Apparatus and method
By using a combination of dispensing nozzles and carriers on a fuel cell or electrolyzer substrate, the problems of low throughput and insufficient precision in the prior art are solved, enabling faster and more accurate binder deposition and improving production efficiency.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- JOHNSON MATTHEY HYDROGEN TECH LTD
- Filing Date
- 2024-10-25
- Publication Date
- 2026-05-08
AI Technical Summary
Existing technologies suffer from low throughput and insufficient precision when applying adhesives to the substrate of fuel cells or electrolyzers.
The device employs a first and second dispensing nozzle, in which different portions of the substrate pass through fixed positions by longitudinal movement of a carrier. The first and second dispensing nozzles dispense adhesive separately, and the combination of electric actuation and suction bed technology ensures high-precision and high-efficiency adhesive deposition.
It significantly improves the speed and accuracy of substrate processing, enhances the throughput of acceptable quality components, reduces processing cycle time, and improves production efficiency.
Smart Images
Figure CN122003300A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to an apparatus for applying an adhesive to a substrate, wherein the substrate is a component for a fuel cell or electrolyzer. Preferably, the substrate is a gas diffusion layer or a porous transport layer, and most preferably a gas diffusion layer. The invention also relates to related methods for applying the adhesive to such a substrate. Background Technology
[0002] A fuel cell is an electrochemical cell comprising two electrodes separated by an electrolyte. Fuel (e.g., hydrogen, alcohol (such as methanol or ethanol), or formic acid) is supplied to the anode, and an oxidant (e.g., oxygen or air) is supplied to the cathode. Electrochemical reactions occur at the electrodes, and the chemical energy of the fuel and oxidant is converted into electrical energy and heat. Electrocatalysts are used to facilitate the electrochemical oxidation of the fuel at the anode and the electrochemical reduction of oxygen at the cathode.
[0003] Fuel cells are typically classified according to the properties of the electrolyte used. The electrolyte is usually a solid polymer membrane, which is electrically insulating but ionicly conductive. In a proton exchange membrane fuel cell (PEMFC), the membrane is proton-conductive, and protons generated at the anode are transported across the membrane to the cathode, where they combine with oxygen to form water.
[0004] An electrolyzer is an electrochemical device used to electrolyze water to produce high-purity hydrogen and oxygen. Electrolyzers can operate in both alkaline and acidic systems. Electrolyzers that use solid proton-conducting polymer electrolyte membranes or proton exchange membranes (PEMs) are called proton exchange membrane water electrolyzers (PEMWEs). Electrolyzers that utilize solid anion-conducting polymer electrolyte membranes or anion exchange membranes (AEMs) are called anion exchange membrane water electrolyzers (AEMWEs).
[0005] The main component of a fuel cell or water electrolyzer is the membrane electrode assembly (MEA). An MEA typically consists of five layers. The middle layer is a polymer ion-conducting membrane. On either side of the ion-conducting membrane lies an electrocatalyst layer containing an electrocatalyst designed for a specific electrolysis reaction. Finally, adjacent to each electrocatalyst layer are a gas diffusion layer and / or a porous transport layer. The gas diffusion layer (or porous transport layer) allows reactants to reach the electrocatalyst layer and conducts the current generated by the electrochemical reaction. The gas diffusion layer (or porous transport layer) is porous and conductive.
[0006] Electrocatalyst layers typically comprise electrocatalyst materials containing metals or metal alloys suitable for oxidation reactions (e.g., fuel oxidation) or reduction reactions (e.g., oxygen reduction), depending on whether the layer is intended for use as an anode or cathode. Electrocatalysts are typically based on platinum or platinum alloyed with one or more other metals. Platinum or platinum alloy catalysts can be in the form of unsupported nanoparticles (such as metallic black or other unsupported granular metal powders), but more conventionally, platinum or platinum alloys are deposited as high-surface-area nanoparticles onto high-surface-area conductive carbon materials (such as carbon black or its heat-treated form). Anode catalysts for PEMWEs typically comprise iridium or iridium oxide (IrOx) materials or oxides containing both iridium and ruthenium.
[0007] The electrocatalyst layer also typically includes proton-conducting materials, such as proton-conducting polymers, to facilitate the transfer of protons from the anode catalyst to the membrane and / or from the membrane to the cathode catalyst.
[0008] Typically, an MEA can be constructed using several methods outlined below:
[0009] (i) An electrocatalyst layer can be applied to a gas diffusion layer (or porous transport layer) to form a gas diffusion electrode (or porous transport electrode). The gas diffusion electrode (or porous transport electrode) can be placed on each side of the ion-conducting membrane and laminated together to form a five-layer MEA;
[0010] (ii) An electrocatalyst layer may be applied to both sides of an ion-conducting membrane to form a catalyst-coated ion-conducting membrane. Subsequently, a gas diffusion layer (and / or a porous transport layer) may be applied to each side of the catalyst-coated ion-conducting membrane.
[0011] (iii) The MEA may be formed by an ion-conducting membrane coated with an electrocatalyst layer on one side, a gas diffusion layer (or porous transport layer) adjacent to the electrocatalyst layer, and a gas diffusion electrode (or porous transport electrode) on the other side of the ion-conducting membrane.
[0012] Typically, dozens or hundreds of MEAs are needed to provide sufficient power for most applications, so multiple MEAs are assembled to form a fuel cell stack. A flow field plate is used to separate the MEAs. This plate performs several functions: supplying reactants to the MEAs; removing products; providing electrical connections; and providing physical support.
