Membrane electrode assembly and method for manufacturing the same

Abstract

Disclosed are a membrane-electrode assembly and a method of manufacturing the same, in which an electrode is modularized into a deteriorated portion and a remaining portion to facilitate repair by replacing the deteriorated module, thereby enabling reduction in time and cost for maintenance and repair. The membrane-electrode assembly of the present invention includes a first electrode, a second electrode, and an electrolyte membrane between the first electrode and the second electrode, wherein the first electrode includes a first electrode module and a second electrode module that are separable from each other.

Description

Technical Field

[0001] This disclosure relates to a membrane electrode assembly and a fuel cell including the membrane electrode assembly, and more particularly to a membrane electrode assembly and a method of manufacturing the same, wherein the membrane electrode assembly is configured such that the electrode is modularized into a deteriorating part and a remaining part, thereby allowing the membrane electrode assembly to be easily repaired by replacing the deteriorated module, thus reducing the time and cost of maintaining the membrane electrode assembly. Background Technology

[0002] Polymer electrolyte membrane fuel cells (PEMFCs) are configured to generate electricity using a stack of cell units, each comprising a membrane electrode assembly (MEA) and a separator (also known as a bipolar plate). They are attracting attention as a next-generation energy source capable of replacing fossil fuels due to their high energy efficiency and environmentally friendly characteristics.

[0003] A membrane electrode assembly typically includes an anode (also known as a fuel electrode), a cathode (also known as an air electrode), and a polymer electrolyte membrane (PEM) disposed between them.

[0004] When fuel such as hydrogen is supplied to the anode, hydrogen ions (H+) are generated at the anode as a result of the hydrogen oxidation reaction. + ) and electrons (e - The generated hydrogen ions are transferred to the cathode through a polymer electrolyte membrane (PEM), while the generated electrons are transferred to the cathode through an external circuit. Oxygen from the air supplied to the cathode combines with the hydrogen ions and electrons and is reduced, thereby producing water.

[0005] Typically, electrode degradation caused by prolonged operation of a fuel cell occurs primarily in specific portions of the electrode (e.g., the portion corresponding to the gas inlet / outlet; hereinafter referred to as the "vulnerable portion"), rather than across the entire electrode area. Therefore, when the vulnerable portion deteriorates due to prolonged fuel cell operation, even if the remaining portion can still be used normally as an electrode, the entire electrode or membrane electrode assembly needs to be discarded or replaced. This increases the time and cost of maintaining the membrane electrode assembly and also results in resource waste. Summary of the Invention

[0006] Technical issues

[0007] Therefore, this disclosure relates to a membrane electrode assembly and a method for manufacturing the membrane electrode assembly, which can solve the problems caused by the limitations and disadvantages of the aforementioned related technologies.

[0008] One aspect of this disclosure is to provide a membrane electrode assembly configured such that the electrode is modularized into a deteriorating portion and a remaining portion, thereby allowing the membrane electrode assembly to be easily repaired by replacing the deteriorated module, thus reducing the time and cost of maintaining the membrane electrode assembly.

[0009] Another aspect of this disclosure is to provide a method for manufacturing a membrane electrode assembly, the membrane electrode assembly being configured such that the electrodes are modularized into easily deteriorated parts and remaining parts, thereby allowing the membrane electrode assembly to be easily repaired by replacing the deteriorated modules, thus reducing the time and cost of maintaining the membrane electrode assembly.

[0010] In addition to the purposes described above, other features and advantages of this disclosure will be described below, or will be clearly understood by those skilled in the art to which this disclosure pertains from the following description.

[0011] Technical solution

[0012] According to an aspect of this disclosure, a membrane electrode assembly is provided, comprising: a first electrode, a second electrode, and an electrolyte membrane between the first electrode and the second electrode, wherein the first electrode comprises a first electrode module and a second electrode module that are separable from each other.

[0013] The first electrode module and the second electrode module can be in contact with each other, and there can be a visible boundary between the first electrode module and the second electrode module. The visible boundary is caused by at least one of the following: a groove between the first electrode module and the second electrode module, a color difference between the first electrode module and the second electrode module, and a structural difference between the first electrode module and the second electrode module.

[0014] The first electrode module and the second electrode module may be spaced apart from each other, and there may be a visible boundary between the first electrode module and the second electrode module caused by the space between the first electrode module and the second electrode module.

[0015] The membrane electrode assembly may further include a first gas diffusion layer, wherein the first gas diffusion layer may be configured such that the first electrode is located between the first gas diffusion layer and the electrolyte membrane, the first gas diffusion layer may include a first gas diffusion module bonded to the first electrode module and a second gas diffusion module bonded to the second electrode module, and the first gas diffusion module and the second gas diffusion module may be separable from each other.

[0016] Alternatively, the membrane electrode assembly may further include a first gas diffusion layer, wherein the first gas diffusion layer may be configured such that the first electrode is located between the first gas diffusion layer and the electrolyte membrane, and the membrane electrode assembly may further include an adhesive layer between the first electrode module and the second electrode module and the first gas diffusion layer.

[0017] The electrolyte membrane may include a first membrane module and a second membrane module that are separable from each other. The second electrode may include a third electrode module and a fourth electrode module that are separable from each other. The membrane electrode assembly may include a first component module and a second component module that are separable from each other. The first component module may include a first electrode module, a third electrode module and a first membrane module located between the first electrode module and the third electrode module. The second component module may include a second electrode module, a fourth electrode module and a second membrane module located between the second electrode module and the fourth electrode module.

[0018] The first membrane module may have an active region in contact with the first electrode module and the third electrode module and an inactive region surrounding the active region. The second membrane module may have an active region in contact with the second electrode module and the fourth electrode module and an inactive region surrounding the active region. The first component module may also include a first sub-wafer module and a third sub-wafer module disposed in the inactive region of the first membrane module, with the first sub-wafer module and the third sub-wafer module surrounding the first electrode module and the third electrode module, respectively. The second component module may also include a second sub-wafer module and a fourth sub-wafer module disposed in the inactive region of the second membrane module, with the second sub-wafer module and the fourth sub-wafer module surrounding the second electrode module and the fourth electrode module, respectively.

[0019] The first component module may include a first gas diffusion module covering a first electrode module and a third gas diffusion module covering a third electrode module, wherein the first electrode module is disposed between the first membrane module and the first gas diffusion module, and the third electrode module is disposed between the first membrane module and the third gas diffusion module. The second component module may include a second gas diffusion module covering a second electrode module and a fourth gas diffusion module covering a fourth electrode module, wherein the second electrode module is disposed between the second membrane module and the second gas diffusion module, and the fourth electrode module is disposed between the second membrane module and the fourth gas diffusion module.

[0020] The membrane electrode assembly may further include: a first elastic gasket having a first window and a second window respectively exposed by a first gas diffusion module and a second gas diffusion module, the first elastic gasket contacting a first sub-gasket module and a second sub-gasket module; and a second elastic gasket having a third window and a fourth window respectively exposed by a third gas diffusion module and a fourth gas diffusion module, the second elastic gasket contacting a third sub-gasket module and a fourth sub-gasket module.

[0021] The first elastic gasket may include a first boundary region between a first window and a second window, the first boundary region contacting both the first sub-gasket module and the second sub-gasket module to prevent gas leakage through the gap between the first component module and the second component module. The second elastic gasket may include a second boundary region between a third window and a fourth window, the second boundary region contacting both the third sub-gasket module and the fourth sub-gasket module to prevent gas leakage through the gap between the first component module and the second component module. The first boundary region may have a plurality of first grooves configured such that the first window and the second window can be fluidly connected to each other through the plurality of first grooves on their surfaces opposite to the surfaces of the first and second sub-gasket modules. The second boundary region may have a plurality of second grooves configured such that the third window and the fourth window can be fluidly connected to each other through the plurality of second grooves on their surfaces opposite to the surfaces of the third and fourth sub-gasket modules.

[0022] Alternatively, the first elastic gasket may include a first boundary region between the first window and the second window, which contacts both the first sub-gasket module and the second sub-gasket module to prevent gas leakage through the gap between the first component module and the second component module. The second elastic gasket may include a second boundary region between the third window and the fourth window, which contacts both the third sub-gasket module and the fourth sub-gasket module to prevent gas leakage through the gap between the first component module and the second component module. The first boundary region may include a first non-porous elastic layer in contact with the first sub-gasket module and the second sub-gasket module and a first porous elastic layer on the first non-porous elastic layer. The second boundary region may include a second non-porous elastic layer in contact with the third sub-gasket module and the fourth sub-gasket module and a second porous elastic layer on the second non-porous elastic layer.

[0023] According to another aspect of this disclosure, a method for manufacturing a membrane electrode assembly is provided, the method comprising: forming a first electrode on a first surface of an electrolyte membrane; and forming a second electrode on a second surface of the electrolyte membrane, the second surface being opposite to the first surface, wherein the first electrode comprises a first electrode module and a second electrode module that are separable from each other.

