Apparatus and method for manufacturing membrane-electrode assemblies for fuel cells

Abstract

The present invention provides an apparatus and a method for manufacturing a membrane-electrode assembly of a fuel cell. A manufacturing apparatus for a membrane-electrode assembly of a fuel cell includes an electrode membrane sheet unwinder for supplying an upper electrode membrane sheet and a lower electrode membrane sheet having upper and lower electrode membranes with an anode layer and a cathode layer along a predetermined transfer path, an electrolyte membrane sheet unwinder for supplying an electrolyte membrane sheet, a driving coupling roller having an engraved portion and a protruding portion, a driven coupling roller to be moved toward the driving coupling roller in a vertical direction, a membrane rewinder for winding up the recovered upper and lower electrode membranes, and a position alignment unit for aligning the positions of the anode layer and the cathode layer when switching the running directions of the upper and lower electrode membrane sheets and the upper and lower electrode membranes.

Description

[0001] Cross-references to related applications

[0002] This application claims priority and benefit to Korean Patent Application No. 10-2020-0046617, filed on April 17, 2020, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to systems for manufacturing components for fuel cell stacks. More specifically, this disclosure relates to apparatus and methods for manufacturing membrane electrode assemblies for fuel cells. Background Technology

[0004] The statements in this section provide only background information in connection with this disclosure and may not constitute prior art.

[0005] As is well known, fuel cells generate electricity through an electrochemical reaction between hydrogen and oxygen. Even without a separate charging process, fuel cells can continuously generate electricity after receiving chemical reactants from an external source.

[0006] Fuel cells can be formed by placing separators (or bipolar plates) on both sides of a membrane electrode assembly (MEA) between them. Multiple fuel cells can be arranged sequentially to form a fuel cell stack.

[0007] Here, an example of a membrane-electrode assembly (MEA) as a core component of a fuel cell is a three-layer structure. This three-layer structure includes an electrolytic membrane in which hydrogen ions are transferred, an anode catalyst electrode layer formed on one surface of the electrolytic membrane, and a cathode catalyst electrode layer formed on the other surface of the electrolytic membrane. Examples of methods for manufacturing the three-layer MEA assembly include direct coating and decal application.

[0008] In the case of the decal method, an electrode film coated with each catalyst electrode layer is deposited on two surfaces of an electrolyte membrane, the catalyst electrode layer is transferred to the two surfaces of the electrolyte membrane to be bonded, and then the electrode film is removed, thereby manufacturing a three-layer membrane-electrode assembly.

[0009] In other words, in the manufacturing process of membrane-electrode components using the decal method, the roller-shaped electrode membrane and the roller-shaped electrolyte membrane coated with each catalyst electrode layer are laminated (thermally compressed) by a high-temperature and high-pressure bonding roller, and the electrode membrane is removed to manufacture a three-layer membrane-electrode component.

[0010] As mentioned above, the decal method of using roll lamination to manufacture three-layer membrane-electrode assemblies may have advantages in mass production because it can increase manufacturing speed.

[0011] However, in the decal method using a roll lamination process, the two sides of the electrode film coated with each catalyst electrode layer are passed through the high-temperature high-pressure bonding rollers with the electrolyte film interposed therebetween, and the catalyst electrode layers and the electrolyte film are laminated in a direction in which they contact each other. We found that it is difficult to align the lamination positions of the cathode catalyst electrode layer and the anode catalyst electrode layer.

[0012] That is, the electrode film and the electrolyte film are continuously passed through the high-temperature high-pressure bonding rollers that are always pressed, and the catalyst electrode layers are laminated on both surfaces of the electrolyte film. In the roll lamination continuous process, we found that it is difficult to correctly align the lamination positions of the catalyst electrode layers due to a difference in the feeding speed of the electrode film.

[0013] In addition, we found that since the spacing between the catalyst electrode layers is not constant in the process of manufacturing the continuous pattern catalyst electrode layers by applying the catalyst slurry to the electrode film, it is difficult to align the lamination positions of the cathode catalyst electrode layer and the anode catalyst electrode layer.

[0014] The above information disclosed in the Background section is only for enhancing the understanding of the background of the present disclosure, and therefore, it can contain information that does not constitute the prior art that is already known in the art. SUMMARY

[0015] The present disclosure provides an apparatus and a method for manufacturing a membrane-electrode assembly for a fuel cell, which can align the transfer positions of the cathode layer and the anode layer on both sides of the electrolyte film in a simple configuration.

[0016] According to an exemplary form of the present disclosure, a manufacturing apparatus for a membrane-electrode assembly of a fuel cell can include: an electrode membrane sheet unwinder configured to supply an upper electrode membrane sheet and a lower electrode membrane sheet each having an upper electrode membrane and a lower electrode membrane, along a predetermined conveying path, wherein the upper electrode membrane and the lower electrode membrane each include an anode layer and a cathode layer continuously applied at a predetermined interval; an electrolyte membrane sheet unwinder configured to supply an electrolyte membrane sheet between the upper electrode membrane sheet and the lower electrode membrane sheet along the conveying path; a driving bonding roller rotatably driven in one direction on the conveying path and having an engraved portion and a protruding portion continuously formed on an outer circumferential surface; a driven bonding roller configured to move toward the driving bonding roller in a vertical direction with the electrolyte membrane sheet and the upper electrode membrane sheet and the lower electrode membrane sheet interposed therebetween, and to be rotationally driven in the other direction; a membrane rewinder installed on the upper side and the lower side of the conveying path from the rear of the driving bonding roller and the driven bonding roller, and winding the upper electrode membrane and the lower electrode membrane, respectively; and a position alignment unit provided on the side of the electrode membrane sheet unwinder and the membrane rewinder, respectively, and aligning the positions of the anode layer and the cathode layer when switching the running directions of the upper electrode membrane sheet and the lower electrode membrane sheet, and the upper electrode membrane and the lower electrode membrane.

[0017] The manufacturing apparatus can further include: a separation blade installed on the upper side and the lower side of the conveying path from the membrane rewinder side, respectively, and separating the upper electrode membrane and the anode layer, and the lower electrode membrane and the cathode layer, respectively; and an electrode layer rewinder winding the membrane-electrode assembly, wherein the anode layer and the cathode layer are transferred to the upper surface and the lower surface of the electrolyte membrane sheet, respectively, by the driving bonding roller and the driven bonding roller at the end of the conveying path.

[0018] In another form of the disclosure, a manufacturing apparatus for a membrane-electrode assembly of a fuel cell can include: an electrode film unwinder for supplying an upper electrode film and a lower electrode film having an anode layer and a cathode layer continuously applied to each of the upper electrode film and the lower electrode film at a predetermined interval along a predetermined transfer path; an electrolyte film unwinder for supplying an electrolyte film between the upper electrode film and the lower electrode film along the transfer path; a driving coupling roller rotatably driven in one direction by a first driver on the transfer path and having an engraved portion and a protruding portion continuously formed on an outer peripheral surface; a driven coupling roller mounted to be movable toward the driving coupling roller in a vertical direction by a second driver and in close contact with the driving coupling roller with the electrolyte film and the upper electrode film and the lower electrode film interposed therebetween, and rotated in the other direction; a film rewinder mounted on the upper side and the lower side of the transfer path from the rear of the driving coupling roller and the driven coupling roller and winding the upper electrode film and the lower electrode film, respectively; a first turning roller set installed in an electrode film supply path on the electrode film unwinder side and selectively switching driving directions of the upper electrode film and the lower electrode film along the electrode film supply path by a third driver and a fourth driver; a second turning roller set installed in an electrode film recovery path on the film rewinder side and selectively switching driving directions of the upper electrode film and the lower electrode film along the electrode film recovery path by a fifth driver and a sixth driver; a first position sensor installed in front of the driving coupling roller and the driven coupling roller and detecting edge positions of the anode layer and the cathode layer; a second position sensor installed on the driving coupling roller side and detecting an edge position of the protruding portion; and a controller analyzing detection signals provided from the first position sensor and the second position sensor and controlling driving of the first driver to the sixth driver according to the edge position of the protruding portion and the edge positions of the anode layer and the cathode layer.

