer containing titanium using conventional methods, then the gas diffusion layer achieves rigidity, but electrical resistance increases markedly
Solution Approach 1:
The patent applies the inert atmosphere principle by conducting the heating process in a nitrogen atmosphere (or other inert gas atmosphere) with oxygen concentration controlled at 0.3% or less. This prevents oxidation of the titanium-based gas diffusion layer during microporous layer formation, thereby suppressing the marked increase in electrical resistance that would otherwise occur. The inert environment protects the electroconductive properties while still allowing the microporous layer to form and provide rigidity.
2Reliability
If a gas diffusion layer is made of carbon material, then it provides good electroconductive properties, but it is difficult to achieve both rigidity and gas diffusivity simultaneously
Solution Approach 1:
The patent applies the composite materials principle by using a titanium-based gas diffusion layer that combines titanium particles with a binder resin to create a composite structure. This composite approach allows the gas diffusion layer to achieve both rigidity (from the titanium framework) and maintained electroconductive properties, while also enabling effective microporous layer formation. The composite structure overcomes the limitations of pure carbon materials that struggle to balance rigidity and gas diffusivity.
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 approach effectively reduces the electrical resistance of the gas diffusion layer with a microporous layer, enhancing both rigidity and gas diffusivity compared to conventional methods.
Implementation Method 1
When removing the dispersant from the precursor by heating, the removal is commonly performed by decomposition of the dispersant into carbon dioxide and water
Implementation Method 2
heating the gas diffusion layer coated with the precursor in a non-oxidation atmosphere where an oxygen concentration is no more than 0.3% by volume to form a microporous layer
Data Source
AI summary
A manufacturing method of a gas diffusion layer with a microporous layer includes coating a gas diffusion layer containing titanium with a precursor containing an electroconductive material, a water-repellent resin, and a polyethylene oxide, and heating the gas diffusion layer coated with the precursor to form a microporous layer containing the electroconductive material and the water-repellent resin on a surface of the gas diffusion layer. The heating atmosphere is a non-oxidation atmosphere where an oxygen concentration is no more than 0.3% by volume.