Mold and composite member for electrochemical device

Abstract

The problem of the present invention is to provide a composite component for molds and electrochemical devices that has high durability and can suppress flash from the liner. The mold (5) includes a first mold (5D) and a second mold (5U). The substrate (2) is disposed in the first mold (5D). The second mold (5U) is configured to face the first mold (5D) in the Y direction and has a cutting portion (50) and a cavity recess (51) disposed inside the cutting portion (50) in the X direction and dividing the cavity (5M) for forming the liner (4). The cutting portion (50) has: a planar top surface (500) that protrudes toward the substrate (2) relative to the parting line (PL) and extends in the X direction; a convex inner surface (501) disposed inside the top surface (500) in the X direction; and a convex outer surface (502) disposed outside the top surface (500) in the X direction. The width (W2) in the X direction between the inner convex side surface (501) and the outer convex side surface (502) narrows in the direction from the parting line (PL) toward the top surface (500).

Description

Technical Field

[0001] This disclosure relates to an insert molding die used in forming a liner onto a substrate, and a composite component for an electrochemical device manufactured using the same die. Background Technology

[0002] Patent Document 1 discloses a mold for forming a gasket capable of suppressing flash. This mold is used when forming a gasket into a component (separator, etc.) of a fuel cell. The mold includes an upper mold and a lower mold. A gasket forming portion and a sealing groove are recessed on the lower surface (mold surface) of the upper mold. The sealing groove is disposed around the gasket forming portion. A sealing member made of an elastomer is disposed in the sealing groove.

[0003] During molding, firstly, the component is placed on the upper surface (mold surface) of the lower mold in the open state. Next, the upper mold comes into contact with the component; that is, the mold closes. By closing the mold, a cavity is created between the component and the gasket forming area of ​​the upper mold. Furthermore, by closing the mold, the sealing member of the sealing groove of the upper mold elastically contacts the upper surface of the component. Through the elastic contact of the sealing member, the cavity is sealed. Then, the gasket material is filled into the sealed cavity.

[0004] Here, the sealing member is made of an elastomer. Therefore, even if the component warps or deforms, the sealing member can remain tightly attached to the upper surface of the component during mold closing. Thus, leakage of material from the cavity can be prevented when filling the gasket. Therefore, the generation of flash can be suppressed.

[0005] Existing technical documents Patent documents Patent document 1: Japanese Patent Application Publication No. 2010-040477. Summary of the Invention

[0006] The problem that the invention aims to solve However, in the case of the mold described in this document, sealing grooves and sealing members are necessary. Therefore, the construction of the lower surface (mold surface) of the upper mold becomes complex. In this regard, if a cut-off portion is provided around the gasket forming area, the generation of flash can be suppressed even without specifically using sealing grooves and sealing members. Specifically, the mold surface of the upper mold in this document is provided with a downwardly protruding cut-off portion instead of sealing grooves and sealing members. Thus, by pressing this cut-off portion against the upper surface of the constituent part, the cavity can be sealed. Therefore, leakage of material from the cavity during gasket material filling can be suppressed. Therefore, the generation of flash can be suppressed.

[0007] However, depending on the rigidity of the constituent components, the durability of the cut-off portion of the mold may decrease. That is, in order to reliably seal the chamber, the cut-off portion needs to be pressed against the upper surface of the constituent components. Therefore, if the rigidity of the constituent components is high, the cut-off portion becomes more prone to breakage as the number of mold closing cycles (shots) increases. In other words, the durability of the cut-off portion decreases.

[0008] Therefore, the object of this disclosure is to provide a mold with high durability of the cut portion and the ability to suppress flash from the liner. Additionally, the object of this disclosure is to provide a composite component for an electrochemical device capable of suppressing flash from the liner.

[0009] means for solving problems (1) To solve the above problems, the mold disclosed herein is a mold for forming a gasket onto a thin plate-shaped substrate disposed within the mold, and includes a mold for embedding a cut portion that suppresses flash from the gasket. The mold is characterized by having the parting line of the mold extending in the X direction as the X direction, the opening and closing direction of the mold as the Y direction, the side of the cavity near the gasket forming chamber in the X direction as the inner side of the X direction, and the side opposite to the inner side of the X direction as the outer side of the X direction. The mold comprises: a first mold for disposing the substrate; and a second... A mold, configured to face the first mold in the Y direction, has the cutting portion and a cavity recess disposed inside the cutting portion in the X direction and dividing the cavity. The cutting portion has: a planar top surface that protrudes toward the substrate relative to the parting line and extends along the X direction; a convex inner surface disposed inside the top surface in the X direction; and a convex outer surface disposed outside the top surface in the X direction. The width in the X direction between the convex inner surface and the convex outer surface narrows in the direction from the parting line toward the top surface.