[0019] The manufacturing apparatus can further include: separation blades respectively mounted on the upper side and the lower side of the transfer path from the film rewinder side and respectively separating the upper electrode film and the cathode layer and the lower electrode film and the anode layer; an electrode layer rewinder winding the membrane-electrode assembly, in which the anode layer and the cathode layer are transferred to upper and lower surfaces of the electrolyte film, respectively, by the driving coupling roller and the driven coupling roller at the end of the transfer path; and a buffer provided between the separation blades and the electrode layer rewinder and compensating for a reverse running length of the electrolyte film.

[0020] The first position sensor and the second position sensor can include: vision sensors respectively simultaneously photographing edges of the anode layer and the cathode layer and an edge of the protruding portion and outputting vision data to the controller; and the first driver can include a servo motor and the second driver can include a driving cylinder.

[0021] The first turning roller set can include a first driven roller disposed to be freely rotatable and to contact the upper and lower electrode films running along the supply path, and a first driving roller mounted to be reciprocally movable in a direction away from or closer to the first driven roller by a third driver and rotatably mounted in a direction opposite to a rotation direction of the first driven roller by a fourth driver.

[0022] The third driver can include a driving cylinder, and the fourth driver can include a servo motor.

[0023] The second turning roller set can include a second driven roller disposed to be freely rotatable and to contact the upper and lower electrode films running along the recovery path, and a second driving roller mounted to be reciprocally movable in a direction away from or toward the second driven roller by a fifth driver and rotatably mounted in a direction opposite to a rotation direction of the second driven roller by a sixth driver.

[0024] The fifth driver can include a driving cylinder, and the sixth driver can include a servo motor.

[0025] The controller can include a signal processing unit configured to analyze a detection signal of the first position sensor and detect edge position values of the anode and cathode layers and match with the protrusion, and the signal processing unit is configured to analyze a detection signal of the second position sensor and detect an edge position value of the protrusion to match with the edge position values of the anode and cathode layers, an arithmetic unit configured to calculate a position difference value between the edge position values of the anode and cathode layers and the edge position value of the protrusion, and a signal application unit configured to apply a control signal to the first to sixth drivers according to the position difference value.

[0026] The buffer portion can include a pair of guide rollers configured to guide the conveyance of the electrolyte film in both directions along the conveyance path, and a buffer roller configured to move in a vertical direction between the guide rollers and control a running length of the electrolyte film by a seventh driver.

[0027] A manufacturing method of a membrane-electrode assembly for a fuel cell using an apparatus for manufacturing a membrane-electrode assembly for a fuel cell, the manufacturing method according to an exemplary form of the present disclosure can include: (a) supplying an electrolyte membrane sheet to a predetermined transfer path through an electrolyte membrane sheet unwinder; (b) supplying an upper electrode membrane sheet and a lower electrode membrane sheet to upper and lower sides of the electrolyte membrane sheet along the transfer path through an electrode membrane sheet unwinder, the upper and lower electrode membrane sheets having an anode layer and a cathode layer applied to each of the upper and lower electrode membranes at a predetermined interval; (c) passing the electrolyte membrane sheet and the upper and lower electrode membrane sheets between a driving bonding roller and a driven bonding roller, and bonding the anode layer of the upper electrode membrane sheet and the cathode layer of the lower electrode membrane sheet to upper and lower surfaces of the electrolyte membrane sheet, respectively; (d) recovering the upper electrode membrane of the upper electrode membrane sheet and the lower electrode membrane of the lower electrode membrane sheet from rear sides of the driving and driven bonding rollers, respectively, through a membrane rewinder; (e) detecting edge positions of the anode and cathode layers at front sides of the driving and driven bonding rollers through a first position sensor, and detecting an edge position of a protrusion of the driving bonding roller through a second sensor; and (f) switching running directions of the upper and lower electrode membrane sheets in the electrode membrane sheet unwinder and the upper and lower electrode membranes in the membrane rewinder, respectively, through first and second deflection roller sets according to detection signals of the first and second position sensors, and aligning transfer positions of the anode and cathode layers.

[0028] During (a)-(d), the driven bonding roller can be lifted, the driving bonding roller can be driven and rotated, and a first driving roller of the first deflection roller set can be separated from a first driven roller, and a second driving roller of the second deflection roller set can be in close contact with a second driven roller, and can drive the second driving roller in a recovery direction of the upper and lower electrode membranes.

[0029] During (a)-(d), the separation blades can separate the upper and lower electrode membranes and the anode layer of the upper electrode membrane sheet and the cathode layer of the lower electrode membrane sheet, respectively, and in a case where the buffer rollers of the buffer portion are lowered, a membrane-electrode assembly having the anode and cathode layers transferred to the upper and lower surfaces of the electrolyte membrane sheet can be transferred in a positive direction and wound to the electrode layer rewinder.

[0030] During (f), by analyzing the detection signal of the first position sensor through the controller, an edge position value of the anode and cathode layers to be matched with an edge position value of the protrusion can be detected. By analyzing the detection signal of the second position sensor through the controller, an edge position value of the protrusion to be matched with edges of the anode and cathode layers can be detected, and the controller can calculate a position difference value between the edge position value of the anode and cathode layers and the edge position value of the protrusion.

[0031] When the controller determines that the position difference satisfies the predetermined reference value, the processes of (a)-(d) can be performed.

[0032] When the controller determines that the position difference does not satisfy the predetermined reference value, the processes of (a)-(d) can be performed as an electrode position alignment mode, the previous anode layer and cathode layer can be bonded to the upper surface and the lower surface of the electrolyte membrane sheet by driving the driving bonding roller and the driven bonding roller. When the blank portion between the anode layer and the cathode layer of the detection target is located at the edge of the protrusion of the driving bonding roller, the conveyance of the upper electrode membrane sheet, the lower electrode membrane sheet, and the electrolyte membrane sheet can be stopped.

[0033] In the electrode position alignment mode, after the conveyance of the electrolyte membrane sheet is stopped, the first driving roller of the first deflection roller set can be separated from the first driven roller, the second driving roller of the second deflection roller set can be in close contact with the second driven roller, and the second driving roller can be driven and rotated in the recovery direction of the upper electrode membrane and the lower electrode membrane. The upper electrode membrane sheet and the lower electrode membrane sheet can be conveyed in the positive direction along the conveyance path by the electrode membrane sheet unwinder and the membrane rewinder, and the anode layer and the cathode layer as the detection target can be conveyed to the separation blade, and the upper electrode membrane and the lower electrode membrane can be separated from the anode layer and the cathode layer bonded to the electrolyte membrane sheet by the separation blade.

[0034] In the electrode position alignment mode, after the upper electrode membrane and the lower electrode membrane are separated, the first driving roller of the first deflection roller set can be in close contact with the first driven roller, the first driving roller can be rotated in the supply opposite direction of the upper electrode membrane sheet and the lower electrode membrane sheet, and can drive the upper electrode membrane sheet and the lower electrode membrane sheet in the supply opposite direction, the second driving roller of the second deflection roller set can be separated from the second driven roller, and can drive the upper electrode membrane and the lower electrode membrane in the opposite direction, and the buffer roller of the buffer portion can be moved in the upward direction, and the electrolyte membrane sheet having the anode layer and the cathode layer transferred to the upper surface and the lower surface can be conveyed in the reverse direction.

[0035] In the electrode position alignment mode, the anode layer and the cathode layer of the detection target can be located in front of the driving bonding roller and the driven bonding roller, the anode layer and the cathode layer bonded to the electrolyte membrane sheet can be located between the driving bonding roller and the driven bonding roller, the anode layer and the cathode layer of the detection target can be aligned at the predetermined matching position, the driving bonding roller can be driven and rotated in the reverse direction corresponding to the section of the blank portion, and the protrusion can be aligned at the predetermined matching position, and the positions of the anode layer and the cathode layer of the detection target and the protrusion can be re-detected by the first position sensor and the second position sensor, and a detection signal can be output to the controller.