[0013] Figure 6A schematic plan view of a prior art device 600 for applying adhesive to a gas diffusion layer of a fuel cell is shown. Device 600 includes a dispensing nozzle 602 disposed within a housing 604 and a carrier 606 adapted to support a pre-cut gas diffusion layer 608. In operation, the dispensing nozzle 602 moves to apply adhesive to the gas diffusion layer 608 in a predetermined pattern (movement indicated by dashed arrows). Typically, the adhesive is applied over the entire periphery of the gas diffusion layer. After adhesive application, the gas diffusion layer can be used to form an MEA as previously described. There is a desire to develop improved devices for applying adhesive to substrates to achieve faster throughput and higher precision. Summary of the Invention
[0014] This invention seeks to address at least some of the aforementioned problems, expectations, and needs. In particular, the apparatus and methods of this disclosure are capable of processing substrates significantly faster while maintaining high accuracy. This can significantly increase the throughput of components of acceptable quality.
[0015] Therefore, in a first aspect, there is provided an apparatus for applying an adhesive to a substrate, wherein the substrate is a component for a fuel cell or an electrolyzer, the apparatus comprising:
[0016] An adhesive dispensing unit, comprising a first dispensing nozzle and a second dispensing nozzle, the first dispensing nozzle being positioned to dispense adhesive at a first fixed position, and the second dispensing nozzle being positioned to dispense adhesive at a second fixed position; and
[0017] A carrier, the carrier including a substrate receiving region, wherein the carrier is movable in a longitudinal direction such that a first portion of the substrate receiving region can pass through a first fixed position and a second portion of the substrate receiving region can pass through a second fixed position;
[0018] The adhesive dispensing unit is configured to dispense adhesive via the first dispensing nozzle when the first portion of the substrate receiving area moves through the first fixed position, and to dispense adhesive via the second dispensing nozzle when the second portion of the substrate receiving area moves through the second fixed position.
[0019] The first and second dispensing nozzles may be spaced apart in a direction parallel to the longitudinal direction. That is, the first and second dispensing nozzles may be arranged such that they do not overlap longitudinally when viewed from a direction perpendicular to the longitudinal direction. When spaced apart in this way, the positions of the first and second dispensing nozzles (which have fixed positions during operation) can be adjusted laterally to accommodate a wider range of substrate sizes. For example, the first and second dispensing nozzles may be spaced apart laterally, with the lateral direction perpendicular to the longitudinal direction. The first and second dispensing nozzles may also overlap laterally. The lateral positions of the first and second dispensing nozzles can be selected based on the cross-sectional dimensions (e.g., width) of the substrate and the desired location of the adhesive.
[0020] The dispensing nozzle can be pneumatically or electrically actuated, preferably electrically actuated.
[0021] The carrier may include at least one base alignment member. The carrier may include at least one base alignment member for each base receiving region.
[0022] The substrate receiving area may include a suction bed.
[0023] The carrier may include multiple substrate receiving regions. The carrier may include at least one column of substrate receiving regions, wherein the column, or each column, includes substrate receiving regions extending in a direction parallel to the longitudinal direction. The carrier may include at least one row of substrate receiving regions, wherein the row, or each row, includes substrate receiving regions extending in a direction substantially perpendicular to the longitudinal direction. The carrier may include an array of substrate receiving regions, the array comprising multiple columns and rows. Each column in the array includes multiple substrate receiving regions extending in a direction parallel to the longitudinal direction. Each row in the array includes substrate receiving regions extending in a direction substantially perpendicular to the longitudinal direction.
[0024] The first and second dispensing nozzles form a pair of dispensing nozzles. The pair of dispensing nozzles operates suitably together to dispense adhesive onto different portions of the same substrate. Preferably, each pair of dispensing nozzles includes a first dispensing nozzle and a second dispensing nozzle, the first dispensing nozzle being positioned to dispense adhesive at a first fixed position, and the second dispensing nozzle being positioned to dispense adhesive at a second fixed position, wherein the first and second fixed positions in the pair of dispensing nozzles are aligned in a direction perpendicular to the longitudinal direction (i.e., in the transverse direction). The device may include multiple pairs of dispensing nozzles. Each pair of dispensing nozzles is suitably arranged to process substrates in different columns. For example, a first column of substrate receiving area is movable through the first and second fixed positions of the first pair of dispensing nozzles, and a second column of substrate receiving area is movable through the first and second fixed positions of the second pair of dispensing nozzles, and so on. Preferably, when viewed in a direction perpendicular to the longitudinal direction, adjacent pairs of dispensing nozzles (i.e., transversely adjacent pairs of dispensing nozzles) are arranged to be spaced apart (i.e., not overlapping). That is, adjacent pairs of dispensing nozzles are preferably arranged in a staggered manner. Adjacent distribution nozzle pairs can be arranged in a direction perpendicular to the longitudinal direction, such that when viewed in a direction parallel to the longitudinal direction, adjacent pairs overlap in space.
[0025] The carrier may be longitudinally movable to enter the adhesive dispensing unit from a first side. The carrier may also be movable to exit the adhesive dispensing unit from a second side. Preferably, the first side is opposite to the second side. Alternatively or otherwise, the carrier may be movable to exit the adhesive dispensing unit from the first side. For example, the carrier may be longitudinally movable to enter the adhesive dispensing unit from the first side and may also be movable in a direction opposite to the longitudinal direction (i.e., antiparallel to the longitudinal direction) to exit the adhesive dispensing unit from the first side.
[0026] The carrier can be longitudinally movable on a linear track. The carrier can be movable in a continuous loop. The carrier may include a conveying device. For example, the carrier may extend between two rollers.