[0010] Here, the methods of "suppressing flash" include, for example, suppressing the generation of flash itself, and suppressing the stretching of generated flash. According to this configuration, the top surface of the cut portion is planar and extends along the X direction. Therefore, compared to cases where the top surface is curved or extends in a direction intersecting the X direction, it is possible to suppress the situation where the top surface partially presses against the substrate (the case where the top surface contacts the substrate on one side) during mold closing. Therefore, it is possible to alleviate stress concentration on a portion of the top surface. Therefore, it is possible to suppress breakage of the cut portion and improve durability. Furthermore, since the durability of the cut portion is improved, the freedom of material selection for the substrate can be increased. For example, a substrate made of a material with a high Young's modulus can be used.

[0011] In addition, compared with the case where the top surface is not provided in the cutting part (for example, the case where a pair of side surfaces (convex inner side surface and convex outer side surface) are directly connected without passing through the top surface), the shape accuracy of the cutting part (especially the height accuracy in the Y direction) can be improved.

[0012] The width in the X direction between a pair of side surfaces (the inner convex side surface and the outer convex side surface) narrows along the direction from the parting line toward the top surface. Therefore, compared to the case where the width in the X direction between a pair of side surfaces is constant in the direction from the parting line toward the top surface, it can alleviate the stress concentration at the boundary between the top surface and the side surfaces during mold closing.

[0013] (1-1) In the configuration described in (1) above, it is preferable that the first mold is a fixed mold and the second mold is a movable mold when the mold is opened and closed. According to this configuration, the first mold is fixed when the mold is opened and closed (when the mold is opened or closed). A substrate is disposed in the first mold. Therefore, it is possible to suppress the positional displacement of the substrate when the mold is opened and closed.

[0014] (1-2) In any of the above configurations, it is preferable that the cut-off portion is disposed on both sides of the recess in the X direction of the cavity. According to this configuration, flash can be suppressed on both sides of the recess in the X direction of the cavity.

[0015] (1-3) In any of the above configurations, it is preferable that the cut-off portion extends in an endless annular shape around the recess for the chamber when viewed from the Y direction. According to this configuration, the cut-off portion surrounds the recess for the chamber. Therefore, leakage of the liner material can be suppressed in the recess for the chamber, in other words, throughout the entire circumference of the chamber.

[0016] (1-4) In any of the above configurations, it is preferable that the ratio of the surface area to the thickness of the substrate (= surface area / thickness) is 30,000 or more and 3,125,000 or less. According to this configuration, the ratio of surface area to thickness is set to 30,000 or more. Therefore, compared to cases where it is less than 30,000, the situation where the thickness relative to the surface area increases, leading to larger stacks (laminated structures) of electrochemical devices such as fuel cells, can be suppressed. Furthermore, according to this configuration, the ratio of surface area to thickness is set to 3,125,000 or less. Therefore, compared to cases where it exceeds 3,125,000, the situation where the thickness relative to the surface area decreases, leading to excessive deformation of the separator, can be suppressed.

[0017] According to this configuration, the ratio of the substrate surface area to the plate thickness is set to 30,000 or more and 3,125,000 or less. That is, the substrate in this configuration is a thin plate. Therefore, the substrate is prone to moderate deformation. Consequently, during mold closing, the shape accuracy of the mold is easily reflected (transferred) to the substrate. For example, to improve the durability of the cut portion, the mold can be hardened to increase its hardness. However, if hardening is performed, deformation such as "warping" can easily occur in the mold. That is, the shape accuracy of the mold can easily decrease. Therefore, if a liner is formed on a thin plate-shaped substrate (an easily deformable substrate) using this mold, there is a risk of reduced shape accuracy of the substrate.

[0018] In this respect, according to this configuration, the durability of the cut portion can be improved without performing processing on the mold to increase hardness (processing that risks reducing shape accuracy). Therefore, even if the substrate is thin, in other words, even if the substrate is easily deformable, the reduction in the shape accuracy of the substrate can be suppressed.

[0019] (1-5) In any of the above configurations, it is preferable that the ratio of the surface area of ​​the substrate to the thickness of the gasket in the Y direction (= surface area / thickness in the Y direction) is 5000 or more and 500000 or less. According to this configuration, the ratio of surface area to the thickness of the gasket in the Y direction is set to 5000 or more. Therefore, compared with the case where it is less than 5000, it is possible to suppress the situation where the thickness of the gasket in the Y direction relative to the surface area increases, and the stack (laminated structure) of electrochemical devices such as fuel cells becomes larger. In addition, according to this configuration, the ratio of surface area to the thickness of the gasket in the Y direction is set to 500000 or less. Therefore, compared with the case where it exceeds 500000, it is possible to suppress the situation where the thickness of the gasket in the Y direction relative to the surface area decreases, and the elastic deformation of the gasket decreases; in other words, it is possible to suppress the situation where the sealing performance decreases.

[0020] (1-6) In any of the above configurations, it is preferable to have a Young's modulus of 100% for the material of the second mold and a Young's modulus of 80% or more and 150% or less for the material of the substrate. According to this configuration, the Young's modulus is set to 80% or more. Therefore, compared to cases where it is less than 80%, the reduction in the rigidity of the substrate can be suppressed. Furthermore, even if the rigidity of the substrate is high, the durability of the cut portion can be ensured. Additionally, according to this configuration, the Young's modulus is set to 150% or less. Therefore, compared to cases where it exceeds 150%, the excessive increase in the rigidity of the substrate can be suppressed.