[0036] The exemplary forms of the present disclosure automatically align the transfer positions of the anode layer and the cathode layer and manufacture a membrane-electrode assembly, so that the transfer uniformity of the anode layer and the cathode layer can be improved, and the quality of the membrane-electrode assembly can be improved.

[0037] In addition, the effects obtained or predicted by the exemplary forms of the present disclosure will be directly or implicitly disclosed in the detailed description of the exemplary forms of the present disclosure. That is, various effects predicted according to the exemplary forms of the present disclosure will be disclosed in the detailed description to be described later.

[0038] Other application fields will become apparent from the description provided herein. It should be understood that the description and specific examples are intended to be illustrative only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF DRAWINGS

[0039] In order to make the present disclosure easily understandable, various forms thereof will now be described by way of examples, and with reference to the accompanying drawings, in which:

[0040] Figure 1 is a view showing a manufacturing apparatus for a membrane-electrode assembly for a fuel cell according to an exemplary form of the present disclosure;

[0041] Figure 2 is a view showing a first set of turning rollers applied to an apparatus for manufacturing a membrane-electrode assembly for a fuel cell according to an exemplary form of the present disclosure;

[0042] Figure 3 is a view showing a second set of turning rollers applied to an apparatus for manufacturing a membrane-electrode assembly for a fuel cell according to an exemplary form of the present disclosure;

[0043] Figure 4 is a flowchart showing a method for manufacturing a membrane-electrode assembly for a fuel cell according to an exemplary form of the present disclosure; and

[0044] Figures 5 to 10 is a view showing the operation of an apparatus for manufacturing a membrane-electrode assembly according to an exemplary form of the present disclosure and a manufacturing method for manufacturing a membrane-electrode assembly for a fuel cell using the apparatus.

[0045] The accompanying drawings described herein are for illustrative purposes only and are not intended to limit the scope of the present disclosure in any way.

[0046] <LEGEND OF REFERENCE NUMERALS>

[0047] 1: Membrane-electrode assembly

[0048] 2: Upper electrode membrane sheet

[0049] 3: Electrolyte membrane 4: Lower electrode membrane sheet

[0050] 5: anode layer 5a, 7a: blank portion

[0051] 6: upper electrode film 7: cathode layer

[0052] 8: lower electrode film 9: electrolyte film sheet

[0053] 10: electrode film sheet unwinder

[0054] 20: electrolyte film sheet unwinder

[0055] 30: drive bonding roller 31: first driver

[0056] 33, 124a, 136a: servo motor 35: engraved portion

[0057] 37: embossing portion 40: driven bonding roller

[0058] 41: second driver 43, 123a, 135a: drive cylinder

[0059] 50: separation blade 60: film rewinder

[0060] 70: electrode layer rewinder 100: manufacturing apparatus

[0061] 110: position alignment unit 120: first deflection roller set

[0062] 121: first driven roller 122: first drive roller

[0063] 123: third driver 124: fourth driver

[0064] 130: second deflection roller set 131: second driven roller

[0065] 132: second drive roller 135: fifth driver

[0066] 136: sixth driver 140: buffer portion

[0067] 141: guide roller 143: buffer roller

[0068] 147: seventh driver 150: first position sensor

[0069] 151, 161: vision sensor 160: second position sensor

[0070] 170: controller 171: signal processing unit

[0071] 173: arithmetic unit 175: signal application unit DETAILED DESCRIPTION

[0072] The disclosure will be described more fully hereinafter with reference to the accompanying drawings, in which exemplary forms thereof are shown. As those skilled in the art will understand, the described forms can be modified in various different ways, all without departing from the spirit or scope of the present disclosure.

[0073] In order to clearly illustrate the disclosure, portions that are irrelevant to the description have been omitted, and throughout the specification, the same or similar components are denoted by the same reference numerals.

[0074] For ease of explanation, the sizes and thicknesses of the respective components shown in the drawings are arbitrarily shown. Thus, the disclosure is not necessarily limited to the drawings, and the thicknesses can be enlarged accordingly.

[0075] In the following detailed description, the names of components are classified as first, second, etc. in order to distinguish the components from each other in the same relationship, and are not necessarily limited to the order in the following description.

[0076] In addition, unless explicitly described to the contrary, the words "comprise" and variations such as "comprises" will be understood to imply the inclusion of stated elements but not the exclusion of any other elements.

[0077] In addition, the terms "unit", "device", "part", and "member" described in the specification indicate a unit of a comprehensive constituent element for performing at least one function or operation.

[0078] Figure 1 is a view showing a manufacturing apparatus for a membrane-electrode assembly for a fuel cell according to an exemplary form of the present disclosure.

[0079] Referring to Figure 1 The apparatus 100 for manufacturing a membrane-electrode assembly for a fuel cell can be applied to an automated system for automatically and continuously manufacturing components of a unit fuel cell constituting a fuel cell stack.

[0080] For example, the apparatus 100 can be applied to manufacture a membrane-electrode assembly 1 including an electrolyte membrane 3 to which an anode layer 5 and a cathode layer 7 are bonded to both surfaces thereof.

[0081] The anode layer 5 is bonded to the upper surface of the electrolyte membrane 3, and the cathode layer 7 is bonded to the lower surface of the electrolyte membrane 3 with a predetermined gap, to manufacture the membrane-electrode assembly 1.

[0082] Meanwhile, the apparatus 100 for manufacturing a membrane-electrode assembly for a fuel cell can automatically and continuously manufacture the membrane-electrode assembly 1 as a roll-to-roll system.

[0083] A roll-to-roll method refers to any process of applying a coating, printing, or performing other processes, which starts with a roll of flexible material and rewinds after the process to create an output roll.

[0084] The device 100 of the roll-to-roll type has a structure in which the anode layer 5 is transferred to the upper surface of the electrolyte membrane 3 and the cathode layer 7 is transferred to the lower surface of the electrolyte membrane 3 by a roll lamination method and a decal method, and a membrane-electrode assembly 1 having a three-layer structure can be manufactured.

[0085] In addition, the device 100 includes a structure in which the membrane-electrode assembly 1 manufactured as described above is wound in a roll shape. Also, although not shown in the drawings, the membrane-electrode assembly 1 wound in a roll shape is unwound as described above, and the membrane-electrode assembly 1 is cut into units including the anode layer 5 and the cathode layer 7, and a membrane-electrode as a final fuel cell component assembly can be manufactured.

[0086] The device 100 for manufacturing a membrane-electrode assembly for a fuel cell as described above includes an electrode membrane unwinder 10, an electrolyte membrane unwinder 20, a driving combination roller 30, a driven combination roller 40, a separation blade 50, a membrane rewinder 60, and an electrode layer rewinder 70.

[0087] Each of these components and other components that will be described later can be configured in a main frame 200 of a roll-to-roll feeding facility. The main frame 200 supports each component, and can be composed of one frame or frames divided into two or more frames.

[0088] The main frame 200 can include various additional components such as a bracket, a bar, a rod, a plate, a housing, a casing, a block, etc. for supporting the components of the device 100.

[0089] However, since the above-described various sub-elements are provided for mounting the components of the device 100 to be described later in the main frame 200, the frame 200 is a collective term.

[0090] Hereinafter, based on the mounting position of the constituent elements, the upper, the upper end, the upper surface, and the upper portion are defined as the upper portion, and the lower, the lower end, the lower surface, and the lower portion are defined as the lower portion.

[0091] The electrode membrane unwinder 10 supplies the first electrode membrane 2 wound in a roll form and the second electrode membrane 4 wound in a roll form along predetermined conveying paths, respectively.

[0092] For better understanding, the first electrode membrane 2 mounted in the upper portion is referred to as an upper electrode membrane 2, and the second electrode membrane 4 is referred to as a lower electrode membrane 4. However, the mounting positions of the first electrode membrane 2 and the second electrode membrane 4 are not limited thereto.

