Method for manufacturing a separator electrode unit

Abstract

The invention relates to a method for manufacturing a membrane electrode unit (MEA) for a fuel cell (101), in particular in a continuous inline process, comprising the following steps: 1) providing a strip-shaped membrane material (M) in the inline direction (D), for example on a reel, such that the membrane material can be unwound from the reel, in particular in the inline process, 2) coating the strip-shaped membrane material (M) with an active material (E), 3) cutting the coated membrane material (M) into individual membrane electrode units (MEA), such that the individual membrane electrode units (MEA) are configured with at least one edge region (TR) which is configured curvedly and / or angularly, viewed in the inline direction (D).

Description

Technical Field

[0001] This invention relates to a method for manufacturing a membrane electrode unit according to the independent method claim. Furthermore, the invention also relates to a corresponding membrane electrode unit according to the independent device claim. Additionally, the invention relates to a corresponding fuel cell system and a corresponding vehicle, particularly a hydrogen-powered vehicle, according to the parallel independent device claims. Background Technology

[0002] In modern fuel cells, there is always an attempt to optimize the portion of the fuel cell used for energy generation. A membrane material, consisting of a coating of active material, the so-called catalyst layer, and, if necessary, a gas diffusion layer, is used to generate energy in the fuel cell. To optimize energy production, in some fuel cells, the surface of the membrane material is also designed to generate energy in the transition region used for media distribution. This can result in a relative increase in volumetric power density of approximately 20-30%. To utilize the expensive components of the membrane material as waste-free as possible, the shape of the cutter can be adjusted so that it can be repeated as seamlessly as possible on the mostly strip-shaped membrane material. Exemplary designs of cutters for membrane materials are shown in documents DE 102015 201 548 A1 and DE 10 2018 200 673 A1. In addition to the primary function, such as energy generation, secondary functions, such as sealing and media distribution (with the so-called port transition region), must also be satisfied in the fuel cell. Compromises must always be made here. Summary of the Invention

[0003] According to a first aspect, the present invention provides a method for manufacturing a membrane electrode unit having the features of a separate method claim. Furthermore, according to a second aspect, the present invention provides a corresponding membrane electrode unit having the features of a separate device claim. Furthermore, according to a third aspect, the present invention provides a corresponding fuel cell system having features of parallel separate device claims. Furthermore, according to a fourth aspect, the present invention provides a corresponding vehicle, particularly a hydrogen-powered vehicle, having additional features of parallel separate device claims. Herein, the features and details described in relation to various aspects of the invention naturally also apply to other aspects of the invention, and vice versa, so that disclosures regarding various aspects of the invention are always mutually referential or mutually referential.

[0004] The present invention is provided according to a first aspect: a method for manufacturing a membrane electrode unit for a fuel cell, such as a PEM fuel cell, particularly in a continuous production line process, comprising the following steps:

[0005] 1) Provide a strip of diaphragm material along the production line direction, for example on a roll, so that the diaphragm material can be unwound from the roll, especially in a production line process.

[0006] 2) Coat the strip-shaped diaphragm material with active material and, if necessary, a gas diffusion layer.

[0007] 3) Cut the coated diaphragm material into individual diaphragm electrode units such that each individual diaphragm electrode unit is constructed with at least one edge region (or configured as a transition region for media dispensing), the edge region being constructed in a curved and / or angled manner when viewed along the flow line direction.

[0008] The steps of the method according to the invention can be performed in a predetermined order or a modified order. Advantageously, the steps of the method according to the invention can be performed simultaneously and / or repeatedly in order to enable automated processes.

[0009] The present invention is conceived of providing cut pieces of coated diaphragm material having edge segments that are curved or angled from the active surface of a single diaphragm electrode unit. Here, the edge segments can be constructed as curved or arc-shaped and / or angled strips (e.g., in the form of parallelograms).

[0010] This approach offers at least two significant advantages. Firstly, the cut pieces are repeated seamlessly on the strip-shaped membrane material. Therefore, almost no waste material composed of expensive active materials is generated after cutting individual membrane electrode units. Secondly, this allows for the formation of narrow, trapezoidal strips of unused volume on one side of each individual membrane electrode unit. When stacking individual fuel cells into a fuel cell system, a trapezoidal storage space (or geometrically, a straight cylinder with a trapezoidal base) can be formed, in which all the appliances and connections of the fuel cell system, such as current rails and electrical connectors, can be arranged in a space-efficient manner. Since these appliances are necessary in the fuel cell system anyway, this advantageously improves the overall space efficiency of the system. Furthermore, this allows for the use of a compact rectangular housing to receive the fuel cell system.