[0024] The method may further include forming a first gas diffusion layer on the first electrode.

[0025] Forming a first gas diffusion layer may include forming a first gas diffusion module on a first electrode module and forming a second gas diffusion module on a second electrode module, and the first gas diffusion module and the second gas diffusion module may be formed in a manner in which the first gas diffusion module and the second gas diffusion module are separable from each other.

[0026] The method may also include applying an adhesive to only one of the first electrode module and the second electrode module immediately before the formation of the first gas diffusion layer.

[0027] The electrolyte membrane may include a first membrane module and a second membrane module that are separable from each other. The second electrode may include a third electrode module and a fourth electrode module that are separable from each other. Forming the first electrode may include forming the first electrode module on a first surface of the first membrane module and forming the second electrode module on a first surface of the second membrane module. Forming the second electrode may include forming the third electrode module on a second surface of the first membrane module and forming the fourth electrode module on a second surface of the second membrane module. The method may further include arranging a first component module including the first electrode module, the third electrode module and the first membrane module between the first electrode module and the third electrode module, and a second component module including the second electrode module, the fourth electrode module and the second membrane module between the second electrode module and the fourth electrode module, in such a way that the first component module and the second component module are adjacent to each other.

[0028] The first membrane module may have an active region in contact with the first electrode module and the third electrode module and an inactive region surrounding the active region. The second membrane module may have an active region in contact with the second electrode module and the fourth electrode module and an inactive region surrounding the active region. The method may further include: forming a first sub-wafer module and a third sub-wafer module surrounding the first electrode module and the third electrode module, respectively, in the inactive region of the first membrane module, before arranging the first component module and the second component module adjacent to each other, to obtain the first component module; and forming a second sub-wafer module and a fourth sub-wafer module surrounding the second electrode module and the fourth electrode module, respectively, in the inactive region of the second membrane module, to obtain the second component module.

[0029] The method may further include: forming a first gas diffusion module on a first electrode module and a third gas diffusion module on a third electrode module before arranging the first component module and the second component module adjacent to each other to obtain a first component module; and forming a second gas diffusion module on a second electrode module and a fourth gas diffusion module on a fourth electrode module to obtain a second component module.

[0030] The method may further include: after arranging the first component module and the second component module adjacent to each other, forming a first elastic gasket on the first sub-gasket module and the second sub-gasket module, the first elastic gasket having a first window and a second window respectively configured to allow the first gas diffusion module and the second gas diffusion module to pass through their exposed first window and second window respectively; and forming a second elastic gasket on the third sub-gasket module and the fourth sub-gasket module, the second elastic gasket having a third window and a fourth window respectively configured to allow the third gas diffusion module and the fourth gas diffusion module to pass through their exposed third window and fourth window respectively.

[0031] The first elastic gasket may include a first boundary region between a first window and a second window, the first boundary region contacting both the first sub-gasket module and the second sub-gasket module to prevent gas leakage through the gap between the first component module and the second component module. The second elastic gasket may include a second boundary region between a third window and a fourth window, the second boundary region contacting both the third sub-gasket module and the fourth sub-gasket module to prevent gas leakage through the gap between the first component module and the second component module. The first boundary region may have: (i) a flow path structure having a plurality of first grooves, configured such that the first window and the second window can, in their contact with the first sub-gasket module and the second sub-gasket module, achieve flow path connection. The surfaces of the blocks are in fluid communication with each other through the plurality of first grooves on opposite surfaces, or (ii) a double-layer structure including a first non-porous elastic layer in contact with the first sub-wafer module and the second sub-wafer module and a first porous elastic layer on the first non-porous elastic layer, wherein the second boundary region may have: (i) a flow path structure having a plurality of second grooves, configured such that the third window and the fourth window are in fluid communication with each other through the plurality of second grooves on their surfaces opposite to the surfaces in contact with the third sub-wafer module and the fourth sub-wafer module, or (ii) a double-layer structure including a second non-porous elastic layer in contact with the third sub-wafer module and the fourth sub-wafer module and a second porous elastic layer on the second non-porous elastic layer.

[0032] The general description of this disclosure provided above is for illustrative or descriptive purposes only and does not limit the scope of the claims made herein.

[0033] Beneficial effects

[0034] According to this disclosure, the electrode of the membrane electrode assembly is modularized into a deteriorating portion and a remaining portion. Therefore, when the deteriorating portion deteriorates earlier than the remaining portion due to prolonged operation of the fuel cell, only the deteriorated portion (i.e., the deteriorated module) can be replaced with a new module, without needing to discard or replace the entire electrode (or the entire membrane electrode assembly). Thus, according to this disclosure, the time and cost spent on maintaining the membrane electrode assembly can be significantly reduced, and the lifespan of the membrane electrode assembly can be increased.

[0035] Furthermore, according to this disclosure, since only the degraded module can be replaced and the remaining portion of the electrode (i.e., the undegraded module) can be used continuously, resource waste can be minimized. Attached Figure Description

[0036] The accompanying drawings, which are included and form part of this specification, are intended to aid in understanding this disclosure and, together with the detailed description thereof, illustrate embodiments of the disclosure and serve to illustrate the principles of the disclosure.

[0037] Figure 1 (a) and Figure 1 (b) are plan and cross-sectional views of a membrane electrode assembly according to one embodiment of the present disclosure, respectively;

[0038] Figure 2 This is a cross-sectional view of a membrane electrode assembly according to one embodiment of the present disclosure;

[0039] Figure 3 This is a cross-sectional view of a membrane electrode assembly according to another embodiment of this disclosure;

[0040] Figure 4 This is a cross-sectional view of a membrane electrode assembly according to yet another embodiment of this disclosure;

[0041] Figure 5 This is a cross-sectional view of a fuel cell according to one embodiment of this disclosure;

[0042] Figure 6 This is a cross-sectional view of a fuel cell according to another embodiment of this disclosure;

[0043] Figure 7 A flow channel in a diaphragm according to one embodiment of the present disclosure is shown;

[0044] Figure 8 (a) and Figure 8 (b) are plan and cross-sectional views of a membrane electrode assembly according to another embodiment of the present disclosure, respectively;

[0045] Figure 9 This is a cross-sectional view of a membrane electrode assembly according to another embodiment of this disclosure;

[0046] Figure 10 (a) is a plan view of an elastic washer according to one embodiment of the present disclosure;

[0047] Figure 10 (b) is an application Figure 10 (a) Cross-sectional view of the membrane electrode assembly with elastic gasket;

[0048] Figure 11 yes Figure 10 (b) An exploded cross-sectional view of the membrane electrode assembly;

[0049] Figure 12 (a) and Figure 12 (b) are a plan view and a partial cross-sectional view of an elastic washer according to another embodiment of the present disclosure, respectively;

[0050] Figure 12 (c) is an application Figure 12 (a) and Figure 12 (b) Cross-sectional view of the membrane electrode assembly with elastic gasket;

[0051] Figure 13 (a) and Figure 13 (b) are a plan view and a partial cross-sectional view of an elastic washer according to yet another embodiment of the present disclosure;

[0052] Figure 13 (c) is an application Figure 13 (a) and Figure 13 (b) Cross-sectional view of the membrane electrode assembly with elastic gasket. Detailed Implementation

[0053] The embodiments of this disclosure will be described in detail below with reference to the accompanying drawings. However, the following exemplary embodiments are provided only for clear understanding of this disclosure and do not limit its scope.

[0054] Figure 1 (a) and Figure 1 (b) are a plan view and a cross-sectional view of a membrane electrode assembly 1100 according to one embodiment of the present disclosure.

[0055] like Figure 1 As shown, the membrane electrode assembly 1100 according to the present disclosure includes: a first electrode 1110, a second electrode 1120 and an electrolyte membrane 1130 located between the first electrode 1110 and the second electrode 1120.

[0056] The electrolyte membrane 1130 may be: (i) a single-film polymer electrolyte membrane formed of an ionomer; or (ii) a reinforced composite polymer electrolyte membrane comprising a porous support impregnated with an ionomer.

[0057] In the two types of electrolyte membranes 1130 described above, the ionomer may be a fluorinated ionomer or a hydrocarbon ionomer, and may have at least one ion exchange group selected from sulfonic acid group, carboxyl group, boric acid group, phosphate group, imide group, sulfonimide group, sulfonamide group and sulfonic acid fluoride group.

[0058] For example, the ionomer can be a fluorinated ionomer, such as poly(perfluorosulfonic acid), poly(perfluorocarboxylic acid), etc.