[0093] Based on the drawing, the anode layer 5 is applied on the lower surface of the upper electrode film 6 of the upper electrode sheet 2 at predetermined intervals. Based on the drawing, the cathode layer 7 is applied on the upper surface of the lower electrode film 8 of the lower electrode sheet 4 at predetermined intervals. The intervals corresponding to the intervals between the anode layer 5 and the cathode layer 7 can be defined as the blank portions 5a, 7a.

[0094] The electrode sheet unwinding machine 10 is rotatably installed on the main frame 200 of the roll-to-roll feeding facility. The electrode sheet unwinding machine 10 can supply the upper electrode film 6 and the lower electrode film 8 along the conveyance path.

[0095] The electrolyte sheet unwinding machine 20 is used to supply the electrolyte film 9 wound in a roll form between the anode layer 5 of the upper electrode sheet 2 and the cathode layer 7 of the lower electrode sheet 4 along the conveyance path.

[0096] The electrolyte sheet unwinding machine 20 is rotatably installed on the main frame 200 of the roll-to-roll feeding facility.

[0097] The driving coupling roller 30 is rotatably installed on the upper side of the conveyance path of the electrolyte film 9 and the upper electrode sheet 2 and the lower electrode sheet 4 in one direction (for example, the counterclockwise direction of the drawing) by the first driver 31.

[0098] The driving coupling roller 30 is rotatably installed on the main frame 200 of the roll-to-roll feeding facility. The driving coupling roller 30 is not limited to rotation in only one direction, but can be rotated in two directions.

[0099] The first driver 31 applies a driving force to rotate the driving coupling roller 30, and is installed in the main frame 200 of the roll-to-roll feeding facility. For example, the first driver 31 can include a known technology servo motor 33 capable of servo-controlling the rotation direction and speed.

[0100] In the driving coupling roller 30, the engraved portions 35 and the protruding portions 37 are continuously formed along the outer periphery on the outer peripheral surface. The engraved portions 35 are formed at predetermined intervals along the outer periphery on the outer peripheral surface of the driving coupling roller 30, and the protruding portions 37 are formed between the engraved portions 35.

[0101] The engraved portions 35 are formed in sections corresponding to the intervals between the cathode layer 7 in the lower electrode sheet 4, and the protruding portions 37 are formed in sections corresponding to the cathode layer 7.

[0102] That is, the engraved portions 35 are portions in which the anode layer 5 of the upper electrode sheet 2 is not compressed at intervals corresponding to the intervals between the cathode layer 7. And the protruding portions 37 are portions in which the anode layer 5 of the upper electrode sheet 2 is compressed in sections corresponding to the cathode layer 7.

[0103] The driven nip roller 40 is installed to be able to reciprocate in the vertical direction from the lower side of the driving nip roller 30 by the second driver 41. The driven nip roller 40 is installed on the main frame 200 of the roll-to-roll feeding facility to be able to reciprocate in the vertical direction.

[0104] The driven nip roller 40 is in close contact with the driving nip roller 30 with the electrolyte membrane 9 and the upper electrode membrane 2 and the lower electrode membrane 4 interposed therebetween, and can be driven in the other direction (for example, the clockwise direction based on the figure) by the driving rotation of the driving nip roller 30. The driven nip roller 40 is rotatably installed on the main frame 200 of the roll-to-roll feeding facility. In the specification and claims, "close contact" means that the driven nip roller moves toward the driving nip roller to be conveyed.

[0105] The second driver 41 applies a driving force to the driven nip roller 40 so that the driven nip roller 40 reciprocates in the vertical direction, and is installed on the main frame 200 of the roll-to-roll feeding facility.

[0106] For example, the second driver 41 can include a driving cylinder 43 of a known technology that provides an operating force in the vertical direction to the driven nip roller 40. The driving cylinder 43 runs forward and backward along the vertical direction with a predetermined stroke, and makes the driven nip roller 40 reciprocate in the vertical direction.

[0107] The electrolyte membrane 9 and the upper electrode membrane 2 and the lower electrode membrane 4 passing between the driving nip roller 30 and the driven nip roller 40 and being pressed can transfer the anode layer 5 of the upper electrode membrane 6 and the cathode layer 7 of the lower electrode membrane 8 to the upper surface and the lower surface of the electrolyte membrane 9 by a roll lamination and a decal method.

[0108] At the rear side of the driving nip roller 30 and the driven nip roller 40, a separation blade 50 separates the anode layer 5 from the upper electrode membrane 6 of the upper electrode membrane 2 and separates the cathode layer 7 from the lower electrode membrane 8 of the lower electrode membrane 4.

[0109] The separation blade 50 is provided as a delamination blade, and is installed on the upper side and the lower side of the transfer path at the rear side of the driving path roller 30 and the driven path roller 40, respectively.

[0110] A film rewinder 60 is installed at the rear side of the driving nip roller 30 and the driven nip roller 40 to recover the upper electrode membrane 6 and the lower electrode membrane 8 separated by the separation blade 50.

[0111] The film rewinder 60 is installed on the upper side and the lower side of the transfer path from the separation blade 50 to wind the recovered upper electrode membrane 6 and lower electrode membrane 8. The film rewinder 60 is rotatably installed on the main frame 200 of the roll-to-roll feeding facility.

[0112] The anode layer 5 and the cathode layer 7 are transferred to the upper and lower surfaces of the electrolyte membrane 9 by driving the driving bonding roller 30 and the driven bonding roller 40, respectively, to form the membrane-electrode assembly 1, and the membrane-electrode assembly 1 is recovered at the end of the transfer path. The electrode layer rewinder 70 recovering the membrane-electrode assembly 1 is rotatably installed on the main frame 200 of the roll-to-roll feeding facility.

[0113] According to the above-described apparatus 100 for manufacturing a membrane-electrode assembly for a fuel cell, the electrolyte membrane 9 is supplied to a predetermined transfer path by the electrolyte membrane unwinder 20.

[0114] The upper and lower electrode membranes 2 and 4 wound in a roll form are supplied by the electrode membrane unwinders 10, respectively, and the electrolyte membrane 9 interposed therebetween is supplied through the transfer path.

[0115] Here, the upper electrode membrane 2 is located on the upper side of the electrolyte because it is located on the lower side of the electrolyte membrane 9, but is not limited thereto. That is, the opposite configuration is also possible. The anode layer 5 is continuously applied on the lower surface of the upper electrode membrane 6 of the upper electrode membrane 2 at a predetermined interval, and the cathode layer 7 is continuously applied on the upper surface of the lower electrode membrane 8 of the lower electrode membrane 4 at a predetermined interval.

[0116] In this process, the driving bonding roller 30 is rotated in the counterclockwise direction at a predetermined rotational speed by the first driver 31, and the driven bonding roller 40 is moved in the upward direction by the second driver 41.

[0117] In this state, the upper and lower electrode membranes 2 and 4 with the electrolyte membrane 9 interposed therebetween enter between the driving bonding roller 30 and the driven bonding roller 40.

[0118] Then, as the driving bonding roller 30 rotates in the counterclockwise direction, the driven bonding roller 40 is passively rotated and comes into close contact with the driving bonding roller 30 in a state in which the electrolyte membrane 9 and the upper and lower electrode membranes 2 and 4 are interposed therebetween.

[0119] Therefore, as the driving bonding roller 30 and the driven bonding roller 40 press the electrolyte membrane 9 and the upper and lower electrode membranes 2 and 4, the anode layer 5 of the upper electrode membrane 2 is attached to the upper surface of the electrolyte membrane 9, and the cathode layer 7 of the lower electrode membrane 4 is attached to the lower surface of the electrolyte membrane 9.

[0120] The anode layer 5 of the upper electrode membrane 2 and the cathode layer 7 of the lower electrode membrane 4 are transferred to the upper and lower surfaces of the electrolyte membrane 9, respectively, by the driving bonding roller 30 and the driven bonding roller 40 through a roll lamination and decal method. Therefore, the anode layer 5 and the cathode layer 7 are bonded to the upper and lower surfaces of the electrolyte membrane 9, respectively.

