A fuel cell membrane electrode assembly roll-to-roll packaging method and system

Abstract

The application discloses a fuel cell membrane electrode integrated roll-to-roll packaging method and system. The application combines plasma etching, electrostatic dust removal, UV glue curing and other technologies into the integrated roll-to-roll packaging process of the membrane electrode preparation, solves two core technical problems existing in the traditional process, that is, the delamination and peeling problems in the use process caused by the insufficient interface bonding force between the proton membrane edge and the frame material, and the low product yield problem caused by the dust and particle pollution in the production process, realizes the continuous production of the whole process of the membrane electrode packaging, improves the product performance consistency and the production efficiency, and reduces the manufacturing cost.

Description

Technical Field

[0001] This invention belongs to the field of fuel cell technology, specifically relating to a method and system for integrated roll-to-roll packaging of fuel cell membrane electrodes. Background Technology

[0002] The membrane electrode assembly (MEA) of a proton exchange membrane fuel cell is the core reaction component of the fuel cell, and its encapsulation process directly determines the product performance, consistency, and production cost.

[0003] The current mainstream packaging process in the industry is wafer-type intermittent production, which involves cutting CCM (Catalyst Coated Membrane), border film, gas diffusion layer (GDL), etc., and then stacking and packaging them to obtain membrane electrode assembly (MEA).

[0004] For example, invention application CN122025694A discloses a single cell structure for a fuel cell and its integrated packaging method. A water field seal is integrally injection-cured and molded on the side of the anode plate away from the membrane electrode assembly (MEA). Bridge plates are installed at the coolant inlet and outlet of the anode plate. A hydrogen bonding film is coated on one of the outer peripheries of the anode plate and the MEA, and an air bonding film is coated on one of the outer peripheries of the cathode plate and the MEA. A partial PEN support for the hydrogen port is bonded to the surface of the MEA facing the anode plate, and a partial PEN support for the air port is bonded to the surface of the MEA facing the cathode plate. The anode plate, MEA, and cathode plate are stacked and subjected to a cold pressing process for positioning and pre-pressing; a hot pressing process is then performed.

[0005] For example, invention application CN118198443A discloses a hydrogen fuel cell structure and its packaging method. First, the membrane electrode, anode plate and cathode plate are placed in the lower mold cavity in sequence, with the first anode sealing groove of the anode plate facing the cathode plate and the second anode sealing groove of the anode plate facing the membrane electrode. The upper mold cavity is then covered on the lower mold cavity, and adhesive is added to the cathode sealing groove. The adhesive is then vulcanized to complete the integrated sealing of the cathode plate, anode plate and membrane electrode.

[0006] The main drawbacks of intermittent sheet production include low production efficiency, low material utilization, poor product consistency, and high risk of process damage.

[0007] Existing roll-to-roll packaging technology only achieves the functions of cutting and bonding the border film, and does not solve core problems such as low interface bonding strength and uneven stress distribution.

[0008] For example, the utility model with authorization announcement number CN223898319U discloses a bonding device for membrane electrode encapsulation and a fuel cell production system. The bonding device for membrane electrode encapsulation includes a bonding component, a frame unwinding component and a driving component. The bonding component includes steel rollers and rubber rollers that are relatively distributed, and there is a gap between the steel rollers and rubber rollers for the membrane material to pass through. The frame unwinding component is located upstream of the steel rollers and is used to transport the frame to the gap via the steel rollers for bonding with the substrate. Summary of the Invention

[0009] To address the aforementioned shortcomings in the prior art, this invention provides a method and system for integrated roll-to-roll packaging of fuel cell membrane electrodes.

[0010] This invention first provides a method for integrated roll-to-roll packaging of fuel cell membrane electrodes, comprising the following steps: Step 1: Unwind the CCM roll, use plasma etching on both sides of the CCM to improve the adhesion of the adhesive, and then perform electrostatic dust removal on the CCM. Step 2: Unroll the frame film on both sides and apply UV-curable adhesive, then bond it to both sides of the CCM treated in Step 1. Step 3: UV light is used to irradiate the adhesive position to cure the UV-curable adhesive, thus bonding the frame film to the CCM. Step 4: Unwind the gas diffusion layer rolls on both sides and apply adhesive, then bond them to both sides of the CCM with frame film obtained in Step 3 to obtain the membrane electrode seven-in-one assembly. Step 5: Cut the membrane electrode assembly obtained in Step 4 into a finished membrane electrode assembly.

