Fuel cell separator material, fuel cell separator using same, and fuel cell stack

• US 9,123,920 B2
• Filed: 10/16/2009
• Issued: 09/01/2015
• Est. Priority Date: 11/28/2008
• Status: Active Grant

• Current Assignee: JX Nippon Mining & Metals Corporation (ENEOS Holdings, Inc.)
• Original Assignee: JX Nippon Mining & Metals Corporation (ENEOS Holdings, Inc.)
• Inventors: Shibuya, Yoshitaka
• Primary Examiner(s): D'Aniello, Nicholas P
• Application Number:
  US13/131,499
• Publication Number:
  US 20110262825A1
• Time in Patent Office: 2,146 Days
• Field of Search: 429/457
• US Class Current: 1/1
• CPC Class Codes: H01M 2008/1095 Fuel cells with polymeric electrolytes
• CPC Class Codes: H01M 8/0206 Metals or alloys
• CPC Class Codes: H01M 8/0215 Glass; Ceramic materials
• CPC Class Codes: H01M 8/0228 in the form of layered or coated products
• CPC Class Codes: H01M 8/1011 Direct alcohol fuel cells [DAFC], e.g. direct methanol fuel cells [DMFC]
• CPC Class Codes: Y02E 60/50 Fuel cells

Abstract

A fuel cell separator material, comprising an alloy layer 6 containing Au and a first component containing Al, Cr, Fe, Co, Ni, Cu, Mo, Sn or Bi, or an Au single layer 8 formed on a Ti base 2; an intermediate layer 2a containing Ti, O, the first component, and less than 20 mass % of Au arranged between the alloy layer or the Au single layer and the Ti base; wherein the alloy layer or the Au single layer has a region having a thickness of 1 nm or more from the uppermost to the lower layer and containing 50 mass % or more of Au, or a region having a thickness of 3 nm or more from the uppermost to the lower layer and containing Au in the range from 10-50 mass %, or the thickness of the Au single layer is 1 nm or more.

Claims

1. A fuel cell separator material, comprising an alloy layer containing Au and a first component containing at least one metal selected from a group consisting of Cr and Mo formed on a Ti base;

and an intermediate layer containing Ti, O, the first component, and less than 20 mass % of Au arranged between the alloy layer and the Ti base;

wherein the intermediate layer exists as a layer having a thickness of 1 nm or more containing 10 mass % or more of Ti and O, respectively, and 20 mass % or more of the first component, wherein the concentration of the first component of the intermediate layer is decreased toward the Ti base in the thickness direction and the concentration of Ti of the intermediate layer is increased toward the Ti base in the thickness direction;

wherein the alloy layer has a region having a thickness of 1 nm or more from the uppermost surface toward the lower layer and containing 50 mass % or more of Au, or a region having a thickness of 3 nm or more from the uppermost surface toward the lower layer and containing Au in the range from 10 mass % or more to less than 50 mass %; and

wherein a metal layer comprising the first component and having a thickness of 3 nm or less is formed between the alloy layer and the intermediate layer.

2. The fuel cell separator material according to claim 1, wherein the concentration of the Au in the alloy layer is increased from the bottom to the upper part of the layer.

3. The fuel cell separator material according to claim 1, wherein an Au single layer is formed on the surface of the alloy layer.

4. The fuel cell separator material according to claim 1, wherein the Ti base is formed by coating a Ti coating with a thickness of 10 nm or more on a material other than Ti.

5. A fuel cell separator material according to claim 1, for use in a polymer electrolyte fuel cell.

6. The fuel cell separator material according to claim 5, for use in a direct methanol polymer electrolyte fuel cell.

7. A fuel cell separator comprising the fuel cell separator material according to claim 1, wherein a reaction gas flow path and/or a reaction liquid flow path is press-formed on the Ti base, and then the alloy layer is formed.

8. A fuel cell separator comprising the fuel cell separator according to claim 1, wherein the alloy layer is formed on the Ti base, and then a reaction gas flow path and/or a reaction liquid flow path is press-formed.

9. A fuel cell stack, comprising the fuel cell separator material according to claim 1.

10. A fuel cell stack, comprising the fuel cell separator according to claim 7.

11. A fuel cell stack, comprising the fuel cell separator according to claim 8.