[0059] Alternatively, the ionomer may be a hydrocarbon ionomer, such as sulfonated polyimide (S-PI), sulfonated polyarylene ether sulfone (S-PAES), sulfonated polyether ether ketone (SPEEK), sulfonated polybenzimidazole (SPBI), sulfonated polysulfone (S-PSU), sulfonated polystyrene (S-PS), sulfonated polyphosphazene, sulfonated polyquinoxaline, sulfonated polyketone, sulfonated polyphenylene ether, sulfonated polyether sulfone, sulfonated polyether ketone, sulfonated polyphenylene sulfone, sulfonated polyphenylene sulfide, sulfonated polyphenylene sulfide sulfone, sulfonated polyphenylene sulfide sulfonate, sulfonated polyarylene ether, sulfonated polyarylene ether nitrile, sulfonated polyarylene ether nitrile, sulfonated polyarylene ether nitrile, sulfonated polyarylene ether sulfone ketone, etc.

[0060] The porous support used to enhance the composite membrane electrolyte membrane 1130 can be formed of polytetrafluoroethylene (PTFE), or it can be formed of PTFE and CF2=CFC. n F 2n+1 (n is a real number from 1 to 5) or CF2 = CFO - (CF2CF(CF3)O) m C n F 2n+1 A copolymer is formed (where m is a real number from 0 to 15, and n is a real number from 1 to 15). For example, PTFE can be extruded into a strip in the presence of a lubricant, and then subjected to an expansion process and a heat treatment process to form an expanded film-type e-PTFE porous support. Further expansion and heat treatment processes can be performed after the heat treatment process. The expansion and heat treatment processes can be controlled to form various microstructures of e-PTFE porous supports. For example, an e-PTFE porous support can have a microstructure in which nodes are connected to each other by fibrils or a microstructure composed only of fibrils.

[0061] Alternatively, the porous support may be a nonwoven web. The nonwoven web may be formed from a support-forming solution comprising at least one hydrocarbon polymer selected from polyolefins (e.g., polyethylene, polypropylene, polybutene, etc.), polyesters (e.g., PET, PBT, etc.), polyamides (e.g., nylon-6, nylon-6,6, aromatic polyamides, etc.), polyamic acid (formed into a web and then converted to polyimide via an imidization process), polyurethane, polybutene, polylactic acid, polyvinyl alcohol, polyphenylene sulfide (PPS), polysulfone, liquid crystal polymers, polyethylene-vinyl acetate copolymers, polyacrylonitrile, cyclic polyolefins, polyoxymethylene, and polyolefin thermoplastic elastomers.

[0062] Nonwoven webs can be manufactured using methods selected from wet web forming, electrospinning, carding, garnetting, air-laid web forming, meltblowing, spunbonding, and stitch bonding.

[0063] The first electrode 1110 and the second electrode 1120 can be formed on the first surface of the electrolyte membrane 1130 and the second surface opposite to the first surface, respectively, by means of decal transfer or by direct coating with a catalyst slurry containing a catalyst, ionomer and dispersion medium.

[0064] To increase the effective surface area of ​​the catalyst, catalysts with metal particles dispersed on a conductive support are typically used.

[0065] The carrier can be (i) a carbon-based carrier, (ii) a conductive inorganic oxide carrier, such as titanium dioxide, zirconium oxide, aluminum oxide, silicon dioxide or cerium dioxide, or (iii) a zeolite carrier.

[0066] Carbon-based supports can be crystalline or amorphous.

[0067] Specifically, the carbon-based support can be graphitized or non-graphitized carbon black, activated carbon, stabilized carbon, carbon spheres, carbon fibers, carbon sheets, carbon ribbons, fullerenes, carbon nanotubes (CNTs), carbon nanofibers, carbon nanowires, carbon nanospheres, carbon nanohorns, carbon nanocages, carbon nanorings, carbon aerogels, graphene, ordered porous carbon, mesoporous carbon, nanoporous carbon, or a combination of two or more of them.

[0068] The term “graphitized or non-graphitized carbon black” as used in this article is a concept that includes all graphitized or non-graphitized Ketjen black, graphitized or non-graphitized Denka black, and graphitized or non-graphitized acetylene black.

[0069] Graphitized carbon black, carbon nanotubes, and carbon nanofibers can be classified as crystalline carbon-based carriers, while non-graphitized carbon black can be classified as amorphous carbon-based carriers.

[0070] The metal particles can be platinum (Pt) particles or platinum alloy particles. The platinum alloy particles can be Pt-Co, Pt-Cr, Pt-Fe, Pt-Mn, Pt-Mo, Pt-Ni, Pt-Pd, Pt-Ru, Pt-Sn, Pt-W, Pt-Au-Co, Pt-Au-Fe, Pt-Au-Ni, Pt-Co-Fe, Pt-Co-Ir, Pt-Co-Mn, Pt-Co-Ni, Pt-Co-P, Pt-Co-S, Pt-Cr-Ir, Pt-Fe-Ir, Pt-Fe-P, Pt-Fe-S, Pt-Ni-Ir, Pt-Ru-Ir, Pt-Ru-Mo, Pt-Ru-Ni, Pt-Ru-W, Pt-Ru-Ir-Ni, Pt-Ru-Rh-Ni, or Pt-Ru-Sn-W.

[0071] The ionomer, which is dispersed in the dispersion medium together with the catalyst, is used to transfer hydrogen ions and also acts as an adhesive to increase the adhesion strength between the first electrode 1110 and the second electrode 1120 and the electrolyte membrane 1130.

[0072] The ionomer described above, which can be used to form the electrolyte membrane 1130, can also be used to form the first electrode 1110 and the second electrode 1120. Preferably, the ionomer of the electrolyte membrane 1130 and the ionomers of the first electrode 1110 and the second electrode 1120 are of the same type. However, this disclosure is not limited thereto. Different types of ionomers can be used to manufacture the electrolyte membrane 1130, the first electrode 1110, and the second electrode 1120.

[0073] The dispersion medium for the catalyst slurry can be ethanol, distilled water, isopropanol, n-propanol, butanol, or a mixture of two or more of these. However, this disclosure is not limited thereto.

[0074] In this disclosure, such as Figure 1 As shown, the first electrode 1110 includes a first electrode module 1111 and a second electrode module 1112 that are separable from each other.

[0075] That is, the method of manufacturing the membrane electrode assembly 1100 according to this disclosure includes the steps of forming a first electrode 1110 on a first surface of an electrolyte membrane 1130 including a first region and a second region adjacent to each other; and forming a second electrode 1120 on a second surface of the electrolyte membrane 1130. Furthermore, the step of forming the first electrode 1110 includes the steps of forming a first electrode module 1111 on the first region; and forming a second electrode module 1112 on the second region. The first electrode module 1111 and the second electrode module 1112 are formed in a manner that allows them to be separable from each other.

[0076] The term "separable" as used in this specification includes: (i) the meaning of two objects in contact with each other being separable from each other; and (ii) the meaning of two objects arranged at a predetermined interval being spaced apart from each other being able to move away from each other.

[0077] The first electrode module 1111 and the second electrode module 1112 can be arranged side by side in a direction parallel to the surface of the electrolyte membrane 1130.

[0078] As described above, the degradation of the first electrode 1110 caused by prolonged operation of the fuel cell mainly occurs in specific portions of the first electrode 1110, such as the portions of the first electrode corresponding to the gas inlet and / or gas outlet, i.e., the easily degraded portions, rather than over the entire area of ​​the first electrode.

[0079] In this disclosure, the first electrode 1110 of the membrane electrode assembly 1100 is modularized into a first electrode module 1111 corresponding to the easily deteriorated portion and a second electrode module 1112 corresponding to the remaining portion. Therefore, when the first electrode module 1111 deteriorates earlier than the second electrode module 1112 due to prolonged operation of the fuel cell, only the deteriorated first electrode module 1110 can be replaced with a new electrode module, without needing to discard or replace the entire first electrode 1110 or the entire membrane electrode assembly 1100. Thus, in this disclosure, the time and cost for maintaining the membrane electrode assembly 1100 can be significantly reduced, and the lifespan of the membrane electrode assembly 1100 can be increased. Furthermore, since only the deteriorated first electrode module 1111 can be replaced, and the remaining portion of electrode 1110, i.e., the second electrode module 1112, can be used continuously, resource waste can be minimized.

[0080] In one embodiment of this disclosure, the first electrode module 1111, which is a vulnerable portion of the first electrode 1110, may occupy less than 50% of the entire active region of the first electrode 1110. However, this disclosure is not limited thereto.

[0081] The first electrode 1110, which is modularized into a first electrode module 1111 and a second electrode module 1112, can be an anode or a cathode.

[0082] Only one of the anode and cathode of the membrane electrode assembly 1100 can be modularized, or both the anode and cathode can be modularized, such as... Figure 1 As shown in the diagram. That is, in one embodiment of this disclosure, not only is the first electrode 1110 modularized into a first electrode module 1111 and a second electrode module 1112, but the second electrode 1120 is also modularized into a third electrode module 1121 and a fourth electrode module 1122 that are separable from each other, as shown in the diagram. Figure 1 As shown in the image.

