Layer System, Bipolar Plate Comprising Such a Layer System, and Fuel Cell Produced Therewith

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The invention describes a multi-layer coating system for bipolar plates used in fuel cells and electrolyzers. The key innovation is a tin oxide-based top layer, in which metal oxides such as tantalum oxide, niobium oxide, titanium oxide, zirconium oxide, or hafnium oxide are homogenously dissolved. This special combination offers a coating that is both highly electrically conductive (≥ 10^2 S/cm) and corrosion-resistant. The invention also covers bipolar plates and fuel cells equipped with this coating, resulting in more durable and efficient energy conversion devices.

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• Proton Exchange Membrane (PEM) fuel cells for vehicles and stationary energy systems
• Electrolyzers used for hydrogen production via water electrolysis
• Metallic bipolar plates in portable or backup power systems
• Fuel cell stacks in transportation (e.g., buses, trucks, trains, ships)
• Stationary or industrial hydrogen generators
• Replacement or retrofitting of existing fuel cell or electrolyzer stack components for improved durability

BenefitsContent extracted from patent full text and abstract with AI.

• Greatly improved corrosion resistance of bipolar plates, extending the lifespan of fuel cells and electrolyzers
• High electrical conductivity of the coating ensures minimal power loss and increased efficiency
• Cost-effective solution due to compatibility with less expensive substrate materials (such as stainless steel)
• Enhanced long-term stability—reducing maintenance and replacement needs
• Flexible: suitable for both the anode and cathode sides of bipolar plates due to additional dopants (e.g., fluorine, nitrogen, or carbon)
• Potential for improved manufacturing scalability using PVD or CVD processes
• Customizable properties by adjusting dopants and layer configurations

Technical Classifications (CPCs)

Inventors & Applicants

Patent Abstract

The invention relates to a layer system (1) for coating a bipolar plate (2), comprising at least one cover layer (1a) made of tin oxide, wherein at least one metal oxide of the group comprising tantatalum oxide, niobium oxide, titanium oxide, zirconium oxide, and hafnium oxide is homogenously dissolved in the tin oxide, and the electric conductivity of the cover layer (1a) is greater than or equal to 102 S/cm. The invention additionally relates to a bipolar plate (2, 2') with an anode side and a cathode side, comprising a substrate (2a, 2a') and such a layer system (1), and to a fuel cell (10) or an electrolyzer comprising such a bipolar plate (2, 2').