[0021] (1-7) In the configuration described in (1-6) above, it is preferable that the material of the substrate is stainless steel. According to this configuration, corrosion of the substrate can be suppressed by the oxide coating of stainless steel. In addition, compared with the case where the substrate is made of a material with low Young's modulus (such as titanium), the rigidity of the substrate can be improved. Furthermore, even if the rigidity of the substrate is high, the durability of the cut portion can be improved.

[0022] (1-8) In any of the above configurations, it is preferable to have corner portions sandwiched between the boundary between the top surface and the inner convex side surface, and between the top surface and the outer convex side surface. According to this configuration, compared with the case where rounded chamfer portions (curved chamfer portions) are sandwiched between the boundary between the top surface and the inner convex side surface, and between the top surface and the outer convex side surface, the shape accuracy of the cut portion can be improved.

[0023] (2) In any of the above configurations, it is preferable that the inner convex side surface and the outer convex side surface are both planar. According to this configuration, both sides (the inner convex side surface and the outer convex side surface) are planar. Therefore, the width in the X direction between the pair of sides gradually narrows along the direction from the parting line toward the top surface. Therefore, during mold closing, it is possible to mitigate the situation where stress concentrates on a portion of the side surface.

[0024] (3) In any of the above configurations, it is preferable that the angle between the inner convex side surface and the outer convex side surface is an obtuse angle. According to this configuration, the angle between a pair of side surfaces (inner convex side surface and outer convex side surface) is set to an obtuse angle (an angle greater than 90°). Therefore, compared with the case where the angle is less than 90°, the stress concentration at the boundary between the top surface and the side surface can be mitigated during mold closing.

[0025] (4) In any of the above configurations, it is preferable to have an angle of 120° or more and 150° or less. According to this configuration, the angle is set to 120° or more. Therefore, compared to the case where the angle is less than 120°, stress concentration at the boundary between the top surface and the side surfaces (convex inner side surface, convex outer side surface) can be mitigated during mold closing. Furthermore, according to this configuration, the angle is set to 150° or less. Therefore, compared to the case where the angle exceeds 150°, the increase in the X-direction width of the cut portion can be suppressed. That is, the cut portion can be miniaturized.

[0026] (4-1) In any of the above configurations, it is preferable that the inclination angle of the inner or outer convex side surface relative to the Y direction is 60° or more. According to this configuration, compared with the case where the inclination angle is less than 60°, it is possible to alleviate the stress concentration at the boundary between the top surface and the inner convex side surface, or the boundary between the top surface and the outer convex side surface, during mold closing.

[0027] (5) In any of the above configurations, it is preferable that the inclination angle of the inner convex side surface relative to the Y direction is the same as the inclination angle of the outer convex side surface relative to the Y direction. According to this configuration, the stress distribution on both sides in the X direction can be balanced relative to the X-direction central axis of the cut portion.

[0028] (6) In any of the above configurations, it is preferable that the convex inner side extends from the top surface to the interior of the cavity recess across the parting line. According to this configuration, compared with the case where the convex inner side of the cut portion does not cross the parting line (the case where it does not extend to the interior of the cavity recess), stress concentration at the opening edge of the cavity recess can be mitigated during mold closing.

[0029] (7) In any of the above configurations, the following configuration is preferred: the second mold has a deformation-absorbing recess disposed on the outer side of the cut portion in the X direction, which absorbs the deformation of the substrate when the top surface is pressed against the substrate.

[0030] During mold closing, if the top surface of the cut portion presses against the substrate, elastic deformation of the substrate may occur. Specifically, the substrate may float up from the first mold. In this case, according to this configuration, the deformed portion of the substrate can be accommodated in the deformation-absorbing recess. Therefore, the cutting depth (appearance bite-in) of the cut portion relative to the surface of the substrate can be increased.

[0031] (8) In any of the above configurations, the following configuration is preferred: the deformation-absorbing recess has: a planar bottom surface that is recessed into the interior of the second mold relative to the parting line and extends along the X direction; an inner recessed side surface disposed on the inner side of the bottom surface in the X direction; and an outer recessed side surface disposed on the outer side of the bottom surface in the X direction, wherein the width in the X direction between the inner recessed side surface and the outer recessed side surface narrows in the direction from the parting line toward the bottom surface.

[0032] According to this configuration, when the deformed portion of the substrate is in the shape of a curved plate bulging out in the direction from the parting line toward the bottom surface, the deformed portion can be easily accommodated in the deformation-absorbing recess.

[0033] (9) In any of the above configurations, the following configuration is preferred: the cut-off portion is disposed adjacent to the deformation-absorbing recess, and the convex outer side is smoothly connected to the concave inner side from the inner side of the X direction toward the outer side of the X direction.