[0083] Figure 1 An example is shown in which the first electrode module 1111, which is the easily deteriorated portion of the first electrode 1110, and the third electrode module 1121, which is the easily deteriorated portion of the second electrode 1120, are arranged in a staggered manner. However, this disclosure is not limited thereto. The first electrode module 1111 and the third electrode module 1121 may be arranged in an overlapping manner.

[0084] The following description will primarily focus on the modularity of the first electrode 1110. However, those skilled in the art will readily understand that the same applies to the second electrode 1120.

[0085] To facilitate the replacement of the deteriorated first electrode module 1111, a visible boundary may exist between the first electrode module 1111 and the second electrode module 1112.

[0086] In one embodiment of this disclosure, such as Figure 2 As shown, the first electrode module 1111 and the second electrode module 1112 can contact each other, and a visible boundary can be formed by the groove G between the first electrode module 1111 and the second module 1112. When the second electrode 1120 is also modularized into a third electrode module 1121 and a fourth electrode module 1122 that are separable from each other, a visible boundary can also exist between them formed by the groove G between the third electrode module 1121 and the fourth electrode module 1122.

[0087] Optionally or additionally, the first electrode module 1111 and the second electrode module 1112 may be in contact with each other, and the visible boundary between the first electrode module 1111 and the second electrode module 1112 may be formed due to a color difference between the first electrode module 1111 and the second electrode module 1112 caused by a difference in the materials constituting the first electrode module 1111 and the second electrode module 1112. That is, the first electrode module 1111 may be formed of a first catalyst slurry, the second electrode module 1112 may be formed of a second catalyst slurry, and the first catalyst slurry may be different from the second catalyst slurry.

[0088] The reason why the first electrode module 1111 and the second electrode module 1112 are formed from different catalyst slurries is that the first electrode module 1111, which is the easily deteriorated part of the first electrode 1110, can be formed to have higher durability than the second electrode module 1112. Thus, the overall durability of the membrane electrode assembly 1100 can be improved without impairing the performance of the second electrode module 1112 or minimizing the performance degradation of the first electrode 1110.

[0089] For example, the first electrode module 1111 and the second electrode module 1112 may include different catalysts to have different durability. That is, the first electrode module 1111 may include a first catalyst with relatively low performance but relatively high durability, while the second electrode module 1112 may include a second catalyst with relatively low durability but relatively high performance.

[0090] The first catalyst may include a first support and first metal particles dispersed on the first support, and the second catalyst may include a second support and second metal particles dispersed on the second support. The first support and the second support may be different from each other, and / or the first metal particles and the second metal particles may be different from each other, such that the first catalyst and the second catalyst have different durability. For example, a crystalline carbon-based support (e.g., graphitized carbon black, carbon nanotubes, carbon nanofibers, etc.) or a conductive inorganic oxide support (e.g., a support including SnO2, TiO2, or mixtures thereof) can be used as the first support, and an amorphous carbon-based support (e.g., non-graphitized carbon black) can be used as the second support. Thus, the first catalyst can have better durability than the second catalyst. Therefore, the durability of the first electrode module 1111 can be higher than that of the second electrode module 1112. In this case, the same type of metal particles can be used as the first metal particles and the second metal particles, or the first metal particles can have higher durability than the second metal particles.

[0091] When the first electrode 1110 is the anode, the first electrode module 1111 may include an oxygen evolution reaction (OER) catalyst (hereinafter referred to as the "OER catalyst") and a first hydrogen oxidation reaction (HOR) catalyst (hereinafter referred to as the "first HOR catalyst"), and the second electrode module 1112 may include a second hydrogen oxidation reaction catalyst (hereinafter referred to as the "second HOR catalyst"). Therefore, the durability of the first electrode module 1111 can be higher than that of the second electrode module 1112. The first HOR catalyst and the second HOR catalyst may be the same as or different from each other.

[0092] The first HOR catalyst and the second HOR catalyst may each include platinum (Pt) particles or platinum alloy particles (i.e., Pt-Co, Pt-Cr, Pt-Fe, Pt-Mn, Pt-Mo, Pt-Ni, Pt-Pd, Pt-Ru, Pt-Sn, Pt-W, Pt-Au-Co, Pt-Au-Fe, Pt-Au-Ni, Pt-Co-Fe, Pt-Co-Ir, Pt-Co-Mn, Pt-Co-Ni, Pt-Co-P, Pt-Co-S, Pt-Cr-Ir, Pt-Fe-Ir, Pt-Fe-P, Pt-Fe-S, Pt-Ni-Ir, Pt-Ru-Ir, Pt-Ru-Mo, Pt-Ru-Ni, Pt-Ru-W, Pt-Ru-Ir-Ni, Pt-Ru-Rh-Ni, or Pt-Ru-Sn-W).

[0093] Typically, the reactions occurring at the hydrogen-supplying anode include (i) the hydrogen oxidation reaction via the HOR catalyst while hydrogen is being supplied normally, and (ii) the carbon oxidation reaction caused when the hydrogen supply is reduced or interrupted due to fuel shortage. The carbon oxidation reaction causes corrosion of the carbon-based support of the HOR catalyst, leading to the elution and / or aggregation of the metal particles in the HOR catalyst. The OER catalyst is a catalyst that induces the oxygen evolution reaction to inhibit the carbon oxidation reaction, comprising a support and metal particles dispersed thereon. The aforementioned carbon-based support, conductive inorganic oxide support, or zeolite support can be used as the support for the OER catalyst, and the metal particles of the OER catalyst may include IrO2, RuO2, Ir... x Sn 1-x O2 (x is a real number greater than 0 and less than 1), PtIr, IrRu, PtRuIr, or a mixture of two or more of them.

[0094] Optionally or additionally, the first electrode module 1111 and the second electrode module 1112 may include different ionomers to have different durability. That is, the first electrode module 1111 may include a first ionomer with relatively high durability, while the second electrode module 1112 may include a second ionomer with relatively low durability. Generally, the durability of the ionomer is closely related to the length of its side chain. The shorter the side chain length, the smaller the performance degradation rate in the accelerated life evaluation of the fuel cell. That is, it can be considered that the shorter the side chain length of the ionomer, the higher its durability.

[0095] When the second electrode 1120, in addition to the first electrode 1110, is also modularized into electrode modules 1121 and 1122 that are separable from each other, the aforementioned visible boundary formed by the difference in color / durability may also exist between the third electrode module 1121 and the fourth electrode module 1122.

[0096] In another embodiment of this disclosure, the first electrode module 1111 and the second electrode module 1112 may be in contact with each other, and the visible boundary may be formed due to the structural differences between the first electrode module 1111 and the second electrode module 1112.

[0097] For example, such as Figure 3 As shown, the first electrode module 1111 has a double-layer structure, including a first sub-layer 1111a and a second sub-layer 1111b formed sequentially on the electrolyte membrane 1130, and the second electrode module 1112 has a single-layer structure.

[0098] When, in addition to the first electrode 1110, the second electrode 1120 is also modularized into electrode modules 1121 and 1122 that are separable from each other, the third electrode module 1121 may have a double-layer structure, including a third sub-layer 1121a and a fourth sub-layer 1121b formed sequentially on the electrolyte membrane 1130, and the fourth electrode module 1122 may have a single-layer structure.

[0099] One of the first sublayer 1111a and the second sublayer 1111b may include a first catalyst, and the other of the first sublayer 1111a and the second sublayer 1111b and the second electrode module 1112 may include a second catalyst with lower durability than the first catalyst, such that the durability of the first electrode module 1111 may be higher than the durability of the second electrode module 1112.

[0100] For example, as described above, a crystalline carbon-based support (e.g., graphitized carbon black, carbon nanotubes, carbon nanofibers, etc.) or a conductive inorganic oxide support (e.g., a support including SnO2, TiO2, or mixtures thereof) can be used as the first support for the first catalyst, and an amorphous carbon-based support (e.g., non-graphitized carbon black) can be used as the second support for the second catalyst, so that the first catalyst can have better durability than the second catalyst.

[0101] Alternatively, when the first electrode 1110 is the anode where the hydrogenation reaction occurs, the aforementioned OER catalyst can be used as the first catalyst, and the aforementioned HOR catalyst can be used as the second catalyst, such that the durability of the first electrode module 1111 can be higher than that of the second electrode module 1112. On the other hand, when the second electrode 1120 is the anode, one of the third sublayer 1121a and the fourth sublayer 1121b may include the OER catalyst, and the other of the third sublayer 1121a and the fourth sublayer 1121b, as well as the fourth electrode module 1122, may include the HOR catalyst.