[0027] The carrier may include a first carrier. The device may also include a second carrier having a substrate receiving region, wherein the second carrier is movable such that a first portion of the substrate receiving region of the second carrier can pass through the first fixed position, and a second portion of the substrate receiving region of the second carrier can pass through the second fixed position. The first carrier and the second carrier may each be longitudinally movable to enter the adhesive dispensing unit from a first side. The first carrier may be longitudinally movable to enter the adhesive dispensing unit from a first side, and the second carrier may be movable in a direction opposite to the longitudinal direction to enter the adhesive dispensing unit from a second side, wherein the first side and the second side are opposite each other.
[0028] The device may include a pick-up and placement robot for providing a substrate to a substrate receiving area.
[0029] The apparatus can be part of a roll-to-roll manufacturing system. Therefore, a roll-to-roll manufacturing system for manufacturing components of a fuel cell or electrolyzer is also provided, the roll-to-roll manufacturing system including the apparatus according to the first aspect.
[0030] According to a second aspect, a method is provided for applying an adhesive to a substrate using the apparatus of the first aspect, wherein the substrate is a component for a fuel cell or electrolyzer, the method comprising the steps of:
[0031] (a) Provide a substrate on the substrate receiving area;
[0032] (b) Move the carrier longitudinally such that a first portion of the base passes through a first fixed position and a second portion of the base passes through a second fixed position;
[0033] (c) As the first portion of the substrate moves past the first fixed position, adhesive is dispensed onto the first portion of the substrate via the first dispensing nozzle; and
[0034] (d) As the second portion of the substrate moves past the second fixed position, adhesive is dispensed onto the second portion of the substrate via the second dispensing nozzle;
[0035] Steps (c) and (d) can occur in any order and / or simultaneously.
[0036] Steps (c) and (d) can begin at different times.
[0037] The first portion of the substrate is suitably located at a different position from the second portion of the substrate. The first and second portions of the substrate may be located at opposite peripheral edges of the substrate. The adhesive may be applied only to the first and second portions of the substrate. The first and second portions may each be independently linear tracks of the adhesive. In step (c), the adhesive may be dispensed onto the first portion of the substrate in the form of continuous adhesive droplets. Alternatively (and preferably), in step (c), the adhesive may be dispensed onto the first portion of the substrate in the form of multiple separate droplets. In step (d), the adhesive may be dispensed onto the second portion of the substrate in the form of continuous adhesive droplets. Alternatively (and preferably), in step (d), the adhesive may be dispensed onto the second portion of the substrate in the form of multiple separate droplets. The deposited adhesive may penetrate into the substrate.
[0038] The adhesive may be a thermoplastic adhesive. Preferably, it is a hot-melt adhesive. The adhesive may include polyolefin materials. The softening point temperature of the adhesive can be in the range of 70°C to 125°C, and preferably in the range of 80°C to 100°C. A softening point temperature can be obtained from Mettler Toledo... ™ The dropping point system is commercially available and determined in accordance with appropriate standards (e.g., ASTM D3954).
[0039] The method may also include providing an additional substrate on a separate substrate receiving area while performing steps (b), (c), and / or (d) on the substrate provided in step (a). For example, the apparatus may include two carriers, each including a substrate receiving area. While one or more substrates supported on the first carrier are being processed (i.e., during steps (b), (c), and (d), an additional substrate can be provided to the second carrier. Preloading carriers in this manner can reduce the time between processing cycles and thus increase processing throughput. In the case where the carrier circulates through an adhesive dispensing unit such as a conveyor, an additional substrate can be provided to a substrate receiving area upstream of the adhesive dispensing unit while the substrate has already been processed, providing a substantially continuous process.
[0040] The substrate may be a porous substrate. The substrate may be a gas diffusion layer or a porous transport layer, and is preferably a gas diffusion layer. In other preferred embodiments, the substrate may be a catalyst-coated ion-conductive membrane, a membrane electrode assembly, or a membrane sealing assembly. The catalyst-coated ion-conductive membrane includes a first electrocatalyst layer applied to a first side of the ion-conductive membrane (e.g., an electrolyte membrane), and a second electrocatalyst layer optionally applied to a second (opposite) side of the ion-conductive membrane. The membrane sealing assembly suitably includes a catalyst-coated ion-conductive membrane and a seal or frame extending around the periphery of the catalyst-coated ion-conductive membrane. A dispensing nozzle may dispense adhesive onto the seal or frame, which may then be attached to the gas diffusion layer or porous transport layer.
[0041] Step (a) may include using a pick-and-place robot to provide a substrate on the substrate receiving area. The method may also include a step after step (d) to remove the substrate from the substrate receiving area, for example, using a pick-and-place robot.
[0042] This method can be part of a roll-to-roll manufacturing method.
[0043] The method may also include subsequent processing steps, such as for manufacturing a membrane electrode assembly. Therefore, a method for manufacturing a membrane electrode assembly is provided, the method comprising the following steps:
[0044] Perform the method according to the second aspect, wherein the substrate is a gas diffusion layer or a porous transport layer;
[0045] A catalyst-coated ion-conducting membrane is provided, comprising a first electrocatalyst layer applied to a first side of the ion-conducting membrane (e.g., an electrolyte membrane); and
[0046] The substrate is attached to the catalyst-coated ion-conducting membrane, such that the first electrocatalyst layer is located between the substrate and the ion-conducting membrane.
[0047] The substrate is typically adjacent to the first electrocatalyst layer.
[0048] Preferably, the step of attaching the substrate to the catalyst-coated ion-conductive membrane includes bonding a first portion and a second portion of the substrate to the catalyst-coated ion-conductive membrane.