[0011] Preferably, in step 1, the plasma etching process has a power of 1200-1500W and a processing time of 5-10s. After etching, the surface roughness Ra of the proton exchange membrane is increased to 2.0-2.7nm.

[0012] Preferably, in step 1, the plasma etching area is a 2-5 mm wide area on each side edge of the CCM.

[0013] Preferably, in step 1, the electrostatic dust removal uses a two-stage electrostatic dust removal device to remove particulate matter from the surface of the proton exchange membrane.

[0014] Preferably, in step 2, after the side frame films are unrolled and the active area windows are cut out, UV-curable adhesive is applied. In step 4, the gas diffusion layer rolls on both sides are unwound, cut, and then adhesive is applied. The size of the cut depends on the dimensions corresponding to the film-forming electrode model.

[0015] Preferably, in step 2, the coating thickness of the UV-curable adhesive is 12-15 μm.

[0016] Preferably, in step 3, the irradiance during ultraviolet light irradiation is 800-1200 mW / cm². 2 The curing time is 8-12 seconds.

[0017] The present invention further provides a system for the integrated roll-to-roll packaging method of the fuel cell membrane electrode assembly, comprising: The CCM unwinding unit includes a CCM unwinding mechanism for unwinding CCM rolls, and a plasma etching mechanism and an electrostatic dust removal mechanism for sequentially performing plasma etching and electrostatic dust removal on the unwound CCM. The frame film unwinding unit includes a frame film unwinding mechanism for unwinding frame film rolls on both sides, an adhesive coating mechanism for applying UV-curable adhesive to the frame film on both sides, a first pre-applied roller for pressing and bonding the frame film with a CCM roller, and a UV irradiation mechanism for curing the UV-curable adhesive. The gas diffusion layer unwinding unit includes a gas diffusion layer unwinding mechanism for unwinding gas diffusion layer rolls on both sides, a dispensing mechanism for dispensing adhesive to the gas diffusion layer on both sides, and a second pre-attach roller for bonding the gas diffusion layer to both sides of a CCM with a border film. The MEA forming and cutting unit is used to cut the membrane electrode assembly into a finished membrane electrode assembly.

[0018] Preferably, the frame film unwinding unit is further provided with a frame cutting mechanism for cutting the frame film out of the active area window between the frame film unwinding mechanism and the adhesive coating mechanism.

[0019] Preferably, the gas diffusion layer unwinding unit is further provided with a gas diffusion layer cutting unit for cutting the gas diffusion layer between the gas diffusion layer unwinding mechanism and the dispensing mechanism.

[0020] This invention combines plasma etching, electrostatic dust removal, and UV adhesive curing technologies into an integrated roll-to-roll packaging process for membrane electrode fabrication, solving two major technical problems in traditional processes: first, insufficient interfacial bonding between the proton exchange membrane edge and the frame material, leading to delamination during use; and second, low product yield due to dust and particulate contamination during production. This invention enables continuous production of the entire membrane electrode packaging process, while improving product performance consistency and production efficiency, and reducing manufacturing costs. Attached Figure Description

[0021] Figure 1 This is a schematic flowchart of the integrated roll-to-roll packaging method for fuel cell membrane electrodes according to the present invention.

[0022] Reference numerals: 1. CCM roll material; 2. Plasma etching mechanism; 3. Electrostatic dust removal mechanism; 4. Frame film unwinding mechanism; 5. Frame cutting mechanism; 6. Glue application mechanism; 7. First pre-attach roller; 8. Ultraviolet irradiation mechanism; 9. Gas diffusion layer roll material unwinding mechanism; 10. Gas diffusion layer cutting unit; 11. Glue dispensing mechanism; 12. Second pre-attach roller; 13. MEA forming and cutting unit; 14. Conveyor roller. Detailed Implementation

[0023] like Figure 1 As shown, a system for the integrated roll-to-roll packaging method of the fuel cell membrane electrode assembly includes a CCM unwinding unit, a border membrane unwinding unit, a gas diffusion layer unwinding unit, and an MEA forming and cutting unit.

[0024] The CCM unwinding unit includes a CCM unwinding mechanism for unwinding CCM roll 1, and a plasma etching mechanism 2 and an electrostatic dust removal mechanism 3 for sequentially performing plasma etching and electrostatic dust removal on the unwound CCM.