[0102] On the other hand, when the first electrode 1110 is the cathode from which the oxygen reduction reaction occurs, the first electrode module 1111 can have a higher porosity than the second electrode module 1112, allowing water generated by the oxygen reduction reaction to drain from the first electrode module 1111 more easily than from the second electrode module 1112. Therefore, the first electrode module 1111, from which water that induces and / or accelerates electrode degradation drains more easily, has higher durability than the second electrode module 1112. In this case, the structural difference between the first electrode module 1111 and the second electrode module 1112, which form the visible boundary between them, is the difference in porosity. The same applies when the second electrode 1120 is the cathode.

[0103] Optionally or additionally, such as Figure 4 As shown, the first electrode module 1111 and the second electrode module 1112 can be spaced apart from each other, and the visible boundary can be generated due to the spacing I between the first electrode module 1111 and the second electrode module 1112. In the same manner, the third electrode module 1121 and the fourth electrode module 1122 can also be spaced apart from each other, and the visible boundary can be generated due to the spacing I between the third electrode module 1121 and the fourth electrode module 1122.

[0104] In the following text, reference will be made to Figures 5 to 7 The detailed description includes a membrane electrode assembly 1100 and a fuel cell 1000 according to the present disclosure.

[0105] Figure 5 This is a cross-sectional view of a fuel cell 1000 according to one embodiment of this disclosure. Figure 6 This is a cross-sectional view of a fuel cell 1000 according to another embodiment of this disclosure. Figure 7 A flow channel 1211 in a diaphragm 1210 according to one embodiment of the present disclosure is shown.

[0106] like Figure 5 As shown, the fuel cell 1000 according to this disclosure includes: a first membrane 1210, a second membrane 1220, and a membrane electrode assembly 1100 located between the first membrane 1210 and the second membrane 1220.

[0107] The first electrode 1110 of the membrane electrode assembly 1100 is disposed between the first diaphragm 1210 and the electrolyte membrane 1130, and the second electrode 1120 of the membrane electrode assembly 1100 is disposed between the second diaphragm 1220 and the electrolyte membrane 1130.

[0108] like Figure 7 As shown, the first diaphragm 1210 includes: a first inlet GI for supplying a first gas to the first electrode 1110; a first outlet GO for the first gas; and a first flow channel 1211 between the first inlet GI and the first outlet GO.

[0109] In one embodiment of this disclosure, the first electrode 1110 includes a first electrode module 1111 and a second electrode module 1112 that are separable from each other, and the first electrode module 1111 is a deteriorable portion corresponding to the first inlet GI and / or the first outlet GO.

[0110] Similarly, the second diaphragm 1220 also includes: a second inlet (not shown) for supplying the second gas to the second electrode 1120; a second outlet (not shown) for the second gas; and a second flow channel 1221 between the second inlet and the second outlet. Furthermore, the second electrode 1120 may also include a third electrode module 1121 and a fourth electrode module 1122 that are separable from each other, and the third electrode module 1121 may be a deteriorating portion corresponding to the second inlet (not shown) and / or the second outlet (not shown) of the second diaphragm 1220.

[0111] By modularizing the first electrode 1110 and / or the second electrode 1120, only the electrode modules that deteriorate due to prolonged operation of the fuel cell 1000 can be selectively replaced. Therefore, the time and cost spent maintaining the fuel cell 1000 can be reduced, and its lifespan can be increased.

[0112] like Figure 5 As shown, the first electrode 1110 and the second electrode 1120 are aligned with each other and an electrolyte membrane 1130 is inserted between them. The electrolyte membrane 1130 has an active region for transferring hydrogen ions between the first electrode 1110 and the second electrode 1120 and an inactive region surrounding the active region. That is, the first electrode 1110 is disposed on a first surface of the active region of the electrolyte membrane 1130, and the second electrode 1120 is disposed on a second surface of the active region of the electrolyte membrane 1130.

[0113] like Figure 5 As shown, the fuel cell 1000 according to the present disclosure may include: a first sub-wafer 1160 disposed on a first surface of an inactive region of an electrolyte membrane 1130; and a second sub-wafer 1170 disposed on a second surface of an inactive region of an electrolyte membrane 1130.

[0114] The first sub-wafer 1160 and the second sub-wafer 1170 (i) prevent damage to the edge portion of the electrolyte membrane 1130 due to repeated expansion and contraction of the electrolyte membrane 1130 during the operation of the fuel cell 1000, (ii) solve the problem of poor operation of the membrane electrode assembly 1100 caused by the very thin electrolyte membrane 1130, and (iii) prevent leakage of gas (i.e., hydrogen and / or air).

[0115] The first sub-washer 1160 and the second sub-washer 1170 each have an electrode window through which one of the corresponding first electrode 1110 and second electrode 1120 is exposed. That is, the first sub-washer 1160 surrounds the first electrode 1110, and the second sub-washer 1170 surrounds the second electrode 1120.

[0116] The first sub-waist gasket 1160 and the second sub-waist gasket 1170 can each be formed by laminating a film onto the electrolyte membrane 1130. This film exhibits good chemical and heat resistance in a temperature range from room temperature to 120°C, can withstand pressures exceeding 100 Nm, and has relatively low permeability. For example, the first sub-waist gasket 1160 and the second sub-waist gasket 1170 can each comprise a polyimide (PI) compound, a polyethylene (PE) compound, a polypropylene (PP) compound, a polyethylene terephthalate (PET) compound, a fluorinated ethylene propylene (FEP) compound, a polyethylene naphthalate (PEN) compound, or a mixture of two or more of these compounds.

[0117] The structure including an electrolyte membrane 1130, a first electrode 1110 and a second electrode 1120, and a first sub-wafer 1160 and a second sub-wafer 1170 is also referred to as a membrane electrode assembly, and a roll-to-roll continuous process can be employed to improve the productivity of such membrane electrode assemblies. For example, the roll-to-roll continuous process may include: (i) a first step of continuously forming the first electrode 1110 and the second electrode 1120 at predetermined intervals on a first surface and a second surface of an electrolyte membrane 1130 provided in the form of a continuous membrane to obtain a catalyst-coated membrane (CCM); (ii) a second step of laminating a first sub-wafer membrane and a second sub-wafer membrane having electrode windows formed at predetermined intervals on opposite surfaces of the continuously provided CCM; and (iii) a step of cutting the resulting laminate to form individual membrane electrode assemblies.

[0118] Alternatively, a first sub-wafer membrane and a second sub-wafer membrane may be laminated onto the first and second surfaces of the electrolyte membrane 1130 provided in the form of a continuous membrane, respectively, and then a first electrode 1110 and a second electrode 1120 may be formed on the portions of the electrolyte membrane 1130 exposed through the windows of the first and second sub-wafer membranes, respectively.

[0119] like Figure 5 As shown, the fuel cell 1000 according to one embodiment of the present disclosure may further include: a first gas diffusion layer 1140 between the first electrode 1110 and the first membrane 1210; and a second gas diffusion layer 1150 between the second electrode 1120 and the second membrane 1220. That is, the method for manufacturing a membrane electrode assembly of the present disclosure may further include the steps of forming the first gas diffusion layer 1140 on the first electrode 1110 and forming the second gas diffusion layer 1150 on the second electrode 1120.

[0120] The entire structure including the electrolyte membrane 1130, the first electrode 1110 and the second electrode 1120, the first sub-gasket 1160 and the second sub-gasket 1170, and the first gas diffusion layer 1140 and the second gas diffusion layer 1150 is also referred to as a membrane electrode assembly. Therefore, the membrane electrode assembly 1100 according to this disclosure may further include the first gas diffusion layer 1140 and the second gas diffusion layer 1150. In this membrane electrode assembly 1100, the first electrode 1110 is located between the first gas diffusion layer 1140 and the electrolyte membrane 1130, and the second electrode 1120 is located between the second gas diffusion layer 1150 and the electrolyte membrane 1130.

[0121] The first gas diffusion layer 1140 and the second gas diffusion layer 1150 have the following main functions: (i) providing a gas diffusion path from the flow channels 1211 and 1221 in the first diaphragm 1210 and the second diaphragm 1220 to the first electrode 1110 and the second electrode 1120, so that the gas (i.e., hydrogen and / or air) can be easily and uniformly supplied to the first electrode 1110 and the second electrode 1120; (ii) allowing water, as a byproduct of the redox reaction, to be easily removed from the first electrode 1110 and the second electrode 1120, thereby preventing flooding; (iii) storing some water therein, thereby preventing a sudden decrease in the moisture content of the electrolyte membrane 1130; and (iv) providing sufficient mechanical strength for the membrane electrode assembly 1100.

[0122] The first gas diffusion layer 1140 and the second gas diffusion layer 1150 can each be a conductive porous component, such as carbon paper, carbon cloth, carbon felt, carbon nonwoven fabric, metal paper, metal cloth, metal felt, metal nonwoven fabric, etc.