[0049] The step of bonding a first and second portion of the substrate to the catalyst-coated ion-conducting film may include heating the adhesive present in the first and second portions to a temperature above the softening point of the adhesive. For example, the bonding step may include contacting the first and second portions with the catalyst-coated ion-conducting film and heating the adhesive present in the first and second portions to a temperature above the softening point of the adhesive. The contacting and heating steps may be performed in any order.
[0050] The catalyst-coated ion-conducting membrane may further include a seal extending around the periphery of the catalyst-coated ion-conducting membrane. That is, the catalyst-coated ion-conducting membrane can be a membrane sealing assembly. Therefore, a method for manufacturing a membrane electrode assembly is also provided, the method comprising the following steps:
[0051] Perform the method according to the second aspect, wherein the substrate is a gas diffusion layer or a porous transport layer;
[0052] A membrane sealing assembly is provided, comprising a seal (or frame) extending around the periphery of a catalyst-coated ion-conductive membrane, wherein the catalyst-coated ion-conductive membrane includes a first electrocatalyst layer applied to a first surface of the ion-conductive membrane (e.g., an electrolyte membrane); and
[0053] The substrate is attached to the membrane sealing assembly such that the first electrocatalyst layer is located between the substrate and the ion-conducting membrane.
[0054] The substrate is typically adjacent to the first electrocatalyst layer.
[0055] Preferably, the step of attaching the substrate to the membrane sealing assembly includes bonding a first portion and a second portion of the substrate to the membrane sealing assembly. Preferably, the first portion and the second portion of the substrate are bonded to the seal.
[0056] The step of bonding the first and second portions to a membrane sealing assembly (e.g., a seal) may include heating the adhesive present in the first and second portions to a temperature above the adhesive's softening point. For example, the bonding step may include bringing the first and second portions into contact with a seal of the membrane sealing assembly and heating the adhesive present in the first and second portions to a temperature above the adhesive's softening point. The contact and heating steps may be performed in any order. Attached Figure Description
[0057] Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, in which:
[0058] Figure 1 It is a schematic diagram in plan view form of an apparatus for applying adhesive to a substrate, showing the stages of the deposition process;
[0059] Figure 2 It is a schematic diagram in plan view form of an apparatus for applying adhesive to a substrate comprising two carriers, and it shows the stages of the deposition process;
[0060] Figure 3 It is a schematic diagram in plan view form of an apparatus for applying adhesive to a substrate comprising two carriers, and it shows the stages of the deposition process;
[0061] Figure 4 It is a schematic diagram in the form of a plan view of a device for applying an adhesive to a substrate, wherein the carrier includes multiple substrate receiving areas;
[0062] Figure 5 It is a schematic diagram in plan view form of an apparatus for applying adhesive to a substrate, wherein the carrier is part of a roll-to-roll manufacturing system; and
[0063] Figure 6 It is a schematic diagram in the form of a plan view of a prior art device for applying an adhesive to a gas diffusion layer. Detailed Implementation
[0064] Preferred and / or optional features of the invention will now be set forth. Unless the context otherwise requires, any aspect of the invention may be combined with any other aspect of the invention. Unless the context otherwise requires, any preferred or optional feature of any aspect may be combined with any aspect of the invention, alone or in combination.
[0065] Figure 1A device 100 for dispensing an adhesive onto a substrate 102, according to a first embodiment, is shown. The substrate 102 is a component for a fuel cell or electrolyzer. Preferably, the substrate is a gas diffusion layer, a gas diffusion electrode, a porous transport layer, or a porous transport electrode. More preferably, the substrate is a gas diffusion layer or a porous transport layer, and most preferably, a gas diffusion layer.
[0066] The device 100 includes an adhesive dispensing unit 110 and a carrier 120. The adhesive dispensing unit 110 typically includes a housing 112 and two dispensing nozzles 114, 116. Each dispensing nozzle 114, 116 has a fixed position within the adhesive dispensing unit 110, such that each nozzle 114, 116 can dispense adhesive at a specific fixed position. The dispensing nozzles 114, 116 are positioned in a direction parallel to the y-axis (e.g.,...). Figure 1 As shown, also referred to as laterally, the dispensing nozzles 114 and 116 are positioned adjacent to each other in the x-axis. The distance between the dispensing nozzles 114 and 116 (on the y-axis) can be selected according to the size of the substrate and the desired location where the adhesive is to be applied. The dispensing nozzles 114 and 116 can be positioned on the same y-axis. This facilitates accurate actuation of the dispensing nozzles; for example, the dispensing nozzles can be configured to begin dispensing adhesive simultaneously. Alternatively, the dispensing nozzles can be positioned in a direction parallel to the x-axis (e.g., y-axis). Figure 1 As shown, or also longitudinally spaced. In such embodiments, the dispensing nozzles 114, 116 may overlap on the y-axis or be spaced apart in a direction parallel to the y-axis. This provides greater flexibility for handling substrates of different sizes.