[0025] The frame film unwinding unit includes a frame film unwinding mechanism 4 for unwinding the frame film rolls on both sides, an adhesive coating mechanism 6 for applying UV-curable adhesive to the frame film on both sides, a first pre-applying roller 7 for bonding the frame film to the CCM roller, and a UV irradiation mechanism 8 for curing the UV-curable adhesive. Between the frame film unwinding mechanism 4 and the adhesive coating mechanism 6, the frame film unwinding unit also includes a frame cutting mechanism 5 for cutting active area windows into the frame film.

[0026] The gas diffusion layer unwinding unit includes a gas diffusion layer unwinding mechanism 9 for unwinding gas diffusion layer rolls on both sides, a dispensing mechanism 11 for dispensing adhesive to the gas diffusion layer on both sides, and a second pre-attach roller 12 for bonding the gas diffusion layer to both sides of the CCM with a border film. The gas diffusion layer unwinding unit also includes a gas diffusion layer cutting unit 10 for cutting the gas diffusion layer between the gas diffusion layer unwinding mechanism 9 and the dispensing mechanism 11.

[0027] MEA forming and cutting unit 13 is used to cut the membrane electrode assembly into a finished membrane electrode assembly. The finished membrane electrode assembly is output via conveyor roller 14.

[0028] Example 1 1. CCM unwinding and pretreatment: 1) A perfluorosulfonic acid proton exchange membrane with a thickness of 8 μm is used, with an unwinding tension of 8 N and a belt speed of 3 m / min; the frame membrane is a PEN membrane with a thickness of 25 μm, with an unwinding tension of 5 N.

[0029] 2) Plasma etching: Argon / oxygen mixed plasma was used to etch a 2mm wide area on each side edge of the proton exchange membrane. The etching power was 1200W and the processing time was 8s. After etching, the surface roughness Ra of the proton exchange membrane increased from 0.8nm to 2.3nm.

[0030] 3) Electrostatic dust removal: A two-stage electrostatic dust removal device is adopted, with the first stage voltage at 12kV and the second stage voltage at 15kV, to remove particulate matter from the surface of the proton exchange membrane.

[0031] 2. Edge trimming, gluing, and bonding: 1) The double-sided frame film roll is unwound synchronously, and the active area window is cut out online through the frame cutting line with a cutting accuracy of ±0.05mm.

[0032] 2) Shanghai Haobang UV-3000 polyolefin UV adhesive was applied to the bonding surface of the frame film using a micro-gravure coating method. The wet film thickness was 12μm, and the coating accuracy was controlled within ±0.5μm.

[0033] 3) Composite lamination: After the etched areas of the frame film and the proton exchange membrane are aligned, they are laminated using two rollers with a lamination pressure of 0.3 MPa and a lamination temperature of 25°C to ensure uniform diffusion of the adhesive layer without bubbles.

[0034] 3. UV curing: Curing was performed using a 365nm UV-LED light source with an irradiance of 800mW / cm². 2 The curing time is 12 seconds.

[0035] 4. GDL cutting, dispensing, and encapsulation process 1) The double-sided GDL rolls are unwound synchronously and then transferred to the dispensing station after being cut by the GDL cutting die.

[0036] 2) The dispensing station applies adhesive at the junction of the gas diffusion layer and the frame to form a sealing point. The dispensing spacing is 5-10mm and the dispensing speed is 100mm / s.

[0037] 3) The GDL is precisely bonded to the frame structure through the pre-applied roller, with a positioning accuracy of ±0.1mm and a pressure of 0.2-0.5MPa.

[0038] 5. MEA molding process 1) The GDL-packaged membrane electrode 7-in-1 assembly is cut by a forming and cutting die, and then transported by conveyor rollers to obtain the final MEA product.

[0039] The membrane electrode prepared in this embodiment was subjected to performance tests: the bonding strength was 7.2 N / cm, the bonding strength retention rate after 1000 h of damp heat aging at 85℃ / 85%RH was 94%, no hydrogen evolution corrosion was observed at the edge of the proton exchange membrane, the yield rate was 99.0%, the shrinkage rate after proton exchange membrane encapsulation was approximately 0.8%, and the current density of a single cell at 0.6V was 1.52 A / cm. 2 .

[0040] Example 2 The only difference between the process parameters in this embodiment and those in Embodiment 1 is that: Plasma etching power was 1500W, etching time was 10s, and the surface roughness Ra of the proton exchange membrane was improved to 2.7nm; UV adhesive coating thickness was 15μm, and curing irradiation intensity was 1000mW / cm². 2 The curing time is 10 seconds.