[0121] The engraved portion 35 of the driving nip roller 30 does not compress the anode layer 5 of the upper electrode film 2 with a gap corresponding to the gap between the cathode layer 7, and the protruding portion 37 compresses the anode layer 5 of the upper electrode film 2 with a section corresponding to the cathode layer 7 and transfers it to the upper surface of the electrolyte film 9.

[0122] In this state, the upper electrode film 6 and the lower electrode film 8 are separated from the upper electrode film sheet 2 and the lower electrode film sheet 4 by the separation blade 50 at the rear side of the driving nip roller 30 and the driven nip roller 40, respectively. The upper electrode film 6 and the lower electrode film 8 separated as described above are recovered by being wound by the film rewinder 60 through the recovery path.

[0123] Also, the membrane-electrode assembly 1 formed by joining the anode layer 5 and the cathode layer 7 to the upper surface and the lower surface of the electrolyte film 9 by the driving nip roller 30 and the driven nip roller 40, respectively, is wound on the electrode layer rewinder 70 at the end of the transfer path.

[0124] Meanwhile, due to the difference in the feeding speed between the upper electrode film sheet 2 and the lower electrode film sheet 4 transferred along the transfer path and the distribution of the gap (interval) between the anode layer 5 and the cathode layer 7 of the upper electrode film 6 and the lower electrode film 8 applied to the upper electrode film sheet 2 and the lower electrode film sheet 4, the device 100 for manufacturing a membrane-electrode assembly for a fuel cell can have difficulty in accurately matching the transfer positions of the anode layer 5 and the cathode layer 7 with respect to the electrolyte film 9.

[0125] In an exemplary form of the present disclosure, there is provided a device 100 for manufacturing a membrane-electrode assembly for a fuel cell, which is capable of automatically aligning the transfer positions of the anode layer 5 and the cathode layer 7 on the upper surface and the lower surface of the electrolyte film 9 with a simple configuration.

[0126] The fuel cell membrane-electrode assembly manufacturing device 100 further includes a position alignment unit 110, a buffer portion 140, a first position sensor 150, a second position sensor 160, and a controller 170.

[0127] The position alignment unit 110 can align the positions of the anode layer 5 and the cathode layer 7 when switching the driving directions of the upper electrode film sheet 2 and the lower electrode film sheet 4 and the upper electrode film 6 and the lower electrode film 8. The position alignment unit 110 is disposed in the vicinity of the electrode film sheet unwinder 10 and the film rewinder 60, respectively.

[0128] Hereinafter, when the positions of the anode layer 5 and the cathode layer 7 to be joined to the electrolyte film 9 are aligned (matched) with each other, this is referred to as matching, and the state in which they are not aligned with each other is referred to as mismatching.

[0129] That is, the position alignment unit 110 is a configuration for correcting (aligning) the positions of the anode layer 5 and the cathode layer 7 to matching positions when the positions of the anode layer 5 and the cathode layer 7 in the upper electrode membrane 2 and the lower electrode membrane 4 conveyed along the conveying path are mismatched positions.

[0130] The position alignment unit 110 includes a first deflection roller set 120 and a second deflection roller set 130.

[0131] The first deflection roller set 120 is installed on the supply path to supply the upper electrode membrane 2 and the lower electrode membrane 4 from the electrode membrane unwinder 10 to the conveying path.

[0132] Figure 2 is a view showing the first deflection roller set applied to the apparatus for manufacturing a membrane-electrode assembly for a fuel cell according to an exemplary form of the present disclosure.

[0133] Referring to Figure 1 and Figure 2 , the first deflection roller set 120 can selectively switch the driving direction of the upper electrode membrane 2 and the lower electrode membrane 4 along the supply path by the third driver 123 and the fourth driver 124.

[0134] The first deflection roller set 120 includes a first driven roller 121 and a first driving roller 122. The first driven roller 121 and the first driving roller 122 are rotatably installed on the main frame 200 of the roll-to-roll feeding facility. The first driven roller 121 contacts the upper electrode membrane 2 and the lower electrode membrane 4 running along the supply path and can freely (passively) rotate.

[0135] The first driving roller 122 is disposed so as to be able to reciprocate in a direction moving away from or toward the first driven roller 121 by the third driver 123. The first driving roller 122 is disposed to be rotated in a direction opposite to the rotation direction of the first driving roller 122 by the fourth driver 124. Also, the first driving roller 122 is disposed to be rotated by the fourth driver 124 to drive in opposite directions of the supply of the upper electrode membrane 2 and the lower electrode membrane 4.

[0136] The first driving roller 122 can be moved in a direction away from the first driven roller 121 by the third driver 123. In this case, the first driving roller 122 is not provided with a driving force by the fourth driver 124, and the first driven roller 121 contacts the upper electrode membrane 2 and the lower electrode membrane 4 and rotates in the direction of movement of the upper electrode membrane 2 and the lower electrode membrane 4.

[0137] In addition, the first driving roller 122 can be moved in a direction closer to the first driven roller 121 by the third driver 123. In this case, the first driving roller 122 receives a driving force by the fourth driver 124 and rotates. The first driving roller 122 is in close contact with the first driven roller 121 and rotates in a direction opposite to the first driven roller 121 (a direction opposite to the supply of the upper electrode membrane sheet 2 and the lower electrode membrane sheet 4), and then the first driving roller 122 can counter-drive the upper electrode membrane sheet 2 and the lower electrode membrane sheet 4 in a direction opposite to the supply of the upper electrode membrane sheet 2 and the lower electrode membrane sheet 4.

[0138] The third driver 123 can include a known technology driving cylinder 123a connected to the first driving roller 122, and provide power to the first driving roller 122 to move forward and backward with respect to the first driven roller 121. In addition, the fourth driver 124 can include a known technology servo motor 124a capable of servo-controlling the rotation direction and speed.

[0139] Figure 3 FIG. 7 is a view showing a second turning roller set applied to an apparatus for manufacturing a membrane-electrode assembly for a fuel cell according to an exemplary form of the present disclosure.

[0140] Referring to Figure 3 The second turning roller set 130 is installed in the recovery path to recover the upper electrode membrane 6 and the lower electrode membrane 8 separated by the separation blade 50 on the membrane rewinding machine 60 side from the upper electrode membrane sheet 2 and the lower electrode membrane sheet 4.

[0141] The second turning roller set 130 can selectively switch the driving direction of the upper electrode membrane 6 and the lower electrode membrane 8 along the recovery path by the fifth driver 135 and the sixth driver 136.

[0142] The second turning roller set 130 includes a second driven roller 131 and a second driving roller 132. The second driven roller 131 and the second driving roller 132 are rotatably installed on the main frame 200 of the roll-to-roll feeding facility. The second driven roller 131 contacts the upper electrode membrane 6 and the lower electrode membrane 8 running along the recovery path and can freely (passively) rotate.

[0143] The second driving roller 132 is disposed so as to be reciprocally movable in a direction moving away from or toward the second driven roller 131 by the fifth driver 135. The second driving roller 132 is disposed so as to be rotatable in a direction opposite to the reverse direction of rotation of the second driven roller 131 by the sixth driver 136. That is, the second driving roller 132 is disposed to be rotated in the recovery direction of the upper electrode membrane 6 and the lower electrode membrane 8 by the sixth driver 136.

[0144] The second driving roller 132 can be moved in a direction closer to the second driven roller 131 by the fifth driver 135. In this case, the second driving roller 132 receives a driving force by the sixth driver 136 and rotates. The second driving roller 132 is in close contact with the second driven roller 131 and rotates in a direction opposite to the second driven roller 131 (a recovery direction of the upper electrode film 6 and the lower electrode film 8) to recover the upper electrode film 6 and the lower electrode film 8.