[0067] The carrier 120 includes a substrate receiving region on which the substrate 102 is positioned. The carrier 120 may include a suction bed comprising a porous surface or a plurality of holes (not shown). Suction or vacuum can be applied to the suction bed to hold the substrate in proper position on the carrier. The carrier 120 includes a clamp or at least one alignment member 122 to facilitate proper positioning of the substrate on the substrate receiving region. At least one alignment member 122 may protrude from the carrier 120. The alignment member may extend at least partially along one or more edges of the substrate receiving region. In use, the substrate may be positioned against the alignment member to ensure proper placement of the substrate on the carrier 120. The alignment member 122 may at least partially define the substrate receiving region. The carrier 120 is capable of positioning along a first axis (in... Figure 1 The carrier 120 (shown as the x-axis) moves into the housing 112 on a transport system such as a linear track 130. In operation, the carrier 120 reciprocates along the linear track. Figure 1(B) shows a carrier 120 within housing 112. The clamps and dispensing nozzles are arranged such that, when the substrate is placed on the substrate receiving area, the portion of the substrate intended for adhesive application passes beneath dispensing nozzles 114 and 116, respectively. Thus, a first portion of the substrate passes through the specific location where adhesive is applied by dispensing nozzle 114. A second portion of the substrate passes through the specific location where adhesive is applied by dispensing nozzle 116. The first and second portions of the substrate intended for adhesive application are each suitably a peripheral edge of the substrate. For example, the first and / or second portions may independently be linear portions no more than 3 mm from the edge of the substrate, and preferably no more than 2 mm. Such linear segments are suitably substantially parallel to the edge of the substrate. Although dispensing nozzles 114 and 116 remain in a fixed position during operation, the relative positions of dispensing nozzles 114 and 116 can be adjusted according to the size of the substrate to be processed. Adhesive dispensing unit 110 is configured to dispense adhesive (and preferably dispense adhesive droplets) as the carrier 120 moves. The first dispensing nozzle 114 is configured to dispense adhesive (and preferably dispense adhesive droplets) as the substrate moves through the specific location where adhesive is applied by dispensing nozzle 114. The second dispensing nozzle 116 is also configured to dispense the adhesive (and preferably dispense adhesive droplets) as the substrate moves to a specific location through which the adhesive is applied via the dispensing nozzle 116. The adhesive may be applied in the form of continuous beads or a series of separate droplets (dashed line 104). Preferably, the adhesive is applied in the form of a series of separate droplets. Each dispensing nozzle may include an actuator, such as a pneumatic or electric actuator, for controlling the release of the adhesive. Preferably, the actuator is an electric actuator.
[0068] The adhesive is preferably a thermoplastic adhesive. It is preferably a hot-melt adhesive. The softening point temperature of the adhesive is at least 70°C, preferably at least 80°C. The softening point temperature of the adhesive is 120°C or lower, preferably 100°C or lower. The softening point temperature of the adhesive can fall within a range including either the upper or lower limits mentioned above. The adhesive may include polyolefin materials. A suitable adhesive is Technomelt, available from Henkel Corporation. ® Supra Cool 100.
[0069] After the carrier 120 has entered the distribution unit 110, the carrier can be subsequently removed. Figure 1 (C) shows the carrier 120 that has been removed from the adhesive dispensing unit 110. Figure 1A preferred process is shown, wherein the adhesive is applied as the carrier 120 enters the adhesive dispensing unit 110. In some embodiments, the adhesive may be applied as the carrier 120 leaves the adhesive dispensing unit 110. In other embodiments, at least one dispensing nozzle may apply the adhesive as the carrier 120 moves into the adhesive dispensing unit 110, and at least one dispensing nozzle may apply the adhesive as the carrier 120 moves out of the adhesive dispensing unit 110.
[0070] Dispensing adhesive from a static dispensing nozzle while the carrier 120 moves significantly reduces the processing time for applying the adhesive to the substrate. For example, when using a device (such as...) Figure 6 As shown), the processing time can be approximately 48 seconds per cycle. However, when using... Figure 1 With the device shown, processing time can be reduced to approximately 3 seconds per cycle (approximately 16 times faster). Furthermore, the device delivers adhesive more precisely and reliably at the desired location because the dispensing nozzle remains in a fixed position relative to the substrate receiving area, thus eliminating the need for periodic position calibration. Therefore, the device increases the throughput and yield of acceptable parts.
[0071] Figure 2 A schematic plan view of an apparatus 200 according to another embodiment of the present disclosure is shown. The apparatus 200 includes an adhesive dispensing unit 210 and two carriers 220, 230.
[0072] Adhesive dispensing unit 210 can be used with about Figure 1 The adhesive dispensing unit 110 described is identical. The same reference numerals are used where features are identical. The adhesive dispensing unit 210 includes two dispensing nozzles 114 and 116. The first dispensing nozzle 114 applies adhesive at a first specific position. The second dispensing nozzle 116 applies adhesive at a second specific position. The dispensing nozzles 114 and 116 are spaced apart in a direction parallel to the x-axis. The dispensing nozzles 114 and 116 overlap in a direction parallel to the y-axis. The first and second positions are spaced apart in the direction parallel to the y-axis by a distance smaller than the cross-sectional dimension of the nozzles 114 and 116. Therefore, the nozzles 114 and 116 overlap in the direction parallel to the y-axis.
[0073] Each carrier 220 and 230 can be associated with about Figure 1 The implementation scheme describes the same carrier 110.
[0074] The device 200 includes a multi-directional track, which includes an operation section 240 and a processing section 250.
[0075] During operation, the substrate 202 is positioned within the substrate receiving region 203 of the carrier 220. Figure 2(A)). The second substrate 204 is positioned in the substrate receiving region of the carrier 230. The carrier 220 first moves along the operating section 240 of the multi-directional track until it is aligned with the processing section of the track 250. Figure 2 (B) The first carrier 220 moves along the processing section of track 250 and below dispensing nozzles 114 and 116. When the substrate moves past a first specific position (below the first dispensing nozzle 114), adhesive is dispensed via the first dispensing nozzle 114. When the substrate moves past a second specific position (below the second dispensing nozzle 116), adhesive is dispensed via the second dispensing nozzle 116. The adhesive can be... Figure 1 The adhesive is deposited in the same manner as described in the implementation scheme. For example, the adhesive is deposited as a continuous series of beads or a series of separated droplets. Figure 2 (C) shows two parallel tracks of adhesive 206 deposited onto the peripheral edge of substrate 202. After the adhesive has been deposited, carrier 220 is removed from adhesive dispensing unit 210 to its starting position along the multi-directional tracks. At this position, the coated substrate can be removed for further processing. Simultaneously, a second carrier 230 moves along the operating section 240 of the multi-directional tracks until it aligns with the processing section 250. Figure 2 (D)). The second carrier 230 moves along the processing section of track 250 and below dispensing nozzles 114 and 116. When the substrate moves past a first specific position (below the first dispensing nozzle 114), adhesive is dispensed via the first dispensing nozzle 114. When the substrate moves past a second specific position (below the second dispensing nozzle 116), adhesive is dispensed via the second dispensing nozzle 116. Figure 2 (E) shows two parallel tracks of adhesive 208 deposited onto the peripheral edge of substrate 204. After the adhesive has been deposited, carrier 230 is removed from adhesive dispensing unit 210 to its starting position along the multidirectional tracks. Figure 2 (F)).