[0034] Here, as a way to "smoothly connect" the convex outer surface and the concave inner surface, examples include connecting in a planar manner and connecting in a curved manner. According to this configuration, compared with the case where the boundary between the convex outer surface of the cut-off portion and the concave inner surface of the deformation-absorbing recess is angular, the stress concentration at that boundary can be mitigated.

[0035] (10) In any of the above configurations, it is preferred that the top surface protrudes more than 10 μm and less than 100 μm in the Y direction relative to the parting line.

[0036] According to this configuration, the Y-direction protrusion of the top surface is set to 10 μm or more. Therefore, compared to the case where the Y-direction protrusion of the top surface is less than 10 μm, leakage of the gasket material from the chamber can be suppressed. That is, the sealing performance can be improved. In addition, compared to the case where the Y-direction protrusion of the top surface is less than 10 μm, the machining accuracy of the mold can be improved.

[0037] Furthermore, according to this configuration, the Y-direction protrusion of the top surface is set to 100 μm or less. Therefore, compared to cases where the Y-direction protrusion of the top surface exceeds 100 μm, excessive biting of the top surface into the substrate can be suppressed. Consequently, damage to the cut portion and the substrate can be suppressed.

[0038] (11) In any of the above configurations, it is preferable that the width of the top surface in the X direction is 10 μm or more and 500 μm or less. According to this configuration, the width of the top surface in the X direction is set to 10 μm or more. Therefore, compared with the case where the width of the top surface in the X direction is less than 10 μm, leakage of the gasket material from the chamber can be suppressed. That is, the sealing performance can be improved.

[0039] Furthermore, according to this configuration, the width of the top surface in the X direction is set to 500 μm or less. Therefore, compared to cases where the width of the top surface in the X direction exceeds 500 μm, the pressing area of ​​the top surface relative to the substrate can be reduced. Thus, damage to the cut portion and the substrate can be suppressed.

[0040] (12) In any of the above configurations, it is preferable that the cutting portion is arranged to be separated from the cavity recess and arranged outward in the X direction at a predetermined interval. According to this configuration, the cutting portion is offset outward in the X direction from the cavity recess. Therefore, compared with the case where the cutting portion and the cavity recess are arranged adjacent to each other, stress concentration at the boundary between the cutting portion and the cavity recess can be mitigated during mold closing.

[0041] (13) To solve the above problems, the composite component for an electrochemical device disclosed herein is a composite component for an electrochemical device comprising a substrate and a pad disposed on the surface of the substrate. It is characterized in that, with the extension direction of the surface as the X direction, the stacking direction of the substrate and the pad as the Y direction, the side closer to the pad in the X direction as the X-direction inner side, and the side opposite to the X-direction inner side as the X-direction outer side, the substrate has a concave trace portion on its surface and a pad placement portion disposed on the X-direction inner side of the trace portion for the pad to be disposed thereon. The trace portion has: a planar bottom surface; a concave inner side surface of the trace portion disposed on the X-direction inner side of the bottom surface; and a concave outer side surface of the trace portion disposed on the X-direction outer side of the bottom surface. The X-direction width between the concave inner side surface and the concave outer side surface of the trace portion narrows in the direction from the surface toward the bottom surface. Here, "electrochemical device" can be exemplified by fuel cells, water electrolysis devices, etc.

[0042] According to this configuration, the X-direction width between a pair of side surfaces (the inner side surface of the trace portion and the outer side surface of the trace portion) narrows along the direction from the surface toward the bottom surface. Therefore, compared to the case where the X-direction width between a pair of side surfaces is constant along the direction from the surface toward the bottom surface, it is possible to mitigate the concentration of residual stress at the boundary between the bottom surface and the side surfaces.

[0043] Furthermore, according to this configuration, when manufacturing composite components for electrochemical devices using molds with any of the above-described configurations, flash from the gasket can be suppressed. Therefore, the shape accuracy of the gasket can be improved. Moreover, the methods of "suppressing flash" include, for example, suppressing the generation of flash itself, and suppressing the stretching of the generated flash.

[0044] When manufacturing a composite component for an electrochemical device using a mold with any of the above-described configurations, the bottom surface of the trace portion is formed by the top surface of the cut portion, the inner concave side of the trace portion is formed by the inner convex side of the cut portion, and the outer concave side of the trace portion is formed by the outer convex side of the cut portion.

[0045] The top surface of the cut section is planar and extends along the X direction. Therefore, compared to cases where the top surface is curved or extends in a direction intersecting the X direction, it is possible to prevent the top surface from partially pressing against the substrate (the top surface making contact with the substrate on one side) during mold closing. Thus, it is possible to mitigate stress concentration on a portion of the top surface; in other words, it is possible to mitigate residual stress concentration on a portion of the bottom surface of the mark area. Furthermore, compared to cases where the cut section does not have a top surface, the shape accuracy of the cut section, or in other words, the mark area, can be improved.