[0123] In one embodiment of this disclosure, such as Figure 5As shown, the first gas diffusion layer 1140 may include a first gas diffusion module 1141 bonded to the first electrode module 1111 and a second gas diffusion module 1142 bonded to the second electrode module 1112, and the first gas diffusion module 1141 and the second gas diffusion module 1142 can be separated from each other. That is, the first gas diffusion layer 1140 can be formed by forming the first gas diffusion module 1141 on the first electrode module 1111 and forming the second gas diffusion module 1142 on the second electrode module 1112, in such a way that the first gas diffusion module 1141 and the second gas diffusion module 1142 are separable from each other. The first gas diffusion module 1141 and the second gas diffusion module 1142 can be formed from the same material using the same method. However, this disclosure is not limited thereto. The first gas diffusion module and the second gas diffusion module can be formed from different materials using different methods. In this embodiment, the first electrode module 1111 and the first gas diffusion module 1141 can form a replacement unit, thereby improving the convenience of replacing the first electrode module 1111.

[0124] For the same reason, such as Figure 5 As shown, the second gas diffusion layer 1150 may also include a third gas diffusion module 1151 bonded to the third electrode module 1121 and a fourth gas diffusion module 1152 bonded to the fourth electrode module 1122, and the third gas diffusion module 1151 and the fourth gas diffusion module 1152 are separable from each other.

[0125] Alternatively, instead of modularizing the first gas diffusion layer 1140 into a first gas diffusion module 1141 and a second gas diffusion module 1142, the adhesive strength between the first gas diffusion layer 1140 and the first electrode module 1111 and the adhesive strength between the first gas diffusion layer 1140 and the second electrode module 1112 can be set to be different from each other, thereby improving the convenience of replacing the first electrode module 1111.

[0126] For example, such as Figure 6 As shown, the membrane electrode assembly 1100 may further include a first adhesive layer 1181 corresponding to the easily deteriorated portion between the first electrode module 1111 and the first gas diffusion layer 1140. That is, the adhesive can be applied only to the first electrode module 1111, and then the first gas diffusion layer 1140 can be formed over the entire first electrode 1110. Through the first adhesive layer 1181, the adhesion strength between the first gas diffusion layer 1140 and the first electrode module 1111 is higher than the adhesion strength between the first gas diffusion layer 1140 and the second electrode module 1112. In this case, the first electrode module 1111 and the entire first gas diffusion layer 1140 can form a replacement unit, thereby improving the convenience of replacing the first electrode module 1111.

[0127] For the same reason, such as Figure 6 As shown, the membrane electrode assembly 1100 may further include a second adhesive layer 1182 between the third electrode module 1121 and the second gas diffusion layer 1150, corresponding to the easily deteriorated portion. That is, the adhesive may be applied only to the third electrode module 1121, and then the second gas diffusion layer 1150 may be formed over the entire second electrode 1120.

[0128] In the following text, reference will be made to Figure 8 A membrane electrode assembly and a method for manufacturing the same according to another embodiment of the present disclosure are described in detail.

[0129] Figure 8 (a) and Figure 8 (b) are plan and cross-sectional views of a membrane electrode assembly according to another embodiment of the present disclosure.

[0130] like Figure 8 As shown, in a membrane electrode assembly according to another embodiment of the present disclosure, the first electrode includes a first electrode module 1111 and a second electrode module 1112 that are separable from each other, the electrolyte membrane includes a first membrane module 1131 and a second membrane module 1132 that are separable from each other, and the second electrode includes a third electrode module 1121 and a fourth electrode module 1122 that are separable from each other.

[0131] exist Figure 8 In the implementation plan, with Figures 1 to 6 The embodiment shown differs in that the first electrode module 1111, which is the easily degraded part of the first electrode, and the third electrode module 1121, which is the easily degraded part of the second electrode, are arranged in an overlapping manner. Therefore, the first electrode module 1111, the third electrode module 1121, and the first membrane module 1131 between them constitute the first component module 1101, and the second electrode module 1112, the fourth electrode module 1122, and the second membrane module 1132 between them constitute the second component module 1102.

[0132] When the first electrode module 1111 and / or the third electrode module 1121, which are easily degraded parts, degrade earlier than the second electrode module 1112 and the fourth electrode module 1122 due to the long-term operation of the fuel cell, the first component module 1101 can be separated from the second component module 1102 and replaced with a new module.

[0133] The first component module 1101 and the second component module 1102 can be manufactured separately. In other words, the first electrode module 1111 can be formed on the first surface of the first membrane module 1131, and the third electrode module 1121 can be formed on the second surface of the first membrane module 1131 opposite to the first surface, thereby obtaining the first component module 1101. Furthermore, the second electrode module 1112 can be formed on the first surface of the second membrane module 1132, and the fourth electrode module 1122 can be formed on the second surface of the second membrane module 1132 opposite to the first surface, thereby obtaining the second component module 1102.

[0134] The materials used for the various electrode modules 1111, 1112, 1121, and 1122 are the same as described above. Furthermore, membrane modules 1131 and 1132 can be manufactured using the materials described above for the electrolyte membrane 1130; therefore, their detailed description will be omitted.

[0135] The membrane electrode assembly can be manufactured by arranging the first component module 1101 and the second component module 1102, which are obtained separately as described above, in an adjacent manner.

[0136] The first membrane module 1131 has an active region in contact with the first electrode module 1111 and the third electrode module 1121 and an inactive region surrounding the active region, and the second membrane module 1132 has an active region in contact with the second electrode module 1112 and the fourth electrode module 1122 and an inactive region surrounding the active region.

[0137] like Figure 8 As shown, the first component module 1101 may further include a first sub-wafer module 1161 and a third sub-wafer module 1171 disposed in the inactive region of the first membrane module 1131, to surround the first electrode module 1111 and the third electrode module 1121, respectively. Similarly, the second component module 1102 may further include a second sub-wafer module 1162 and a fourth sub-wafer module 1172 disposed in the inactive region of the second membrane module 1132, to surround the second electrode module 1112 and the fourth electrode module 1122, respectively.

[0138] Therefore, the method of manufacturing a membrane electrode assembly according to one embodiment of the present disclosure may further include, before arranging the first assembly module 1101 and the second assembly module 1102 in an adjacent manner, (i) forming a first sub-wafer module 1161 and a third sub-wafer module 1171 respectively surrounding the first electrode module 1111 and the third electrode module 1121 in the inactive region of the first membrane module 1131 to obtain the first assembly module 1101, and (ii) forming a second sub-wafer module 1162 and a fourth sub-wafer module 1172 respectively surrounding the second electrode module 1112 and the fourth electrode module 1122 in the inactive region of the second membrane module 1132 to obtain the second assembly module 1102.

[0139] The descriptions provided above in conjunction with sub-washers 1160 and 1170 will supersede the descriptions of the functions and materials of sub-washer modules 1161, 1162, 1171 and 1172.

[0140] therefore, Figure 8 Implementation plan and Figures 1 to 6 The difference in the embodiment shown is that (i) the electrolyte membrane includes a first membrane module 1131 and a second membrane module 1132 that are separable from each other, (ii) the first electrode module 1111 and the third electrode module 1121, which are easily degraded parts, are arranged in an overlapping manner, (iii) the first sub-wafer includes a first sub-wafer module 1161 and a second sub-wafer module 1162 that are separable from each other, (iv) the second sub-wafer includes a third sub-wafer module 1171 and a fourth sub-wafer module 1172 that are separable from each other, and (v) when the first electrode module 1111 and the third electrode module 1121 are replaced, the first membrane module 1131, the first sub-wafer module 1161 and the third sub-wafer module 1171 can also be replaced.

[0141] Figure 9 This is a cross-sectional view of a membrane electrode assembly according to another embodiment of this disclosure.

[0142] like Figure 9 As shown, the first component module 1101 may further include a first gas diffusion module 1141 covering the first electrode module 1111 and a third gas diffusion module 1151 covering the third electrode module 1121, and the second component module 1102 may further include a second gas diffusion module 1142 covering the second electrode module 1112 and a fourth gas diffusion module 1152 covering the fourth electrode module 1122.

[0143] The first electrode module 1111 is disposed between the first membrane module 1131 and the first gas diffusion module 1141, the third electrode module 1121 is disposed between the first membrane module 1131 and the third gas diffusion module 1151, the second electrode module 1112 is disposed between the second membrane module 1132 and the second gas diffusion module 1142, and the fourth electrode module 1122 is disposed between the second membrane module 1132 and the fourth gas diffusion module 1152.

[0144] Therefore, the method of manufacturing a membrane electrode assembly according to one embodiment of the present disclosure may further include: (i) forming a first gas diffusion module 1141 on the first electrode module 1111 and a third gas diffusion module 1151 on the third electrode module 1121 to obtain the first component module 1101 before arranging the first component module 1101 and the second component module 1102 in an adjacent manner to each other, and (ii) forming a second gas diffusion module 1142 on the second electrode module 1112 and a fourth gas diffusion module 1152 on the fourth electrode module 1122 to obtain the second component module 1102.