[0145] Also, the second driving roller 132 can be moved in a direction away from the second driven roller 131 by the fifth driver 135. In this case, the second driving roller 132 does not receive a driving force by the sixth driver 136, and the second driven roller 131 contacts the upper electrode film 6 and the lower electrode film 8 running in the opposite direction of recovery and can be passively rotated in the opposite direction of recovery of the upper electrode film 6 and the lower electrode film 8.

[0146] The fifth driver 135 can include a known technology driving cylinder 135a connected to the second driving roller 132 and provide power to the second driving roller 132 to move forward and backward with respect to the second driven roller 131. In addition, the sixth driver 136 can include a known technology servo motor 136a capable of servo-controlling the rotation direction and speed.

[0147] Reference Figure 1 The buffer portion 140 is used to compensate for the reverse running length of the electrolyte membrane 9. The buffer portion 140 is used to suppress the unwinding of the electrode layer rewinder 70 when the electrolyte membrane 9 runs backward along the conveying path.

[0148] The buffer portion 140 is disposed between the separation blade 50 and the electrode layer rewinder 70 on the conveying path. The buffer portion 140 includes a guide roller 141 and a buffer roller 143.

[0149] The guide roller 141 can be rotatably installed in pairs on the conveying path. The guide roller 141 guides the conveyance of the electrolyte membrane 9 in both directions along the conveying path. The guide roller 141 is in contact with the electrolyte membrane 9 and can be rotated by the tension of the electrolyte membrane 9.

[0150] The buffer roller 143 is used to adjust the running length of the electrolyte membrane 9 and is installed to be movable in a vertical direction between the guide rollers 141 by a seventh driver 147. The buffer roller 143 is in contact with the electrolyte membrane 9 and can be rotated by the tension of the electrolyte membrane 9.

[0151] The seventh driver 147 is connected to the buffer roller 143 and can include a known technology driving cylinder that provides an operating force in a vertical direction to the buffer roller 143.

[0152] The first position sensor 150 is installed in the main frame 200 of the roll-to-roll feeding facility from the front side of the driving nip roller 30 and the driven nip roller 40. The first position sensor 150 is installed on the upper side and the lower side of the driving nip roller 30 and the driven nip roller 40 between which the conveyance path passes, respectively.

[0153] The first position sensor 150 detects the edge positions of the anode layer 5 and the cathode layer 7 of the upper electrode sheet 2 and the lower electrode sheet 4 supplied by the electrode sheet unwinder 10 along the conveyance path, respectively, and outputs the detected signals to the controller 170.

[0154] For example, the first position sensor 150 includes a known technology vision sensor 151 that photographs the edges of the anode layer 5 and the cathode layer 7 and outputs vision data to the controller 170.

[0155] The second position sensor 160 is installed in the main frame 200 of the roll-to-roll feeding facility from the front side of the driving nip roller 30. The second position sensor 160 detects the edge position of the protrusion 37 of the driving nip roller 30 and outputs the detected signal to the controller 170.

[0156] For example, the second position sensor 160 includes a known technology vision sensor 161 that photographs the edge of the protrusion 37 and outputs vision data to the controller 170.

[0157] The first position sensor 150 and the second position sensor 160 can photograph the edges of the anode layer 5 and the cathode layer 7 and the edge of the protrusion 37, respectively, at the same time, and the operation of the vision photographing can be controlled by the controller 170.

[0158] On the first position sensor 150 side, a color sensor that detects the colors of the above-mentioned anode layer 5 and cathode layer 7 and the blank portions 5a, 7a and outputs the detected signal to the controller 170 can be installed.

[0159] The controller 170 is a controller that controls the overall operation of the device 100, and can be implemented as at least one control processor operated by a predetermined program, and the controller 170 can include a series of commands for performing the contents according to the exemplary form of the present disclosure.

[0160] The controller 170 can analyze the detection signals provided from the first position sensor 150 and the second position sensor 160, and can control the driving of the first to seventh drivers 31, 41, 123, 124, 135, 136, and 147 according to the edge position of the protrusion 37 and the edge positions of the anode layer 5 and the cathode layer 7.

[0161] The controller 170 can include a signal processing unit 171, an arithmetic unit 173, and a signal application unit 175.

[0162] The signal processing unit 171 analyzes the detection signal of the first position sensor 150 and detects the edge position value of the anode layer 5 and the cathode layer 7 to match with the protrusion 37. Also, the signal processing unit 171 analyzes the detection signal of the second position sensor 160 and detects the edge position value of the protrusion 37 to match with the edges of the anode layer 5 and the cathode layer 7.

[0163] The operation unit 173 calculates the position difference between the edge position value of the anode layer 5 and the cathode layer 7 and the edge position value of the protrusion 37. The signal application unit 175 can apply the control signal to the first driver to the seventh driver (31, 41, 123, 124, 135, 136, 147) according to the position difference value.

[0164] Hereinafter, the operation of the manufacturing apparatus 100 for a membrane-electrode assembly for a fuel cell configured as described above according to an exemplary form of the present disclosure and the manufacturing method for a membrane-electrode assembly for a fuel cell using the manufacturing apparatus 100 will be described with reference to the accompanying drawings.

[0165] Figure 4 is a flowchart illustrating a method for manufacturing a membrane-electrode assembly for a fuel cell according to an exemplary form of the present disclosure, and Figures 5 to 10 is a diagram illustrating the operation of an apparatus for manufacturing a membrane-electrode assembly according to an exemplary form of the present disclosure and a manufacturing method for manufacturing a membrane-electrode assembly for a fuel cell using the apparatus.

[0166] Referring to Figure 1 , Figure 4 and Figure 5 , at step S11, the electrolyte membrane sheet 9 wound in a roll form is supplied to a predetermined transfer path by an electrolyte membrane sheet unwinder 20.

[0167] Meanwhile, at step S12, the upper electrode membrane sheet 2 and the lower electrode membrane sheet 4 in which the anode layer 5 and the cathode layer 7 are continuously applied to each of the upper electrode membrane 6 and the lower electrode membrane 8 at a predetermined interval are supplied to the upper side and the lower side of the electrolyte membrane sheet 9 along the transfer path by the electrode membrane sheet unwinder 10, respectively.

[0168] Here, the driven coupling roller 40 is in a state of being lifted by the second driver 41, and the driven coupling roller 30 is in a state of being driven and rotated by the first driver 31. The driven coupling roller 30 and the driven coupling roller 40 are rotated in opposite directions along the transfer path, and the driven coupling roller 40 is passively rotated by the driven coupling roller 30.

[0169] The first driving roller 122 of the first turning roller set 120 is separated from the first driven roller 121 by the third driver 123. Also, the second driving roller 132 of the second turning roller set 130 is in close contact with the second driven roller 131 by the fifth driver 135 and is rotated in the recovery direction of the upper electrode film 6 and the lower electrode film 8 by the sixth driver 136. The buffer roller 143 of the buffer section 140 is moved downward by the seventh driver 147.

[0170] In this state, the electrolyte film sheet 9 and the upper electrode film sheet 2 and the lower electrode film sheet 4 are supplied between the driving engagement roller 30 and the driven engagement roller 40, and in step S13, the anode layer 5 and the cathode layer 7 of the upper electrode film sheet 2 and the lower electrode film sheet 4 are transferred to the upper surface and the lower surface of the electrolyte film sheet 9, respectively.

[0171] Then, the upper electrode film 6 and the lower electrode film 8 are separated from the upper electrode film sheet 2 and the lower electrode film sheet 4 by the separation blade 50 at the rear side of the driving engagement roller 30 and the driven engagement roller 40, respectively.

[0172] Next, in step S14, the upper electrode film 6 and the lower electrode film 8 separated by the separation blade 50 are driven in the recovery direction along the recovery path by the film rewinder 60 and are recovered.