[0046] The width in the X direction between the pair of side surfaces (the inner convex side surface and the outer convex side surface) of the cut portion narrows along the direction from the parting line toward the top surface. Therefore, compared to the case where the width in the X direction between the pair of side surfaces is constant along the direction from the parting line toward the top surface, stress concentration at the boundary between the top surface and the side surfaces can be mitigated during mold closing. Therefore, residual stress concentration at the boundary between the bottom surface and the side surfaces (the inner concave side surface and the outer concave side surface of the trace portion) of the mark portion can be suppressed.

[0047] Invention Effects The mold disclosed herein can improve the durability of the cut portion. Furthermore, it can suppress flash from the gasket. The composite component for the electrochemical device disclosed herein can suppress flash from the gasket. Attached Figure Description

[0048] Figure 1 This is a top view of the composite component for a fuel cell according to the first embodiment.

[0049] Figure 2 yes Figure 1 Enlarged view within box II.

[0050] Figure 3 yes Figure 2 Sectional view in direction III-III.

[0051] Figure 4 yes Figure 3 Enlarged view within frame IV.

[0052] Figure 5 This is a cross-sectional view of the mold used to manufacture the composite component for the fuel cell.

[0053] Figure 6 This is a partial cross-sectional view of the mold used in the injection molding process (forming process (mold opening state)) of the manufacturing method of the composite component for the fuel cell.

[0054] Figure 7 This is a partial sectional view of the mold used in the injection molding process (forming process (mold closing state)) of this manufacturing method.

[0055] Figure 8 yes Figure 7 Enlarged view within box VIII.

[0056] Figure 9 This is a partial cross-sectional view of the mold used in the injection process (injection process) of this manufacturing method.

[0057] Figure 10 yes Figure 9 A magnified view within the box X.

[0058] Figure 11 This is a partial cross-sectional view of the mold used in the vulcanization process of this manufacturing method.

[0059] Figure 12 yes Figure 11 Enlarged view within frame XII.

[0060] Figure 13 This is a partial cross-sectional view of the mold according to the second embodiment.

[0061] Figure 14 This is a partial cross-sectional view of the mold according to the third embodiment.

[0062] Figure 15 This is a partial cross-sectional view of the mold according to the fourth embodiment.

[0063] Figure 16 This is a partial top view of a composite component for a fuel cell according to other embodiments. Detailed Implementation

[0064] The following describes embodiments of the mold and composite component for fuel cells disclosed herein. The composite component for fuel cells is included in the concept of "composite component for electrochemical devices" in this disclosure.

[0065] <First Implementation> [Composition of composite components for fuel cells] First, the structure of the composite component for the fuel cell according to this embodiment will be described. In the following figures, at least one of the front-back, left-right (horizontal) directions corresponds to the "X direction" of this disclosure. The up-down (vertical) direction corresponds to the "Y direction" of this disclosure.

[0066] Figure 1 A top view (surface view) showing the composite component for fuel cells according to this embodiment. Figure 2 express Figure 1 Enlarged view within box II. Figure 3 express Figure 2 Sectional view in direction III-III. Figure 4 express Figure 3 Enlarged view within frame IV.

[0067] In addition, for ease of explanation, in Figure 1 In the diagram, pad 4 is shaded. The burr B is omitted. The mark 21 is schematically represented by a straight line. Figure 2 In the diagram, sparse shading is marked for padding 4, and dense shading is marked for burr B. Figure 3 , Figure 4 In the diagram, the thick line represents the burr B.

[0068] like Figure 1As shown, the composite component 1 for fuel cells is an integrally spaced separator. Within the frame H of the upper surface (surface) 2U, a membrane electrode assembly (MEA) (hereinafter referred to as "power generation unit") formed by stacking gas diffusion layers (GDL) is layered (not shown). A stack of fuel cells is constructed by alternately stacking multiple composite components 1 for fuel cells and multiple power generation units in the vertical direction (surface-back direction, stacking direction). The composite component 1 for fuel cells includes a separator 2 and multiple gaskets 4. The separator 2 is included in the concept of a "substrate" in this disclosure.

[0069] like Figure 2 , Figure 3 As shown, the left side (inner frame side) has the same configuration as the right side (outer frame side) relative to the central axis (orthogonal to the extending direction of the padding configuration section 20) in the frame-inner / outer direction, or in other words, the X-direction central axis A. The configuration of the left side and the right side is symmetrical in the left-right direction (frame-inner / outer direction) relative to the X-direction central axis A. The following description, representing the configurations of both sides in the left and right directions, will primarily focus on the configuration of the right side.

[0070] (Isolation component 2) like Figures 1-3 As shown, the spacer 2 is made of stainless steel (corrosion-resistant steel) and is in the shape of a rectangular thin plate. Multiple manifolds (openings) 23 for gas and air are provided on the spacer 2. Multiple gasket placement portions 20 and multiple trace portions 21 are disposed on the upper surface 2U of the spacer 2. The upper surface 2U of the spacer 2 is included in the concept of "surface of the substrate" in this disclosure.

[0071] like Figure 1 As shown, the padding configuration section 20 is frame-shaped. (As indicated...) Figure 3 As shown, the padding configuration section 20 is planar. A padding 4 is disposed in the padding configuration section 20.