[0076] While the second substrate 204 is being processed, another substrate 202' is positioned on the first carrier 220. In this way, the substrate can be preloaded onto the carrier while the other substrate has already been processed. This arrangement reduces the time between each consecutive processing cycle and further increases the throughput of the coated components.
[0077] Figure 3A schematic plan view of an apparatus 300 according to another embodiment of the present disclosure is shown. The apparatus 300 includes an adhesive dispensing unit 310, two carriers 320 and 330, and a linear track 340. The adhesive dispensing unit 310 includes a housing 312 having openings on opposite sides. The linear track 340 extends through the housing 312. A first carrier 320 is disposed on one side of the housing 312, and a second carrier 330 is disposed on the other side of the housing 312. Figure 3 (A)). In operation, the first carrier 320 moves along a linear track (along the x-axis) into the adhesive dispensing unit 310. Adhesive is applied to a first portion of the substrate as the substrate moves past a first specific position below the first dispensing nozzle 114. Adhesive is applied to a second portion of the substrate as the substrate moves past a second specific position below the second dispensing nozzle 116. In this embodiment, the first dispensing nozzle 114 and the second dispensing nozzle 116 are arranged adjacent to each other (in the lateral direction) and simultaneously and appropriately dispense adhesive onto the first substrate 302. Figure 3 (B) shows the first carrier in the housing 312 after the two adhesive tracks 306 have been deposited.
[0078] Then, the first carrier 320 returns to its starting position, as follows: Figure 3 As shown in (C). When the first carrier has returned to its starting position, the processed substrate can be removed from the carrier for subsequent processing, and a new substrate 302' can be positioned on the substrate receiving region 303 of the first carrier 320. Meanwhile (as shown in...) Figure 3 (As shown in (D)), the second carrier 330 moves into the housing 312, and adhesive is deposited onto the second substrate 304. Specifically, the second dispensing nozzle 116 applies adhesive when the second substrate moves past a second specific position below the second dispensing nozzle 116; and the first dispensing nozzle 114 applies adhesive when the second substrate moves past a first specific position below the first dispensing nozzle 114. In this embodiment, the first dispensing nozzle 114 and the second dispensing nozzle 116 can simultaneously dispense adhesive onto the second substrate 304. Then, the second carrier 330 returns to its starting position, as... Figure 3 As shown in (E).
[0079] While the second substrate 304 is being processed, another substrate 302' is positioned on the first carrier 320. In this way, the substrate can be preloaded onto the carrier while the other substrate has already been processed. This arrangement reduces the time between each consecutive processing cycle and further increases the throughput of the coated components.
[0080] The carrier may include multiple substrate receiving areas. That is, the carrier may include areas designated for receiving substrates. The number of substrate receiving areas on the carrier is not particularly limited. For example, the carrier may include at least two substrate receiving areas, preferably at least four, at least six, and more preferably at least eight. Each substrate receiving area may be at least partially defined by a clamp. The carrier may include an array of substrate receiving areas. The array may include at least one row of substrate receiving areas and at least one column of substrate receiving areas. A row of substrate receiving areas includes at least two substrate receiving areas. The term "row" is used to refer to an arrangement of substrate receiving areas extending in a direction parallel to the y-axis (i.e., generally perpendicular to the direction of travel of the carrier, and sometimes referred to as the transverse direction). A column of substrate receiving areas includes at least two substrate receiving areas. The term "column" is used to refer to an arrangement of substrate receiving areas extending in a direction parallel to the x-axis (i.e., generally parallel to the direction of travel of the carrier, and sometimes referred to as the longitudinal direction). Rows and columns are perpendicular to each other. The carrier may include a single row or a single column of substrate receiving areas. The size of the array is not particularly limited. The carrier may include a 2x3 array, preferably a 2x4 array, and more preferably a 3x4 array of substrate receiving areas. Larger arrays allow more substrates to be processed as part of the same processing cycle. However, larger arrays typically require longer loading times, potentially increasing the time between consecutive processing cycles. The carrier preferably has about 6-12, and more preferably 8-9, substrate receiving areas arranged in 2-3 rows and 3-4 columns. Most preferably, the carrier comprises substrate receiving areas arranged in 2 rows and 4 columns. This arrangement provides a good balance between processing time and the time required to load each carrier.