[0011] In other words, the advantage of the invention is at least that the edge region of the active side of the coated membrane material is manufactured almost 100% waste-free, and at the same time, the packaging possibilities of the fuel cell system are maximized.

[0012] Furthermore, in the method for manufacturing a membrane electrode unit for a fuel cell, the present invention can be configured such that, in step 3), a single membrane electrode unit is constructed with two edge regions, both of which are curved and / or angled when viewed from the production line direction. This provides a symmetrical membrane electrode unit that is easily manipulated when stacking fuel cells into a fuel cell system. Therefore, the assembly of the fuel cell system can be simplified.

[0013] Furthermore, within the scope of this invention, it is conceivable that the two edge regions are constructed curved and / or angled in the same direction. This can provide a particularly compact fuel cell system.

[0014] Furthermore, within the scope of this invention, it is conceivable that the two edge regions are constructed to be curved and / or angled in opposite directions. This can provide a fuel cell system with a more uniform stress profile.

[0015] Furthermore, in the method for manufacturing a membrane electrode unit for a fuel cell, the present invention can be configured such that the two edge regions are symmetrically constructed. This allows for the realization of a fuel cell with symmetrical ports on the two edge regions, thereby simplifying the interconnection of fuel cells within the fuel cell system and the components for media supply.

[0016] According to a second aspect, the present invention provides a membrane electrode unit for a fuel cell, which can be manufactured as described above. The same advantages described above in relation to the method according to the invention can be achieved by means of the membrane electrode unit according to the invention. These advantages are now fully referenced.

[0017] According to a third aspect, the present invention provides a fuel cell system having at least one fuel cell comprising a membrane electrode unit capable of being manufactured as described above. The fuel cell system according to the invention can be implemented in the form of a fuel cell stack, a so-called fuel cell pile, having a plurality of repeating units stacked in the form of individual fuel cells, preferably PEM fuel cells. The same advantages described above in relation to the method according to the invention can be achieved by means of the fuel cell system according to the invention. These advantages are now fully referenced.

[0018] Furthermore, in a fuel cell system, the present invention can be configured with a rectangular housing (or, geometrically, a straight cylinder with a rectangular base) for at least one fuel cell. Such a housing is not only simple to manufacture but also easy to operate, for example, when installed in a vehicle. Therefore, multiple fuel cell systems can be flexibly assembled into a modular system of any size in a simple manner. Thus, a flexible number of fuel cell systems can be used for different applications.

[0019] Furthermore, in a fuel cell system, the present invention can be configured to form a preferably trapezoidal storage space (or, geometrically, a straight cylinder with a trapezoidal base) when viewed from the stacking direction of the fuel cell system, in order to arrange at least one functionally important component of the fuel cell system. This can be conceived as including at least one functionally important component of the fuel cell system such as a manifold, electrical connector, compressor, turbine, humidifier, fuel tank, pump, water tank, cooling medium tank, and / or control unit. Therefore, a space-saving structure for the fuel cell system can be achieved.

[0020] Furthermore, in the case of a fuel cell system, the present invention can be configured such that the storage space is implemented as a support structure for receiving, preferably in a form-locking and / or force-locking manner, a current collector, particularly a vehicle support structure. In this way, the fuel cell system can be easily and with minimal effort arranged in a vehicle to serve, for example, as an energy supplier for at least one consumption device in the vehicle, preferably an electric motor.

[0021] According to a fourth aspect, the present invention provides a vehicle, particularly a hydrogen-powered vehicle, having at least one fuel cell system implemented as described above. The same advantages described above in relation to the method and / or fuel cell system according to the invention can be achieved by means of the vehicle according to the invention. These advantages are now fully referenced. Attached Figure Description

[0022] The present invention and its extensions, as well as their advantages, are described in detail below with reference to the accompanying drawings. The drawings schematically illustrate:

[0023] Figure 1 Examples of known designs for cutting strip-shaped diaphragm material into individual diaphragm electrode units.

[0024] Figure 2 A schematic diagram of a known fuel cell with rectangular membrane electrode units.

[0025] Figure 3 A schematic diagram of the method according to the present invention.

[0026] Figure 4 A schematic diagram of a fuel cell according to the present invention, and

[0027] Figure 5 : A schematic diagram of a fuel cell according to the present invention.