[0173] At this time, since the first driving roller 122 of the first turning roller set 120 is separated from the first driven roller 121, the upper electrode film sheet 2 and the lower electrode film sheet 4 travel along the supply path through the first driven roller 121. Also, the second driving roller 132 of the second turning roller set 130 is in close contact with the second driven roller 131 and is rotated in the recovery direction of the upper electrode film 6 and the lower electrode film 8. Accordingly, the upper electrode film 6 and the lower electrode film 8 pass through between the second driven roller 131 and the second driving roller 132 rotating in opposite directions and are wound on the film rewinder 60 and recovered.

[0174] Since the processes of S11, S12, S13, and S14 have been described in the operation of the membrane-electrode assembly manufacturing apparatus 100 for a fuel cell, a more detailed description will be omitted.

[0175] Meanwhile, in the case where the upper electrode film 6 and the lower electrode film 8 are separated, the membrane-electrode assembly 1 in which the anode layer 5 and the cathode layer 7 are transferred to the upper surface and the lower surface of the electrolyte film sheet 9 is conveyed along the conveyance path. Also, in step S15, the membrane-electrode assembly 1 is wound on the electrode layer rewinder 70.

[0176] In this process, the membrane-electrode assembly 1 is conveyed in the positive direction by the guide roller 141 and the buffer roller 143 of the buffer section 140, and the membrane-electrode assembly 1 can be wound by the electrode layer rewinder 70.

[0177] Here, since the buffer roll 143 of the buffer section 140 is moved downward by the seventh driver 147, the running length (or buffer length) of the electrolyte membrane sheet 9 is increased, and the electrolyte membrane sheet 9 is conveyed to the electrode layer rewinder 70 via the guide roll 141.

[0178] On the other hand, while the process as described above is performed, the first position sensor 150 detects the edge positions of the anode layer 5 and the cathode layer 7 as detection targets entering between the driving combination roll 30 and the driven combination roll 40, and outputs a detection signal to the controller 170, in a first position in front of the driving combination roll 30 and the driven combination roll 40. Then, in step S16, the edge position of the protruding portion 37 of the driving combination roll 30 is detected by the second position sensor 160, and a detection signal is output to the controller 170.

[0179] Here, the first position sensor 150 and the second position sensor 160 simultaneously capture the edges of the anode layer 5 and the cathode layer 7 and the edge of the protruding portion 37, and transmit visual data to the controller 170.

[0180] The signal processing unit 171 of the controller 170 analyzes the detection signal of the first position sensor 150 and detects the edge position values of the anode layer 5 and the cathode layer 7 to match the edge of the protruding portion 37. Also, in step S17, the signal processing unit 171 of the controller 170 analyzes the detection signal of the second position sensor 160 to detect the edge position values of the protruding portion 37 to match the edges of the anode layer 5 and the cathode layer 7.

[0181] In addition, in step S18, the arithmetic unit 173 of the controller 170 calculates the positional difference value between the edge position values of the anode layer 5 and the cathode layer 7 and the edge position value of the protruding portion 37. Then, in step S19, the controller 170 determines whether the positional difference value between the edge position values of the anode layer 5 and the cathode layer 7 and the edge position value of the protruding portion 37 satisfies a predetermined reference value.

[0182] Whether the positional difference value between the edge position values of the anode layer 5 and the cathode layer 7 and the edge position value of the protruding portion 37 satisfies a predetermined reference value depends on whether the positional difference value is within an allowable error range.

[0183] If it is determined in the process S19 that the positional difference value satisfies the reference value, the series of processes S11 to S15 as described above are performed.

[0184] However, in step S19, if it is determined that the positional difference value does not satisfy the predetermined reference value, an electrode position alignment mode is performed.

[0185] In this process, as Figure 6As shown, the anode layer 5 and the cathode layer 7(A) to be detected and the previous other anode layer 5 and cathode layer 7(B) of the anode layer 5 and the cathode layer 7(A) undergo processes S11-S15. That is, at step S21, the previous other anode layer 5 and cathode layer 7(B) are bonded (transferred) to the upper surface and the lower surface of the electrolyte sheet 9 by the driving bonding roller 30 and the driven bonding roller 40.

[0186] When the electrode position alignment mode is executed, at the time when the blank portion 5a, 7a between the anode layer 5 and the cathode layer 7(A) to be detected is located at the edge of the protruding portion 37 of the driving bonding roller 30, the conveyance of the electrolyte sheet 9 is stopped.

[0187] After that, as shown in Figure 7 at step S23, the first driver 31 stops driving the driving bonding roller 30, and the second driver 41 lowers the driven bonding roller 40.

[0188] Next, the third driver 123 separates the first driving roller 122 of the first turning roller set 120 from the first driven roller 121, and the fifth driver 135 attaches the second driving roller 132 of the second turning roller set 130 to the second driven roller 131, and the sixth driver 136 maintains the state in which the second driving roller 132 is driven and rotated along the recovery direction of the upper electrode film 6 and the lower electrode film 8.

[0189] Accordingly, the upper electrode sheet 2 and the lower electrode sheet 4 are conveyed in the positive direction along the conveyance path by the electrode sheet unwinding machine 10 and the film rewinding machine 60, and the anode layer 5 and the cathode layer 7(A) of the detection target are conveyed toward the separation blade 50. At this time, the upper electrode sheet 2 and the lower electrode sheet 4 are driven in the conveyance path by the first driven roller 121.

[0190] After that, at step S24, the upper electrode film 6 and the lower electrode film 8 are separated from the anode layer 5 and the cathode layer 7 bonded to the electrolyte sheet 9 by the separation blade 50.

[0191] The separated upper electrode film 6 and the lower electrode film 8 can be individually corrected by the first turning roller set 120 and the second turning roller set 130.

[0192] The upper electrode film 6 and the lower electrode film 8 separated as above pass between the second driven roller 131 and the second driving roller 132 rotating in the opposite direction, and are wound on the film rewinding machine 60 when driven in the recovery direction.

[0193] After the process is performed, as Figure 8As shown, the third driver 123 brings the first driving roller 122 of the first turning roller set 120 into close contact with the first driven roller 121, and the fourth driver 124 rotates the first driving roller 122 in the opposite direction of the supply of the upper electrode film 2 and the lower electrode film 4. Then, the first driven roller 121 and the first driving roller 122 rotate in the opposite direction, driving the upper electrode film 2 and the lower electrode film 4 in reverse.

[0194] Meanwhile, the second driving roller 132 of the second turning roller set 130 is separated from the second driven roller 131 by the fifth driver 135. Then, at step S25, the upper electrode film 6 and the lower electrode film 8 wound on the film rewinder 60 are released, and the upper electrode film 6 and the lower electrode film 8 are driven in reverse along the recovery path by the second driven roller 131.

[0195] In the above process, the buffer roller 143 is moved in the upward direction by the seventh driver 147 of the buffer unit 140, and the electrolyte film 9 having the anode layer 5 and the cathode layer 7 transferred on the top surface and the bottom surface is transferred in the reverse direction by the guide roller 141.

[0196] As described above, when the buffer roller 143 moves from the bottom to the top, the running length of the electrolyte film 9 in the reverse direction is compensated for to suppress the unwinding of the electrode layer rewinder 70, and the electrolyte film 9 can be reversed by the guide roller 141.

[0197] Thus, the anode layer 5 and the cathode layer 7 (A) to be detected are located in front of the driving combination roller 30 and the driven combination roller 40 (original position), and the other anode layer 5 and the cathode layer 7 (B) are located between the driving combination roller 30 and the driven combination roller 40.

[0198] In this state, as Figure 9 shown, the upper electrode film 2 and the lower electrode film 4 are reversely run up to the position difference, and the anode layer 5 and the cathode layer 7 of the detection target are aligned at the predetermined matching position. Meanwhile, at step S26, the driving combination roller 30 is driven in the reverse direction as long as the blank portions 5a, 7a and the protrusion 37 of the driving combination roller 30 are aligned to the predetermined matching position.

[0199] Then, at step S27, the first position sensor 150 and the second position sensor 160 re-detect the positions of the anode layer 5 and the cathode layer 7 of the detection target and the protrusion 37, and output the detection signal to the controller 170.