[0145] The descriptions provided above in conjunction with gas diffusion layers 1140 and 1150 will supersede the descriptions of the functions and materials of gas diffusion modules 1141, 1142, 1151 and 1152.

[0146] exist Figure 9 In one implementation, when the first electrode module 1111 and / or the third electrode module 1121, which are easily degraded parts, degrade earlier than the second electrode module 1112 and the fourth electrode module 1122 due to the long-term operation of the fuel cell, and thus the first component module 1101 is separated from the second component module 1102 and replaced with a new module, the first gas diffusion module 1141 and the third gas diffusion module 1151 can also be replaced.

[0147] exist Figure 8 and Figure 9 In the embodiment, since the electrolyte membrane includes a first membrane module 1131 and a second membrane module 1132 that are separable from each other, therefore, with Figures 1 to 6 Different implementation schemes may present a risk of gas leakage / flow through the gaps between them. The following will refer to... Figure 10 and Figure 11 A detailed description of an example of a membrane electrode assembly that can overcome this risk.

[0148] Figure 10 (a) is a plan view of an elastic washer according to one embodiment of the present disclosure. Figure 10 (b) is an application Figure 10 (a) is a cross-sectional view of the membrane electrode assembly with an elastic washer. Figure 11 yes Figure 10 (b) An exploded cross-sectional view of the membrane electrode assembly.

[0149] like Figure 10 and Figure 11 As shown, the membrane electrode assembly, which includes a first component module 1101 and a second component module 1102 that are separable from each other, also includes a first elastic washer 1191 and a second elastic washer 1192.

[0150] The first elastic gasket 1191 has a first window W1 and a second window W2. The first gas diffusion module 1141 and the second gas diffusion module 1142 are exposed through the first window W1 and the second window W2, respectively, and are in contact with the first sub-gasket module 1161 and the second sub-gasket module 1162.

[0151] Similarly, the second elastic gasket 1192 has a third window W3 and a fourth window W4 that expose the third gas diffusion module 1151 and the fourth gas diffusion module 1152 respectively, and is in contact with the third sub-gasket module 1171 and the fourth sub-gasket module 1172.

[0152] Therefore, a method for manufacturing a membrane electrode assembly according to one embodiment of the present disclosure may further include: after arranging the first assembly module 1101 and the second assembly module 1102 in an adjacent manner, (i) forming a first elastic washer 1191 on the first sub-wafer module 1161 and the second sub-wafer module 1162, and (ii) forming a second elastic washer 1192 on the third sub-wafer module 1171 and the fourth sub-wafer module 1172.

[0153] The first elastic gasket 1191 and the second elastic gasket 1192 can each be formed of an elastic material such as rubber (e.g., EPDM rubber), thereby allowing them to be tightly fitted between the first component module 1101 and the second component module 1102, and more specifically between the first gas diffusion module 1141 and the second gas diffusion module 1142, and between the third gas diffusion module 1151 and the fourth gas diffusion module 1152, so as to prevent gas from leaking / flowing through the gap between the first component module 1101 and the second component module 1102.

[0154] When, due to prolonged operation of the fuel cell, the first electrode module 1111 and / or the third electrode module 1121, being the more easily degraded components, deteriorate earlier than the second electrode module 1112 and the fourth electrode module 1122, the first elastic gasket 1191 and the second elastic gasket 1192 can be separated from the first component module 1101 and the second component module 1102, respectively. Then, the first component module 1101 can be separated from the second component module 1102 for replacement with a new module (the first component module). Figure 11 As shown in the image.

[0155] Meanwhile, when the in-plane flow of gas introduced into the first gas diffusion module 1141 and the second gas diffusion module 1142 through the flow channels (not shown) in the diaphragm is disturbed by the first elastic gasket 1191, turbulence may occur, and this possibility cannot be ignored. Similarly, when the in-plane flow of gas introduced into the third gas diffusion module 1151 and the fourth gas diffusion module 1152 is disturbed by the second elastic gasket 1192, turbulence may also occur. This turbulence leads to pressure loss, which in turn causes performance degradation of the fuel cell.

[0156] In the following text, reference will be made to Figure 12 and Figure 13 A detailed description of an example of an elastic washer capable of suppressing such turbulence.

[0157] like Figure 12 and Figure 13 As shown, the first elastic gasket 1191 includes a first boundary region 1191a between the first window W1 and the second window W2. The first boundary region 1191a contacts both the first sub-gasket module 1161 and the second sub-gasket module 1162 to prevent gas leakage through the gap between the first component module 1101 and the second component module 1102.

[0158] Similarly, the second elastic gasket 1192 includes a second boundary region 1192a between the third window W3 and the fourth window W4. The second boundary region 1192a contacts both the third sub-gasket module 1171 and the fourth sub-gasket module 1172 to prevent gas leakage through the gap between the first component module 1101 and the second component module 1102.

[0159] exist Figure 12 In one embodiment of the present disclosure shown, the first boundary region 1191a may have a structure including a plurality of first grooves G1, such that the first window W1 and the second window W2 are fluidly connected to each other through the plurality of first grooves G1 on their surfaces opposite to the surfaces of the first sub-gasket modules 1161 and 1162, i.e., having a flow path structure. Therefore, the portion of the first boundary region 1191a in contact with the first sub-gasket modules 1161 and 1162 can act as a sealing member to prevent gas leakage / flow through the gap between the first component module 1101 and the second component module 1102, while the remaining portion of the first boundary region 1191a with the first grooves G1 can ensure in-plane flow of gas introduced into the first gas diffusion module 1141 and the second gas diffusion module 1142, thereby preventing turbulence.

[0160] Similarly, the second boundary region 1192a may have a flow path structure including a plurality of second grooves G2, such that the third window W3 and the fourth window W4 are in fluid communication with each other through the plurality of second grooves G2 on their surfaces opposite to the surfaces of the third sub-gasket module 1171 and the fourth sub-gasket module 1172. Therefore, the portion of the second boundary region 1192a in contact with the third sub-gasket module 1171 and the fourth sub-gasket module 1172 can act as a sealing member to prevent gas leakage / flow through the gap between the first component module 1101 and the second component module 1102, while the remaining portion of the second boundary region 1192a with the second grooves G2 can ensure in-plane flow of gas introduced into the third gas diffusion module 1151 and the fourth gas diffusion module 1152, thereby preventing turbulence.

[0161] exist Figure 13 In one embodiment of the present disclosure shown, the first boundary region 1191a may have a structure comprising a first non-porous elastic layer 1191aa contacting the first sub-gasket module 1161 and the second sub-gasket module 1162, and a first porous elastic layer 1191ab on the first non-porous elastic layer 1191aa, i.e., a double-layer structure. The first non-porous elastic layer 1191aa can act as a sealing member to prevent gas leakage / flow through the gap between the first component module 1101 and the second component module 1102, while the first porous elastic layer 1191ab can ensure in-plane flow of gas introduced into the first gas diffusion module 1141 and the second gas diffusion module 1142, thereby preventing turbulence.

[0162] Similarly, the second boundary region 1192a may have a double-layer structure, comprising: a second non-porous elastic layer 1192aa contacting the third sub-gasket module 1171 and the fourth sub-gasket module 1172; and a second porous elastic layer 1192ab on the second non-porous elastic layer 1192aa. The second non-porous elastic layer 1192aa can act as a sealing member to prevent gas leakage / flow through the gap between the first component module 1101 and the second component module 1102, while the second porous elastic layer 1192ab can ensure in-plane flow of gas introduced into the third gas diffusion module 1151 and the fourth gas diffusion module 1152, thereby preventing turbulence.

[0163] The first non-porous elastic layer 1191aa and the second non-porous elastic layer 1192aa, which act as sealing members, can each be formed of an elastic material such as rubber (e.g., EPDM rubber). The first porous elastic layer 1191ab and the second porous elastic layer 1192ab, which provide flow paths, can also each be formed of an elastic material such as rubber, and include a plurality of pores having a size (e.g., pore diameter from 1 μm to 1000 μm) that allows gas to flow through them.

Claims

1. A membrane electrode assembly, comprising: First electrode; Second electrode; and The electrolyte membrane between the first electrode and the second electrode, wherein, The first electrode includes a first electrode module and a second electrode module that are separable from each other. The second electrode includes a third electrode module and a fourth electrode module that are separable from each other. The electrolyte membrane comprises a first membrane module and a second membrane module that are separable from each other. The membrane electrode assembly includes a first component module and a second component module that are separable from each other. The first component module includes a first electrode module, a third electrode module, and a first membrane module located between the first electrode module and the third electrode module. The second component module includes the second electrode module, the fourth electrode module, and the second membrane module located between the second electrode module and the fourth electrode module. The first membrane module has an active region in contact with the first electrode module and the third electrode module, and an inactive region surrounding the active region. The second membrane module has an active region in contact with the second electrode module and the fourth electrode module, and an inactive region surrounding the active region. The first component module further includes a first sub-wafer module and a third sub-wafer module disposed in the inactive region of the first membrane module, the first sub-wafer module and the third sub-wafer module respectively surrounding the first electrode module and the third electrode module. The second component module further includes a second sub-wafer module and a fourth sub-wafer module disposed in the inactive region of the second membrane module, the second sub-wafer module and the fourth sub-wafer module surrounding the second electrode module and the fourth electrode module, respectively.