[0081] Figure 4 It shows having with Figure 1An embodiment of the apparatus 400 operates similarly to the embodiment of the present invention, except that the carrier 420 comprises an array of substrate receiving regions. This array comprises 2 rows and 4 columns. The adhesive dispensing unit 410 includes a pair of dispensing nozzles 114 and 116 for each column. Each pair of dispensing nozzles is configured to apply adhesive to a first portion and a second portion of each substrate 402 in its respective column. In each pair, the first dispensing nozzle 114 is configured to apply adhesive to the first portion of each substrate in the respective column, and the second dispensing nozzle 116 is configured to apply adhesive to the second portion of each substrate in the same respective column. The dispensing nozzles 114 and 116 in each pair are arranged in a direction parallel to the y-axis such that their respective specific positions for dispensing adhesive are adapted to the size of the substrate to be treated. The dispensing nozzles 114 and 116 in each pair are aligned such that their respective specific positions for dispensing are aligned in a direction parallel to the y-axis (i.e., parallel to the transverse and perpendicular to the longitudinal). In this way, the dispensing nozzles 114, 116 in each pair can be configured to begin dispensing adhesive simultaneously, which simplifies the adhesive dispensing process. Preferably, when viewed in a direction perpendicular to the longitudinal direction, adjacent dispensing nozzle pairs are arranged to be spaced apart (i.e., non-overlapping). That is, adjacent dispensing nozzle pairs are preferably arranged in a staggered manner, for example as... Figure 4 As shown. Adjacent dispensing nozzle pairs can be arranged in a direction parallel to the y-axis, such that when viewed in a direction parallel to the longitudinal direction (i.e., parallel to the x-axis), adjacent pairs spatially overlap. Preferably, when viewed in a direction parallel to the x-axis, the first dispensing nozzle 114 of the first pair of dispensing nozzles can spatially overlap with the second dispensing nozzle 116 of the second pair of dispensing nozzles. In this way, the substrate can be more tightly packed onto the carrier, which reduces the area occupied by the device.
[0082] The carrier 420 is positioned on the linear track 440 such that it can move below the dispensing nozzles 114, 116 in the adhesive dispensing unit 410. Adhesive is applied from each of the first dispensing nozzles 114 as the corresponding substrate (a first portion) moves past the specific position of the first dispensing nozzle for adhesive application. Adhesive is applied from each of the second dispensing nozzles 116 as the corresponding substrate (a second portion) moves past the specific position of the second dispensing nozzle for adhesive application. In this embodiment, each dispensing nozzle in the same pair appropriately begins dispensing adhesive simultaneously.
[0083] After the adhesive is applied (when the carrier 420 enters or leaves the adhesive dispensing unit 410), the carrier 420 returns to its starting position, allowing the treated substrate (i.e., the substrate including the adhesive tracks) to be removed from the carrier 420 for subsequent processing (e.g., attachment to a catalyst-coated membrane or membrane sealing assembly). The process can then be repeated for a new substrate array.
[0084] Figure 5 An embodiment of an apparatus as part of a roll-to-roll manufacturing system is shown. In this embodiment, carrier 520 includes a conveying device or an elongated backing sheet. The conveying device 520 extends between two rollers (not shown) and through adhesive dispensing unit 510. The conveying device 520 can... Figure 5 The movement is indicated by the arrow direction. A substrate may be provided on each substrate receiving area before it moves into the adhesive dispensing unit 510. As in any of the embodiments described, a pick-and-place robot can be used to place the substrate onto the substrate receiving area. The conveyor 520 may optionally include one or more substrate alignment members 522 to facilitate proper placement of the substrate onto the substrate receiving area. After processing, the substrate may be removed from the conveyor 520 or retained on the conveyor 520 for further processing. The substrate can be removed from the conveyor 520 by a pick-and-place robot.
[0085] In this way, the substrate can be processed in a substantially continuous manner. There is no particular limitation on the number of substrate receiving regions on the carrier 520. The carrier 520 may include a single row of substrate receiving regions or an array of substrate receiving regions. Figure 5 The illustrated implementation has a single-row substrate receiving area.
[0086] In all embodiments, each dispensing nozzle is configured to dispense adhesive as the substrate moves past a specific dispensing position below the respective dispensing nozzle. The movement of the carrier is preferably automatic and can be controlled by a controller. The controller can also control the operation of the adhesive dispensing unit. In some embodiments, the movement of the carrier is manually initiated, and the dispensing nozzle is configured to dispense adhesive after a preset time following the commencement of carrier movement. In other embodiments, an alignment system can be used, wherein the dispensing nozzle is configured to dispense adhesive in response to the alignment system detecting an alignment mark (e.g., the leading edge of the substrate).
Claims
1. An apparatus for applying an adhesive to a substrate, wherein the substrate is a component for a fuel cell or electrolyzer, the apparatus comprising: An adhesive dispensing unit includes a first dispensing nozzle and a second dispensing nozzle, wherein the first dispensing nozzle is positioned to dispense adhesive at a first fixed position and the second dispensing nozzle is positioned to dispense adhesive at a second fixed position. and A carrier, the carrier including a substrate receiving region, wherein the carrier is movable in a longitudinal direction such that a first portion of the substrate receiving region can pass through a first fixed position and a second portion of the substrate receiving region can pass through a second fixed position; The adhesive dispensing unit is configured to dispense adhesive via the first dispensing nozzle when the first portion of the substrate receiving area moves through the first fixed position, and to dispense adhesive via the second dispensing nozzle when the second portion of the substrate receiving area moves through the second fixed position.
2. The apparatus of claim 1, wherein the first fixed position and the second fixed position are aligned in a direction substantially perpendicular to the longitudinal direction.
3. The apparatus according to claim 1 or 2, wherein the carrier comprises at least one substrate alignment member.
4. The apparatus according to any of the preceding claims, wherein the substrate receiving region comprises a suction bed.
5. The apparatus according to any of the preceding claims, wherein the carrier comprises a plurality of substrate receiving regions.
