Layer and Layer System, as well as Bipolar Plate, Fuel Cell and Electrolyzer

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This patent describes an improved coating (layer and layer system) for the metallic bipolar plates used in fuel cells and electrolyzers. The coating comprises compounds or solid solutions based on iridium (optionally with ruthenium) and at least one additional non-metallic element such as nitrogen, carbon, boron, fluorine, or hydrogen. The coating can be applied as a very thin layer (1–50 nm), optionally with supplemental sublayers containing elements like titanium, niobium, zirconium, hafnium, or tantalum. This novel coating enhances both the corrosion resistance and electrical conductivity of the bipolar plates, providing improved durability and performance in harsh environments compared to traditional materials like gold or titanium nitride.

Use CasesContent extracted from patent full text and abstract with AI.

• Bipolar plates in polymer electrolyte membrane (PEM) fuel cells for automotive or stationary power applications.
• Bipolar plates in electrolyzers for hydrogen production via water electrolysis.
• Electrochemical cells requiring long-term stability in harsh acidic or oxidizing environments.
• Current collectors in advanced energy conversion systems where high electrical conductivity and corrosion resistance are critical.
• Next-generation energy storage devices or redox flow batteries that benefit from corrosion-resistant, conductive metallic layers.

BenefitsContent extracted from patent full text and abstract with AI.

• Greatly enhanced corrosion resistance in both acidic and oxidizing environments, prolonging device lifetime.
• Lower electrical resistance, improving system efficiency and reducing energy losses.
• High durability and performance even at thin layer thicknesses, leading to savings in expensive noble metals.
• Self-healing properties due to formation of protective oxides under high load, maintaining protective function over time.
• Suitable for mass-produced, portable, and stationary energy systems, potentially reducing overall manufacturing costs.
• Improved barrier properties, such as resistance to hydrogen embrittlement in metallic substrates.
• Compatible with a range of manufacturing processes including PVD and ARC, facilitating industrial adoption.

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

The invention relates to a layer (3a), in particular for a bipolar plate (1) of a fuel cell or an electrolyser, wherein the layer (3a) consists of a homogeneous or heterogeneous solid metal solution or compound. According to the invention, the layer (3a) has either a first chemical element from the group of noble metals in the form of iridium, or a first chemical element from the group of noble metals in the form of iridium and a second chemical element from the group of noble metals in the form of ruthenium, as well as at least one further non-metal chemical element from the group comprising nitrogen, carbon, boron, fluorine, hydrogen. The invention also relates to a layer system (3), a bipolar plate (1) having a layer system (3) of this type, a fuel cell and an electrolyser.