[0200] Here, the separated upper electrode film 6 and the lower electrode film 8 can be individually corrected in position by the first turning roller set 120 and the second turning roller set 130, respectively.

[0201] That is, the controller 170 can correct each position of the separated upper electrode film 6 and lower electrode film 8 by outputting the corresponding signal to the first and second turning roller groups 120 and 130 according to the detection signal of each of the up-down first and second position sensors 150 and 160.

[0202] If it is determined in step S28 that the position difference satisfies the predetermined reference value, as shown in Figure 10 the upper and lower electrode film pieces 2 and 4 and the electrolyte film piece 9 are conveyed in the positive direction, and the anode layer 5 and cathode layer 7 aligned at the matching position are placed between the driving and driven joining rollers 30 and 40.

[0203] This is to suppress the overlapping compression of the other anode layer 5 and cathode layer 7 joined to the electrolyte film piece 9 by the driving and driven joining rollers 30 and 40.

[0204] Next, the processes of S11-S15 as described above are performed, such as lowering the driven joining roller 40 and transferring the anode layer 5 and cathode layer 7 to the upper and lower surfaces of the electrolyte film piece 9.

[0205] And, if it is determined in step S28 that the position difference does not satisfy the predetermined reference value, the processes of S25-S27 as described above are performed.

[0206] According to the manufacturing apparatus 100 and method for a membrane-electrode assembly for a fuel cell according to the exemplary form of the present disclosure as described so far, by switching the running direction of the upper and lower electrode film pieces 2 and 4 and the upper and lower electrode films 6 and 8, the transfer position of the anode layer 5 and cathode layer 7 can be automatically aligned.

[0207] Therefore, in the exemplary form of the present disclosure, it is possible to suppress the reduction in the transfer uniformity of the anode layer 5 and cathode layer 7 due to the gap distribution between the anode layer 5 and cathode layer 7 applied to the upper and lower electrode films 6 and 8. In addition, a good quality membrane-electrode assembly 1 can be provided, and the productivity of the membrane-electrode assembly 1 can be improved.

[0208] While the present disclosure has been described in connection with what is presently considered to be the practical exemplary forms, it is to be understood that the present disclosure is not limited to the disclosed forms. On the contrary, it is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.

Claims

1. A manufacturing method of a membrane-electrode assembly for a fuel cell, the manufacturing method comprising the steps of: a) supplying an electrolyte membrane sheet to a predetermined transfer path through an electrolyte membrane sheet unwinder; b) supplying an upper electrode membrane sheet and a lower electrode membrane sheet each having an upper electrode membrane and a lower electrode membrane along the transfer path through an electrode membrane sheet unwinder, wherein the upper electrode membrane and the lower electrode membrane each include an anode layer and a cathode layer applied to upper and lower sides of the electrolyte membrane sheet at a predetermined interval through the electrode membrane sheet unwinder; c) bonding the anode layer of the upper electrode membrane sheet and the cathode layer of the lower electrode membrane sheet to upper and lower surfaces of the electrolyte membrane sheet, respectively, through a driving bonding roller and a driven bonding roller; d) recovering the upper electrode membrane of the upper electrode membrane sheet and the lower electrode membrane of the lower electrode membrane sheet, respectively, through a membrane rewinder; e) detecting edge positions of the anode layer and the cathode layer at a front side of the driving bonding roller and the driven bonding roller through a first position sensor, and detecting an edge position of a protrusion of the driving bonding roller through a second position sensor; and f) switching a running direction of the upper electrode membrane sheet and the lower electrode membrane sheet in the electrode membrane sheet unwinder and a running direction of the upper electrode membrane and the lower electrode membrane in the membrane rewinder, respectively, according to detection signals of the first position sensor and the second position sensor, and aligning transfer positions of the anode layer and the cathode layer through a first deflection roller set and a second deflection roller set, wherein in the steps a), b), c), and d) of the manufacturing method, the driven bonding roller is lifted, the driving bonding roller is driven and rotated, a first driving roller of the first deflection roller set is separated from a first driven roller, a second driving roller of the second deflection roller set is in close contact with a second driven roller, and the second driving roller is driven along a recovery direction of the upper electrode membrane and the lower electrode membrane.

2. The manufacturing method according to claim 1, wherein the steps a), b), c), and d) of the manufacturing method include: separating the anode layer of the upper electrode membrane and the upper electrode membrane sheet and the cathode layer of the lower electrode membrane and the lower electrode membrane sheet, respectively, through a separation blade; and transferring and winding a membrane-electrode assembly having the anode layer and the cathode layer transferred to upper and lower surfaces of the electrolyte membrane sheet, respectively, in a positive direction through an electrode layer rewinder in a state where a buffer roller of a buffer portion is lowered.

3. The manufacturing method according to claim 1, wherein the step f) of the manufacturing method includes: analyzing a detection signal of the first position sensor and detecting an edge position value of the anode layer and the cathode layer to match an edge position value of the protrusion through a controller; analyzing a detection signal of the second position sensor and detecting the edge position value of the protrusion to match the edge position value of the anode layer and the cathode layer through the controller; and calculating a position difference value between the edge position value of the anode layer and the cathode layer and the edge position value of the protrusion through the controller. ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ 4. The manufacturing method according to claim 3, wherein the steps a), b), c), and d) of the manufacturing method are performed when it is determined by the controller that the positional difference satisfies a predetermined reference value.

5. The manufacturing method according to claim 3, further comprising: performing the steps a) to d) of the manufacturing method in an electrode position alignment mode when it is determined by the controller that the positional difference does not satisfy a predetermined reference value; bonding the anode layer and the cathode layer to the upper surface and the lower surface of the electrolyte membrane, respectively, by the driving bonding roller and the driven bonding roller; and stopping the conveyance of the upper electrode membrane, the lower electrode membrane, and the electrolyte membrane when the blank portion between the anode layer and the cathode layer of the sensing target is located at the edge of the protrusion of the driving bonding roller.

6. The manufacturing method according to claim 5, wherein in the electrode position alignment mode, after stopping the conveyance of the electrolyte membrane, lowering the driven bonding roller, separating the first driving roller of the first turning roller set from the first driven roller, bringing the second driving roller of the second turning roller set into close contact with the second driven roller, driving and rotating the second driving roller in a recovery direction of the upper electrode membrane and the lower electrode membrane, conveying the upper electrode membrane and the lower electrode membrane in a forward direction along the conveyance path by an electrode membrane unwinder and a membrane rewinder, and conveying the anode layer and the cathode layer as the sensing target to a separation blade, and separating the upper electrode membrane and the lower electrode membrane from the anode layer and the cathode layer bonded to the electrolyte membrane by the separation blade, respectively.

7. The manufacturing method according to claim 6, wherein in the electrode position alignment mode, after separating the upper electrode membrane and the lower electrode membrane, bringing the first driving roller of the first turning roller set into close contact with the first driven roller, rotating the first driving roller in a supply opposite direction of the upper electrode membrane and the lower electrode membrane, driving the upper electrode membrane and the lower electrode membrane in the supply opposite direction, separating the second driving roller of the second turning roller set from the second driven roller, driving the upper electrode membrane and the lower electrode membrane in the opposite direction, and moving a buffer roller of a buffer portion in an upward direction, and conveying the electrolyte membrane with the anode layer and the cathode layer transferred to the upper surface and the lower surface, respectively, in a reverse direction.

8. The manufacturing method according to claim 7, wherein in the electrode position alignment mode, positioning the anode layer and the cathode layer of the sensing target in front of the driving bonding roller and the driven bonding roller, positioning the anode layer and the cathode layer bonded to the electrolyte membrane between the driving bonding roller and the driven bonding roller, aligning the anode layer and the cathode layer of the sensing target at a predetermined matching position; driving and rotating the driving bonding roller corresponding to a section of the blank portion in a reverse direction, aligning the protrusion at a predetermined matching position, and The positions of the anode layer and the cathode layer of the detection target and the protruding portion are re-detected by the first position sensor and the second position sensor, and detection signals are output to the controller.

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