[0072] exist Figure 1 A pair of traces 21 are arranged on the inner and outer sides (in other words, on both sides in the X direction) of any of the padding configurations 20 shown. The traces 21 are frame-shaped. For example... Figure 2 As shown, the trace portion 21 extends along the padding arrangement portion 20. The trace portion 21 and the padding arrangement portion 20 are arranged separately at predetermined intervals along the inward and outward direction (X direction) of the frame. Figure 3 , Figure 4 As shown, the trace portion 21 is recessed on the upper surface 2U of the isolation member 2.

[0073] like Figures 2-4As shown, of the pair of trace portions 21, the right trace portion 21 has a bottom surface 210, an inner surface 211, and an outer surface 212. The bottom surface 210 is positioned relative to the upper surface 2U, protruding downwards (inner side of the spacer 2). The bottom surface 210 is planar, extending in the front-back and left-right direction (X direction). The inner surface 211 is located on the left side of the bottom surface 210 (inner side in the X direction, on the side of the pad placement portion 20). The inner surface 211 is planar. The inner surface 211 connects the upper surface 2U and the bottom surface 210. The outer surface 212 is located on the right side of the bottom surface 210 (outer side in the X direction, opposite to the pad placement portion 20). The outer surface 212 is planar. The outer surface 212 connects the upper surface 2U and the bottom surface 210.

[0074] like Figure 4 As shown, the width (width in the left-right direction) W1 between the inner surface 211 and the outer surface 212 of the trace portion gradually decreases from the top to the bottom (from the upper surface 2U to the bottom surface 210). That is, the inner surface 211 and the outer surface 212 of the trace portion are configured as a cone shape that tapers at the front end from the top to the bottom. The angle θ1 between the inner surface 211 and the outer surface 212 of the trace portion is an obtuse angle. The angle θ1 is within the range of 120° and 150°. The inclination angle α1 of the inner surface 211 of the trace portion relative to the vertical direction (Y direction) is the same as the inclination angle β1 of the outer surface 212 of the trace portion relative to the vertical direction (Y direction).

[0075] (Pad 4) like Figure 3 As shown, the gasket 4 is fixed and stacked on the upper surface 2U of the separator 2. Figure 1 As shown, the gasket 4 is made of rubber (thermosetting elastomer) and is frame-shaped. The large central gasket 4 surrounds the two manifolds 23 on the left and right sides and the frame H (power generation section) in an endless ring shape from the surface direction outwards. The remaining gaskets 4 each surround the manifolds 23 in an endless ring shape from the surface direction outwards.

[0076] like Figures 1-4 As shown, the gasket 4 is disposed in the gasket placement section 20. Figure 1 The inner and outer sides of the frame of any pad 4 shown, such as Figure 2 As shown, a pair of flash edges B are formed. (As...) Figure 2 As shown, the burr B extends along the pad 4. Figures 2-4 As shown, of the two pairs of flashes B, the right flash B extends and protrudes to the right side of the pad 4 (in the direction of separation from the pad 4). However, as will be discussed later, there are no particular limitations on the presence, shape, size, or number of flashes B.

[0077] [Mold Composition] Next, the configuration of the mold used for manufacturing the composite component for fuel cells according to this embodiment will be described. As described below, the manufacturing method of the composite component for fuel cells according to this embodiment includes an injection molding process and a vulcanization process (crosslinking process).

[0078] Figure 5 This is a cross-sectional view of the mold used to manufacture the composite component for the fuel cell in this embodiment. The middle portion in the left-right direction is omitted. Figure 5 The cross-section of the isolation element 2 shown is... Figure 1 The VV section corresponds to this. Figure 5 frame II and Figure 1 The corresponding box II.

[0079] Figure 6 A partial cross-sectional view of the mold used in the injection molding process (forming process (mold opening state)) of the manufacturing method of the composite component for fuel cell of this embodiment. Figure 7 A partial sectional view of the mold representing the injection molding process (forming process (mold closing state)) of this manufacturing method. Figure 8 express Figure 7 Enlarged view within box VIII. Figure 9 A partial cross-sectional view of the mold representing the injection process (injection process) of this manufacturing method. Figure 10 express Figure 9 A magnified view within the box X. Figure 11 A partial cross-sectional view of the mold used in the vulcanization process of this manufacturing method. Figure 12 express Figure 11 A magnified view within frame XII. Furthermore, Figure 6 , Figure 7 , Figure 9 , Figure 11 and Figure 3 ( Figure 2 (Corresponds to the sectional view in direction III-III). Figure 8 , Figure 10 , Figure 12 and Figure 4 The corresponding box IV.

[0080] like Figure 6 , Figure 7 , Figure 9 , Figure 11 As shown, in the inward and outward directions relative to the padding configuration section 20 (padding 4) (refer to...) Figure 1 The left side (inner part of the frame) is configured identically to the right side (outer part of the frame) along the X-axis center A. The configuration of the left side is symmetrical to that of the right side along the left-right direction (inner and outer directions of the frame). The following descriptions illustrate the configuration of both sides, focusing primarily on the right side.