[0041] The performance test results of the membrane electrode prepared in this embodiment are as follows: the adhesion strength is 7.8 N / cm, the adhesion strength retention rate after 1000 h of damp heat aging at 85℃ / 85%RH is 95%, the yield rate is 99.4%, the shrinkage rate after proton exchange membrane encapsulation is about 0.8%, and the current density of a single cell at 0.6V is 1.50 A / cm. 2 .

[0042] Example 3 The only difference between the process parameters in this embodiment and those in Embodiment 1 is that: The conveyor belt speed was increased to 5 m / min, the plasma etching time was adjusted to 5 s, the surface roughness Ra of the proton exchange membrane was increased to 2.0 nm, the UV curing time was adjusted to 8 s, and the irradiation intensity was increased to 1200 mW / cm². 2 .

[0043] The performance test results of the membrane electrode prepared in this embodiment are as follows: the adhesion strength is 6.9 N / cm, the adhesion strength retention rate after 1000 h of damp heat aging at 85℃ / 85%RH is 92%, the yield rate is 98.9%, and the current density of a single cell at 0.6V is 1.51 A / cm. 2 .

[0044] Comparative Example 1 The only difference between this comparative example and Example 1 is that no plasma etching treatment was performed on the edge of the proton exchange membrane, and the surface roughness Ra of the proton exchange membrane was 0.8 nm. All other process parameters are the same.

[0045] The performance test results of the membrane electrode prepared in this comparative example are as follows: the adhesion strength is 3.1 N / cm; the adhesion strength retention rate after 1000 h of damp heat aging at 85℃ / 85%RH is 62%; the yield rate is 92.9%; the frame detachment rate after 1000 h of cycling is 12%; and the current density at 0.6V for a single cell is 1.45 A / cm. 2 .

[0046] Comparative Example 2 The only difference between this comparative example and Example 1 is that a traditional thermosetting adhesive is used instead of a UV adhesive, the curing temperature is 120°C, the curing time is 30s, and the surface roughness Ra of the proton exchange membrane is 0.8nm. All other process parameters are the same.

[0047] The performance test results of the membrane electrode prepared in this comparative example are as follows: the adhesion strength is 5.5 N / cm, the adhesion strength retention rate after 1000 h of damp heat aging at 85℃ / 85%RH is 69%, the proton exchange membrane shrinkage rate due to high temperature is 4.2%, the yield rate is 90.1%, and the current density of a single cell at 0.6V is 1.38 A / cm. 2 .

[0048] Comparative Example 3 This comparative example uses a membrane electrode prepared by a commercially available conventional roll-to-roll packaging process, without employing a two-stage electrostatic dust removal process. The remaining process parameters are similar to those in Example 1.

[0049] The performance test results of the membrane electrode prepared in this comparative example are as follows: the bonding strength is 6.2 N / cm, the bonding strength retention rate after 1000 h of humid heat aging at 85℃ / 85%RH is 65%, the yield rate is 92.3%, the pinhole defect rate caused by particulate matter is 4.7%, and the membrane electrode decay rate after 1000 h of cycling is 21%.

[0050] Detection Example 1 The test data are shown in Table 1.

[0051] Table 1 As can be seen from the test results of the above embodiments and comparative examples, the technical advantages of the present invention compared with traditional processes are: 1) Improved production efficiency: Enables continuous production throughout the entire process, with fast production speed and high efficiency, and a single production line can achieve an annual capacity of one million pieces.

[0052] 2) Improved product performance: The gradient interface modification formed by edge plasma etching and the UV low-temperature curing process improve the interface bonding strength by more than 130% compared with the traditional process, and the damp heat aging stability is improved by more than 50% after 1000 hours of damp heat cycling.

[0053] 3) Improved yield: The two-stage electrostatic dust removal process effectively controls particulate contamination during production, increasing the product yield from 90.1% in the traditional process to 99.4%.

[0054] 4) Reduced energy consumption: This process uses a 365nm LED ultraviolet light source for room temperature curing, with a curing time of only 3-5 seconds and a unit energy consumption of only 12.3kWh / thousand pieces. Compared with the traditional hot pressing process, which requires heating the hot pressing plate to 120-150℃ and maintaining pressure for 30-60 seconds, with a unit energy consumption of about 30.8kWh / thousand pieces, energy consumption is reduced by more than 60%. It eliminates the high temperature and high energy consumption link of the traditional hot pressing process and meets the requirements of green manufacturing.