[0028] In different drawings, the same parts of the present invention are always given the same reference numerals, so these parts are usually described only once. Detailed Implementation

[0029] Figure 1 and Figure 2The diagram illustrates a known geometry for cutting strip-shaped membrane material M into individual membrane electrode units (MEAs). The membrane material M typically has a coating consisting of an active material E, a so-called catalyst layer, and, if necessary, a gas diffusion layer (not shown).

[0030] The active material E is used to form the active surface of the membrane electrode unit (MEA). In a modern fuel cell 101, the edge regions of the membrane material M used for media distribution are also provided with the active material E, so that these edge regions can also be used to generate energy.

[0031] To cut the membrane electrode unit (MEA) as close to the material as possible without wasting the expensive active material E, the MEA can be cut into a rectangle, for example, in... Figure 1 As shown on the left side of the image. However, this may result in the area around the membrane electrode unit (MEA) not being optimally utilized. As this is in... Figure 2 As shown, this may create an area that cannot be fully utilized on the long side of the membrane electrode unit (MEA) within the fuel cell 101.

[0032] exist Figure 1 The right side shows the membrane electrode assembly (MEA), which is implemented, for example, with a triangular edge segment TR. The triangular edge segment TR attempts to find a compromise between providing an edge region capable of generating current and a fuel cell with a compact design. However, from... Figure 1 As can be seen, waste containing expensive active material E is formed here.

[0033] This invention utilizes Figures 3 to 5 To explain.

[0034] Figure 3 This method, according to the present invention, is used to visually illustrate the method for manufacturing a membrane electrode assembly (MEA) for a fuel cell 101, particularly in a continuous production line process. The method comprises the following steps:

[0035] 1) A strip of diaphragm material M is provided along the production line direction D, for example on a roll, so that the diaphragm material M can be unwound from the roll during the production line process.

[0036] 2) Coat the strip-shaped membrane material M with the active material E and, if necessary, a gas diffusion layer (not shown).

[0037] 3) Cut the coated diaphragm material M into individual diaphragm electrode units MEA, such that each individual diaphragm electrode unit MEA is constructed with at least one edge region TR, which is curved and / or angled when viewed from the flow line direction D.

[0038] According to the invention, in step 3), a coated diaphragm material M having such an edge segment TR is provided, the edge segment being bent or angled by the active surface FF of a single diaphragm electrode unit MEA. Figures 2 to 5 The diagram shows an edge segment TR, which is essentially a strip with an angle on the edge side of the active surface FF of a single membrane electrode unit (MEA). However, in principle, edge segments TR in the form of curved or arc-shaped strips can also be provided within the scope of this invention.

[0039] At least two important advantages can be achieved by using this invention:

[0040] - The cut piece can follow the strip-shaped diaphragm material M without gaps, resulting in almost no waste material composed of expensive active material E after cutting individual diaphragm electrode units (MEAs).

[0041] -Only one ( ) is generated on one or both long sides of a single diaphragm electrode unit MEA. Figure 4 ) or produce two ( Figure 5 Narrow, for example, trapezoidal ( Figure 4 ) or rectangle ( Figure 5 The unused volume of the strip.

[0042] According to Figure 4 When the individual fuel cells 101 are stacked to form a fuel cell system 100, a trapezoidal storage space A (or geometrically, a straight cylinder with a trapezoidal base) can be formed. Within this storage space, all the appliances and connections of the fuel cell system 100, such as manifolds, electrical connectors, compressors, turbines, humidifiers, fuel tanks, pumps, water tanks, cooling medium tanks, and / or at least one control unit, can be arranged in a space-saving manner. Since these functionally important components are required in the fuel cell system 100 anyway, the overall space efficiency of the fuel cell system 100 can be improved. This also allows for the use of a compact rectangular housing to receive the fuel cell system 100, which is not shown in the figures only for simplicity.

[0043] like Figure 3 As shown, the edge region TR used for dielectric distribution can be almost completely coated with active material E, wherein a single diaphragm electrode unit MEA can be cut from the coated diaphragm material M almost 100% waste-free.

[0044] at the same time, Figure 4 and Figure 5 This indicates that the packaging possibilities of the fuel cell system 100 can be improved in an advantageous manner.

[0045] In addition, such as Figures 3 to 5As shown, in step 3), a single diaphragm electrode unit (MEA) may have edge regions TR on two narrow sides, which are curved and / or angled when viewed from the pipeline direction D. However, in principle, it is also possible that only one edge region TR is curved and / or angled when viewed from the pipeline direction D.