[0081] like Figure 5 As shown, the mold (forming mold) 5 includes a first mold 5D and a second mold 5U. Both the first mold 5D and the second mold 5U are made of iron. The mold 5 is used to form the liner 4 onto the thin plate-shaped spacer 2 disposed within the mold. The mold 5 has a cut-off portion 50 to suppress flash B from the liner 4. The parting line PL of the mold 5 extends in the horizontal direction (X direction). The opening and closing direction (opening-closing direction) of the mold 5 corresponds to the vertical direction (Y direction). A guide member (not shown) is disposed on the left-right outer side (horizontal outer side) of the mold 5. The mold 5 is positioned horizontally by means of the guide member.

[0082] (First Model 5D) like Figure 5 As shown, a plurality of manifold protrusions 53 protrude upward from the mold surface 50D of the first mold 5D toward the upper side (the side of the second mold 5U). In the injection molding process described later, a spacer 2 is disposed on the mold surface 50D. The manifold 23 of the spacer 2 is inserted into the manifold protrusions 53.

[0083] (Second Module 5U) like Figure 5 As shown, the second mold 5U is positioned vertically opposite the first mold 5D on its upper side. The second mold 5U can be approached and separated from the first mold 5D from above. In the injection molding process described later, the first mold 5D is a fixed mold, and the second mold 5U is a movable mold.

[0084] like Figure 7 , Figure 8 As shown, the vertical position of the mold surface (forming surface) 50U of the second mold 5U corresponds to the parting line PL. The mold surface 50U is provided with a cavity recess 51, a pair of left and right cutting portions 50, and a pair of left and right deformation absorption recesses 52.

[0085] like Figure 8 As shown, the cavity recess 51 is recessed upward from the mold surface 50U (the inner side of the second mold 5U). In the injection process described later, the cavity recess 51, together with the liner placement portion 20 of the spacer 2, divides the cavity 5M for liner 4 molding.

[0086] like Figure 7 As shown, of the pair of left and right cut-off portions 50, the right cut-off portion 50 is arranged to separate from the chamber recess 51 to the right (towards the deformation absorption recess 52, outwards in the X direction) at predetermined intervals. Figure 8 As shown, the cutting portion 50 protrudes downward from the mold surface 50U (towards the separator 2). The vertical cross-sectional shape of the cutting portion 50 is trapezoidal, tapering towards the lower end. In the injection molding process described later, the cutting portion 50 suppresses the material G (refer to...) from the chamber 5M. Figure 10 Leakage of ) . That is, suppressing flash edge B (refer to Figure 12 ).

[0087] like Figure 8 As shown, the cutting portion 50 includes a top surface 500, a convex inner surface 501, and a convex outer surface 502. The top surface 500 is positioned downwardly protruding relative to the parting line PL (mold surface 50U). The top surface 500 is a planar shape extending in the horizontal direction (X direction). The convex inner surface 501 is located on the left side of the top surface 500 (towards the cavity recess 51 side, inside in the X direction). The convex inner surface 501 is planar. The convex inner surface 501 connects the parting line PL (mold surface 50U) to the top surface 500. The convex outer surface 502 is located on the right side of the top surface 500 (opposite to the cavity recess 51 side, to the deformation-absorbing recess 52 side, outside in the X direction). The convex outer surface 502 is planar. The convex outer surface 502 connects the parting line PL (mold surface 50U) to the top surface 500.

[0088] like Figure 8 As shown, the width (left-right width) W2 in the X direction between the convex inner surface 501 and the convex outer surface 502 gradually decreases from the top to the bottom (from the parting line PL to the top surface 500). That is, the convex inner surface 501 and the convex outer surface 502 are configured as a tapered shape that tapers from the top to the bottom. The angle θ2 between the convex inner surface 501 and the convex outer surface 502 is an obtuse angle. The angle θ2 is within the range of 120° to 150°. The inclination angle α2 of the convex inner surface 501 relative to the vertical direction is the same as the inclination angle β2 of the convex outer surface 502 relative to the vertical direction.

[0089] The aforementioned trace portion 21 of the separator 2 is formed by pressing the cut portion 50 onto the upper surface 2U of the separator 2. Therefore, the cut portion 50 and the trace portion 21 are modularly symmetrical. Thus, as... Figure 8 As shown, the angle θ1 of the trace portion 21 is approximately the same as the angle θ2 of the cut portion 50. Furthermore, the tilt angle α1 of the trace portion 21 is approximately the same as the tilt angle α2 of the cut portion 50. Additionally, the tilt angle β1 of the trace portion 21 is approximately the same as the tilt angle β2 of the cut portion 50.

[0090] like Figure 7 As shown, of the pair of deformation-absorbing recesses 52, the right-side deformation-absorbing recess 52 is positioned adjacent to the right side of the right-side cut-off portion 50. That is, the cut-off portion 50 and the deformation-absorbing recess 52 are positioned adjacent to each other. Figure 8 As shown, the deformation-absorbing recess 52 is recessed upward from the mold surface 50U. The vertical cross-sectional shape of the deformation-absorbing recess 52 is a trapezoid that tapers from the bottom to the top.