[0055] 5) Reduced Proton Exchange Damage: The heat-free UV curing process used in this patent reduces the proton exchange membrane thickness deformation rate from 4.2% to 0.8%, a reduction of 80.9%, compared to the traditional heat-pressing encapsulation process. This avoids membrane material shrinkage and catalyst layer structure damage caused by heat pressing; compared to the defects of traditional heat pressing processes, which cause thickness deformation of the proton exchange membrane and microcracks in the catalyst layer under high temperature and pressure, thus affecting the service life of the membrane electrode assembly.

Claims

1. A method for integrated roll-to-roll packaging of fuel cell membrane electrode assembly, characterized in that, Includes the following steps: Step 1: Unwind the CCM roll, use plasma etching on both sides of the CCM to improve the adhesion of the adhesive, and then perform electrostatic dust removal on the CCM. Step 2: Unroll the frame film on both sides and apply UV-curable adhesive, then bond it to both sides of the CCM treated in Step 1. Step 3: UV light is used to irradiate the adhesive position to cure the UV-curable adhesive, thus bonding the frame film to the CCM. Step 4: Unwind the gas diffusion layer rolls on both sides and apply adhesive, then bond them to both sides of the CCM with frame film obtained in Step 3 to obtain the membrane electrode seven-in-one assembly. Step 5: Cut the membrane electrode assembly obtained in Step 4 into a finished membrane electrode assembly.

2. The integrated roll-to-roll packaging method for fuel cell membrane electrodes according to claim 1, characterized in that, In step 1, the plasma etching process has a power of 1200-1500W and a processing time of 5-10s.

3. The integrated roll-to-roll packaging method for fuel cell membrane electrodes according to claim 1, characterized in that, In step 1, the plasma etching process is performed on the two sides of the CCM, each with a width of 2-5 mm.

4. The integrated roll-to-roll packaging method for fuel cell membrane electrodes according to claim 1, characterized in that, In step 1, a two-stage electrostatic precipitator is used to remove particulate matter from the surface of the proton exchange membrane.

5. The integrated roll-to-roll packaging method for fuel cell membrane electrodes according to claim 1, characterized in that, In step 2, after the side frame films are unrolled and the active area windows are cut out, UV-curable adhesive is applied. In step 4, the gas diffusion layer rolls on both sides are unwound, the gas diffusion layer is cut, and then glue is applied.

6. The integrated roll-to-roll packaging method for fuel cell membrane electrodes according to claim 1, characterized in that, In step 2, the coating thickness of the UV-curable adhesive is 12-15 μm.

7. The integrated roll-to-roll packaging method for fuel cell membrane electrodes according to claim 1, characterized in that, In step 3, the irradiance during ultraviolet light irradiation is 800-1200 mW / cm². 2 The curing time is 8-12 seconds.

8. A system for the integrated roll-to-roll packaging method for fuel cell membrane electrode assembly according to any one of claims 1-7, characterized in that, include: The CCM unwinding unit includes a CCM unwinding mechanism for unwinding CCM rolls, and a plasma etching mechanism and an electrostatic dust removal mechanism for sequentially performing plasma etching and electrostatic dust removal on the unwound CCM. The frame film unwinding unit includes a frame film unwinding mechanism for unwinding frame film rolls on both sides, an adhesive coating mechanism for applying UV-curable adhesive to the frame film on both sides, a first pre-applied roller for pressing and bonding the frame film with a CCM roller, and a UV irradiation mechanism for curing the UV-curable adhesive. The gas diffusion layer unwinding unit includes a gas diffusion layer unwinding mechanism for unwinding gas diffusion layer rolls on both sides, a dispensing mechanism for dispensing adhesive to the gas diffusion layer on both sides, and a second pre-attach roller for bonding the gas diffusion layer to both sides of a CCM with a border film. The MEA forming and cutting unit is used to cut the membrane electrode assembly into a finished membrane electrode assembly.

9. The system according to claim 8, characterized in that, The frame film unwinding unit is further provided with a frame cutting mechanism between the frame film unwinding mechanism and the adhesive coating mechanism for cutting the frame film to form the active area window.

10. The system according to claim 8, characterized in that, The gas diffusion layer unwinding unit is located between the gas diffusion layer unwinding mechanism and the dispensing mechanism, and is also equipped with a gas diffusion layer cutting unit for cutting the gas diffusion layer.

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