Coating and Layer System, and Bipolar Plate, Fuel Cell and Electrolyser

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This invention presents a new type of protective coating, specifically designed for bipolar plates used in fuel cells and electrolysers. The coating is primarily made from iridium, optionally with a small addition of ruthenium, and includes minor amounts of non-metallic elements like carbon, nitrogen, or fluorine. This specialized coating, and corresponding layer system, drastically increases corrosion resistance, electrical conductivity, and durability of bipolar plates. It ensures reliable performance in harsh electrochemical environments and extends the operational lifetime of fuel cells and electrolysers while reducing costs compared to traditional materials like gold or platinum coatings.

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• Bipolar plates in polymer electrolyte membrane (PEM) fuel cells for vehicles and stationary power applications
• Electrolyser components for hydrogen generation systems, particularly for water electrolysis at high current densities
• Electrochemical reactors requiring stable and conductive metal substrates in aggressive chemical environments
• Galvanic cell and electrolyser electrode components needing enhanced corrosion resistance
• Micro fuel cells and compact energy converters for portable electronics

BenefitsContent extracted from patent full text and abstract with AI.

• Provides significantly improved corrosion resistance and operational stability even under aggressive chemical and high-voltage conditions, increasing device lifetime.
• Improves electrical conductivity comparable to gold, but at lower material costs and without the corrosion problems associated with gold coatings.
• Allows use of thinner, lightweight metallic substrates (like stainless steel or titanium), reducing both weight and size of fuel cells and electrolysers.
• Reduces the amount of expensive precious metals required compared to thick coatings or pure component use, lowering the overall manufacturing cost.
• Enhances the long-term durability and reliability of fuel cells and electrolysis devices, supporting operation durations of over 10 years or many thousands of operational hours.
• The layered design, including nonmetallic elements and refractory metals, provides physical self-healing properties and serves as a barrier against hydrogen embrittlement.

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Inventors & Applicants

Patent Abstract

The invention relates to a coating (3a), in particular for a bipolar plate (1) of a fuel cell or an electrolyser, the coating (3a) consisting of a homogeneous or heterogeneous solid metal solution. According to the invention, the coating (3a) comprises either a first chemical element from the group of precious metals in the form of iridium in a concentration of at least 99 atomic % or a first chemical element from the group of precious metals in the form of iridium and a second chemical element from the group of precious metals in the form of ruthenium, the first chemical element and the second chemical element being present overall in a concentration of at least 99 atomic %, and also at least one further non-metallic chemical element from the group comprising nitrogen, carbon, fluorine, wherein oxygen and/or hydrogen are still optionally present only in traces. The invention further relates to a layer system (3), a bipolar plate (1) having such a layer system (3), a fuel cell and an electrolyser.