2. The membrane electrode assembly according to claim 1, wherein, The first electrode module and the second electrode module are in contact with each other, and There is a visible boundary between the first electrode module and the second electrode module, which is formed by at least one of the color difference between the first electrode module and the second electrode module and the structural difference between the first electrode module and the second electrode module.

3. The membrane electrode assembly according to claim 1, wherein, The first electrode module and the second electrode module are spaced apart from each other, and There is a visible boundary between the first electrode module and the second electrode module due to the interval between the first electrode module and the second electrode module.

4. The membrane electrode assembly according to claim 1, further comprising: The first gas diffusion layer, wherein... The first gas diffusion layer is configured such that the first electrode is located between the first gas diffusion layer and the electrolyte membrane. The first gas diffusion layer includes a first gas diffusion module attached to the first electrode module and a second gas diffusion module attached to the second electrode module. The first gas diffusion module and the second gas diffusion module are separable from each other.

5. The membrane electrode assembly according to claim 1, further comprising: The first gas diffusion layer, wherein... The first gas diffusion layer is configured such that the first electrode is located between the first gas diffusion layer and the electrolyte membrane, and The membrane electrode assembly further includes an adhesive layer between one of the first electrode module and the second electrode module and the first gas diffusion layer.

6. The membrane electrode assembly according to claim 1, wherein, The first component module includes a first gas diffusion module covering the first electrode module and a third gas diffusion module covering the third electrode module. The first electrode module is disposed between the first membrane module and the first gas diffusion module, and the third electrode module is disposed between the first membrane module and the third gas diffusion module. The second component module includes a second gas diffusion module covering the second electrode module and a fourth gas diffusion module covering the fourth electrode module. The second electrode module is disposed between the second membrane module and the second gas diffusion module, and the fourth electrode module is disposed between the second membrane module and the fourth gas diffusion module.

7. The membrane electrode assembly according to claim 6, further comprising: A first elastic gasket has a first window and a second window exposed by the first gas diffusion module and the second gas diffusion module respectively, and the first elastic gasket contacts the first sub-gasket module and the second sub-gasket module. and A second elastic gasket has a third window and a fourth window exposed by the third gas diffusion module and the fourth gas diffusion module, respectively, which are configured to contact the third sub-gasket module and the fourth sub-gasket module.

8. The membrane electrode assembly according to claim 7, wherein, The first elastic gasket includes a first boundary region between the first window and the second window, which contacts both the first sub-gasket module and the second sub-gasket module to prevent gas leakage through the gap between the first component module and the second component module. The second elastic gasket includes a second boundary region between the third window and the fourth window, which contacts both the third sub-gasket module and the fourth sub-gasket module to prevent gas leakage through the gap between the first component module and the second component module. The first boundary region has a plurality of first grooves configured such that the first window and the second window can be in fluid communication with each other through the plurality of first grooves on their surfaces opposite to the surfaces that contact the first sub-washer module and the second sub-washer module. The second boundary region has a plurality of second grooves configured such that the third window and the fourth window can be in fluid communication with each other through the plurality of second grooves on their surfaces opposite to the surfaces that contact the third sub-washer module and the fourth sub-washer module.

9. The membrane electrode assembly according to claim 7, wherein, The first elastic gasket includes a first boundary region between the first window and the second window, which contacts both the first sub-gasket module and the second sub-gasket module to prevent gas leakage through the gap between the first component module and the second component module. The second elastic gasket includes a second boundary region between the third window and the fourth window, which contacts both the third sub-gasket module and the fourth sub-gasket module to prevent gas leakage through the gap between the first component module and the second component module. The first boundary region includes a first non-porous elastic layer in contact with the first sub-washer module and the second sub-washer module, and a first porous elastic layer on the first non-porous elastic layer. The second boundary region includes a second non-porous elastic layer that contacts the third sub-washer module and the fourth sub-washer module, and a second porous elastic layer on the second non-porous elastic layer.

10. A method for manufacturing a membrane electrode assembly, the method comprising: A first electrode is formed on the first surface of the electrolyte membrane; and A second electrode is formed on a second surface of the electrolyte membrane, the second surface being opposite to the first surface, wherein... The first electrode includes a first electrode module and a second electrode module that are separable from each other. The second electrode includes a third electrode module and a fourth electrode module that are separable from each other. The electrolyte membrane includes a first membrane module and a second membrane module that are separable from each other. The first membrane module has an active region in contact with the first electrode module and the third electrode module, and an inactive region surrounding the active region. The second membrane module has an active region in contact with the second electrode module and the fourth electrode module, and an inactive region surrounding the active region. The formation of the first electrode includes: The first electrode module is formed on the first surface of the first membrane module; and The second electrode module is formed on the first surface of the second membrane module. The formation of the second electrode includes: The third electrode module is formed on the second surface of the first membrane module; and The fourth electrode module is formed on the second surface of the second membrane module, and The method also includes: A first sub-waist module and a third sub-waist module are formed in the inactive region of the first membrane module, respectively surrounding the first electrode module and the third electrode module, to obtain a first component module, which includes the first electrode module, the third electrode module, the first membrane module between the first electrode module and the third electrode module, as well as the first sub-waist module and the third sub-waist module; A second sub-wafer module and a fourth sub-wafer module are formed in the inactive region of the second membrane module, respectively surrounding the second electrode module and the fourth electrode module, to obtain a second component module, which includes a second electrode module, a fourth electrode module, a second membrane module between the second electrode module and the fourth electrode module, and the second and fourth sub-wafer modules; and The first component module and the second component module are arranged so that they are adjacent to each other.

11. The method of claim 10, further comprising forming a first gas diffusion layer on the first electrode.

12. The method according to claim 11, wherein, The formation of the first gas diffusion layer includes: A first gas diffusion module is formed on the first electrode module; and A second gas diffusion module is formed on the second electrode module, and The first gas diffusion module and the second gas diffusion module are formed in a manner in which the first gas diffusion module and the second gas diffusion module are separable from each other.

13. The method of claim 11, further comprising applying an adhesive to only one of the first electrode module and the second electrode module immediately prior to the formation of the first gas diffusion layer.

14. The method of claim 10, wherein, The first component module also includes a first gas diffusion module and a third gas diffusion module. The second component module also includes a second gas diffusion module and a fourth gas diffusion module, and The method also includes, before deploying the first component module and the second component module: The first gas diffusion module and the third gas diffusion module are formed on the first electrode module and the third electrode module, respectively, to obtain the first component module; and The second gas diffusion module and the fourth gas diffusion module are formed on the second electrode module and the fourth electrode module, respectively, to obtain the second component module.

15. The method of claim 14, further comprising, after arranging the first component module and the second component module in an adjacent manner: A first elastic gasket is formed on the first sub-gasket module and the second sub-gasket module, the first elastic gasket having a first window and a second window respectively exposed by the first gas diffusion module and the second gas diffusion module; and A second elastic gasket is formed on the third sub-gasket module and the fourth sub-gasket module. The second elastic gasket has a third window and a fourth window that are configured to allow the third gas diffusion module and the fourth gas diffusion module to pass through their respective exposed windows.

16. The method according to claim 15, wherein, The first elastic gasket includes a first boundary region between the first window and the second window, which contacts both the first sub-gasket module and the second sub-gasket module to prevent gas leakage through the gap between the first component module and the second component module. The second elastic gasket includes a second boundary region between the third window and the fourth window, which contacts both the third sub-gasket module and the fourth sub-gasket module to prevent gas leakage through the gap between the first component module and the second component module. The first boundary region has: (i) a flow path structure having a plurality of first grooves, configured such that the first window and the second window can be fluidly connected to each other through the plurality of first grooves on their surfaces opposite to the surfaces that contact the first sub-wafer module and the second sub-wafer module; or (ii) a double-layer structure comprising a first non-porous elastic layer in contact with the first sub-wafer module and the second sub-wafer module and a first porous elastic layer on the first non-porous elastic layer. The second boundary region has: (i) a flow path structure having a plurality of second grooves, configured such that the third window and the fourth window can be fluidly connected to each other through the plurality of second grooves on their surfaces opposite to the surfaces that contact the third sub-washer module and the fourth sub-washer module, or (ii) a double-layer structure including a second non-porous elastic layer that contacts the third sub-washer module and the fourth sub-washer module and a second porous elastic layer on the second non-porous elastic layer.

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