6. The apparatus of claim 5, wherein the carrier comprises at least one column of substrate receiving regions and / or at least one row of substrate receiving regions, wherein the column or each column comprises substrate receiving regions extending in a direction parallel to the longitudinal direction, and the row or each row comprises substrate receiving regions extending in a direction substantially perpendicular to the longitudinal direction.
7. The apparatus of claim 5 or 6, wherein the carrier comprises an array of substrate receiving regions, the array comprising a plurality of columns and rows, wherein each column comprises a plurality of substrate receiving regions extending in a direction parallel to the longitudinal direction, and each row comprises a substrate receiving region extending in a direction substantially perpendicular to the longitudinal direction.
8. The apparatus according to any of the preceding claims, wherein the first dispensing nozzle and the second dispensing nozzle form a pair of dispensing nozzles, and the apparatus includes multiple pairs of dispensing nozzles.
9. The apparatus of claim 8, wherein adjacent pairs of dispensing nozzles are arranged to be spaced apart in the longitudinal direction.
10. The apparatus according to any of the preceding claims, wherein the carrier is movable in the longitudinal direction to enter the adhesive dispensing unit from a first side and is movable to exit the adhesive dispensing unit from a second side.
11. The apparatus according to any of the preceding claims, wherein the carrier is movable in the longitudinal direction to enter the adhesive dispensing unit from the first side, and is movable in a direction opposite to the longitudinal direction to exit the adhesive dispensing unit from the first side.
12. The apparatus according to any of the preceding claims, wherein the carrier is capable of moving in the longitudinal direction on a linear track.
13. The apparatus according to any of the preceding claims, wherein the carrier includes a conveying device.
14. The apparatus according to any of the preceding claims, wherein the carrier is a first carrier, and the apparatus further comprises a second carrier, the second carrier including a substrate receiving region, wherein the second carrier is movable such that a first portion of the substrate receiving region of the second carrier can pass through the first fixed position, and a second portion of the substrate receiving region on the second carrier can pass through the second fixed position.
15. The apparatus of claim 14, wherein the first carrier and the second carrier are each movable in the longitudinal direction to enter the adhesive dispensing unit from the first side.
16. The apparatus of claim 14, wherein the first carrier is movable in the longitudinal direction to enter the adhesive dispensing unit from a first side, and the second carrier is movable in a direction opposite to the longitudinal direction to enter the adhesive dispensing unit from a second side, wherein the first side is opposite to the second side.
17. The apparatus according to any of the preceding claims, wherein the apparatus further comprises a pick-up and place robot for providing a substrate to the substrate receiving area.
18. A roll-to-roll manufacturing system for manufacturing components of a fuel cell or electrolyzer, the roll-to-roll manufacturing system comprising the apparatus according to any of the preceding claims.
19. A method for applying an adhesive to a substrate using the apparatus according to any preceding claim, wherein the substrate is a component for a fuel cell or electrolyzer, the method comprising the steps of: (a) Provide a substrate on the substrate receiving area; (b) The carrier is moved longitudinally such that a first portion of the base passes through the first fixed position and a second portion of the base passes through the second fixed position; (c) As the first portion of the substrate moves past the first fixed position, adhesive is dispensed onto the first portion of the substrate via the first dispensing nozzle; as well as (d) As the second portion of the substrate moves past the second fixed position, adhesive is dispensed onto the second portion of the substrate via the second dispensing nozzle; Steps (c) and (d) can occur in any order and / or simultaneously.
20. The method of claim 19, wherein steps (c) and (d) begin at different times.
21. The method of claim 19 or 20, wherein the first portion and the second portion of the substrate are located at opposite peripheral edges of the substrate.
22. The method according to any one of claims 19 to 21, wherein the adhesive is applied only to the first portion and the second portion of the substrate.
23. The method according to any one of claims 19 to 22, wherein in step (c), the adhesive is dispensed onto the first portion of the substrate in the form of a plurality of separation droplets; and / or in step (d), the adhesive is dispensed onto the second portion of the substrate in the form of a plurality of separation droplets.
24. The method according to any one of claims 19 to 23, wherein the adhesive is a hot melt adhesive.
25. The method according to any one of claims 19 to 24, wherein the softening point temperature of the adhesive is in the range of 70°C to 125°C, and preferably in the range of 80°C to 100°C.
26. The method according to any one of claims 19 to 25, wherein the method further comprises providing an additional substrate on a separate substrate receiving region while performing steps (b), (c) and / or (d) on the substrate provided in step (a).
27. The method according to any one of claims 19 to 26, wherein the substrate is a gas diffusion layer or a porous transport layer.
28. The method according to any one of claims 19 to 27, wherein the method is part of a roll-to-roll manufacturing method.
29. A method for manufacturing a membrane electrode assembly, the method comprising the following steps: Perform the method according to any one of claims 19 to 28, wherein the substrate is a gas diffusion layer or a porous transport layer; A catalyst-coated ion-conductive membrane is provided, the catalyst-coated ion-conductive membrane comprising a first electrocatalyst layer applied to a first side of the ion-conductive membrane; as well as The substrate is attached to the catalyst-coated ion-conductive membrane such that the first electrocatalyst layer is located between the substrate and the ion-conductive membrane.
30. The method of claim 29, wherein the catalyst-coated ion-conductive membrane is a membrane sealing assembly, the membrane sealing assembly comprising a seal extending around the periphery of the catalyst-coated ion-conductive membrane.
31. The method of claim 30, wherein the step of bonding the substrate to the membrane sealing assembly comprises bonding the first portion and the segment portion of the substrate to the seal.
32. The method according to any one of claims 29 to 31, wherein the step of attaching the substrate comprises heating the adhesive present in the first portion and the second portion of the substrate to a temperature above the softening point of the adhesive.