[0046] like Figure 4 As shown, the two edge regions TR can be bent in the same direction and / or constructed at an angle. This can result in improved space savings in the fuel cell system 100.

[0047] like Figure 5 As shown, the two edge regions TR can be bent and / or angled in opposite directions. This can result in an improved stress profile in the fuel cell system 100.

[0048] like Figures 3 to 5 As further illustrated, the two edge regions TR are constructed symmetrically. This simplifies the fabrication and operation of a single membrane electrode assembly (MEA).

[0049] The membrane electrode unit (MEA) manufactured accordingly for the fuel cell 101 also constitutes an aspect of the present invention.

[0050] A fuel cell system 100 having multiple fuel cells 101 also constitutes an aspect of the present invention, each of which has a membrane electrode unit (MEA).

[0051] Advantageously, the fuel cell system 100 according to the invention can be housed in a rectangular housing 102 in a space-saving manner.

[0052] In addition, such as Figure 4 and Figure 5 As indicated and mentioned above in relation to the method according to the invention, a trapezoidal storage space A or two rectangular storage spaces are formed when viewed from the stacking direction R of the fuel cell system 100 in order to arrange the functionally important components of the fuel cell system 100.

[0053] Furthermore, within the scope of this invention, it is advantageous that storage space A, or at least one of the two storage spaces A, can be configured not only to receive functionally essential components of the fuel cell system 100, but also additionally or alternatively to receive, for example, form-locking and / or force-locking, the carrier structure of the current collector, particularly the carrier structure of a vehicle. In this way, the fuel cell system 100 according to the invention can be mounted on the carrier structure of the current collector in a particularly simple and elegant manner, for example, within a vehicle.

[0054] A corresponding vehicle having at least one or more modularly assembled fuel cell systems 100 also constitutes an aspect of the invention, said fuel cell systems being implemented as described above. The vehicle as a whole is not shown in the drawings for simplicity only.

[0055] The foregoing accompanying drawings describe the invention only within the scope of examples. Of course, the various features of these embodiments can be freely combined with each other without departing from the scope of the invention, provided it is technically meaningful.

Claims

1. A method for manufacturing a membrane electrode assembly (MEA) for a fuel cell (101), comprising the following steps: 1) Provide strip-shaped diaphragm material (M) along the flow line direction (D). 2) The strip-shaped diaphragm material (M) is coated with an active material (E). 3) Cut the coated membrane material (M) into individual membrane electrode units (MEAs), so that... The individual membrane electrode unit (MEA) is configured with at least one edge region (TR). The at least one edge region is located on both sides of the strip-shaped diaphragm material (M) different from the cut position and is configured to bend and / or bend at an angle to the flow line direction (D), such that the edge region and the cut position form two sides of a trapezoid on the outside of the diaphragm material (M).

2. The method according to claim 1, Its features are, In step 3), a single membrane electrode unit (MEA) is constructed with two edge regions (TR). Viewed from the flow line direction (D), the two edge regions are constructed in a curved and / or angled manner.

3. The method according to claim 2, Its features are, The two edge regions (TR) are constructed in a curved and / or angled manner in the same direction.

4. The method according to claim 2, Its features are, The two edge regions (TR) are constructed in opposite directions and / or at an angle.

5. The method according to any one of the preceding claims, characterized in that, The two edge regions (TR) are constructed symmetrically.

6. A membrane electrode unit (MEA) for a fuel cell (101), said membrane electrode unit being manufactured by the method according to any one of claims 1 to 5.

7. A fuel cell system (100) having at least one fuel cell (101) having a membrane electrode assembly (MEA) according to claim 6.

8. The fuel cell system (100) according to claim 7. Its features are, A rectangular housing (102) is provided for at least one fuel cell (101).

9. The fuel cell system (100) according to claim 7 or 8. Its features are, Viewed from the stacking direction (R) of the fuel cell system (100), a particularly trapezoidal storage space (A) is formed to accommodate at least one functionally important component of the fuel cell system (100).

10. The fuel cell system (100) according to claim 9, characterized in that, The storage space (A) is implemented as a support structure for receiving the receiving current collector.

11. The fuel cell system (100) according to claim 10, characterized in that, The storage space (A) is implemented as a load-bearing structure for receiving vehicles in a form-locking and / or force-locking manner.

12. A vehicle having a fuel cell system (100) according to any one of claims 7 to 11.

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