[0091] like Figure 8As shown, the deformation-absorbing recess 52 includes a bottom surface 520, an inner recessed surface 521, and an outer recessed surface 522. The bottom surface 520 is positioned to be recessed upwards relative to the parting line PL (mold surface 50U). The bottom surface 520 is a planar shape extending in the horizontal direction. The inner recessed surface 521 is located on the left side of the bottom surface 520 (towards the cavity recess 51 side, inside in the X direction). The inner recessed surface 521 is planar. Figure 8 As shown, the inner concave side 521 and the outer convex side 502 of the cut-off portion 50 are connected in a planar manner without bending. That is, the inner concave side 521 and the outer convex side 502 are connected smoothly. The outer concave side 522 is disposed on the right side of the bottom surface 520 (the side opposite to the recessed portion 51 of the chamber, outward in the X direction). The outer concave side 522 is planar.

[0092] like Figure 8 As shown, the width in the left-right direction between the inner concave side surface 521 and the outer concave side surface 522 gradually decreases from the bottom to the top (from the parting line PL to the bottom surface 520). That is, the inner concave side surface 521 and the outer concave side surface 522 are configured as a tapered shape that tapers at the front end from the bottom to the top.

[0093] [Manufacturing method of composite components for fuel cells] Next, the manufacturing method of the composite component for fuel cells according to this embodiment will be described. As mentioned above, the manufacturing method of this embodiment includes an injection molding process and a vulcanization process (crosslinking process).

[0094] (Injection procedure) The injection molding process includes the placement of spacers, the shaping process, and the injection process. For example... Figure 5 As shown, in the isolation component configuration process, the isolation component 2 is configured from above onto the mold surface 50D of the first mold 5D of the mold 5 in the open state. Furthermore, an adhesive is pre-applied to the upper surface 2U of the isolation component 2 (not shown). When configuring the isolation component 2, the manifold protrusion 53 is inserted into the manifold 23 of the isolation component 2. That is, the isolation component 2 is positioned on the mold surface 50D.

[0095] like Figures 6-8 As shown, in the shaping process, the second mold 5U is pressed against the first mold 5D by a predetermined clamping force. That is, mold closing is performed. Through mold closing, the cutting part 50 is pressed against the upper surface 2U of the separator 2. At this time, the top surface 500 of the cutting part 50 is pressed against the upper surface 2U without contacting only one side. Through this pressing, a recessed mark 21 is formed on the upper surface 2U.

[0096] like Figure 8To exaggerate, when the cut portion 50 recesses the groove portion 21 in the spacer 2, the adjacent portion 22 of the groove portion 21 in the spacer 2 floats upward from the mold surface 50D. Here, the deformation-absorbing recess 52 of the second mold 5U is arranged correspondingly to this adjacent portion 22. Therefore, the floating adjacent portion 22 is accommodated in the deformation-absorbing recess 52. In this way, the deformation-absorbing recess 52 absorbs the deformation of the spacer 2 when the top surface 500 of the cut portion 50 is pressed against the spacer 2.

[0097] Furthermore, if the number of mold closing cycles of mold 5 increases, there is a possibility that the mold surface 50D may become recessed due to the cut portion 50. In this case, if... Figure 7 , Figure 8 As indicated by the dashed lines, a protrusion 24 is formed on the lower surface 2D. Additionally, a recess 54 is formed on the mold surface 50D. Viewed from above (top view), the cut portion 50, the mark portion 21, the protrusion 24, and the recess 54 overlap.

[0098] like Figure 9 , Figure 10 As shown, in the injection process, the raw material G of the filling liner 4 is injected into the cavity 5M after mold closing. Due to the injection pressure, the raw material G should leak out of the cavity 5M to the outside through the boundary between the mold surface 50U of the second mold 5U and the upper surface 2U of the separator 2. However, the cut portion 50 of the mold surface 50U is pressed against the mark portion 21 of the upper surface 2U. Therefore, the raw material G does not easily leak out of the cavity 5M to the outside.

[0099] (Vulcanization process) In the vulcanization process, firstly, the mold 5, in its post-injection state (closed state), is moved from the injection site to the vulcanization site. Next, as... Figure 11 , Figure 12 As shown, the mold 5 in its closed state is heated at a predetermined temperature for a predetermined time to solidify the raw material G in the chamber 5M, thus creating the gasket 4. Then, the gasket 4 is bonded and fixed to the gasket placement section 20 by applying an adhesive to the upper surface 2U of the separator 2. Afterwards, the mold is opened, and the composite component 1 for the fuel cell is removed from the mold 5. Furthermore, the deformation of the adjacent sections 22 in the previous process (injection process) (such as...) Figures 6-8 As shown, the deformation from a flat plate to a curved plate is an elastic deformation. Therefore, by opening the mold, the adjacent parts 22 return to their shape before mold closing (see...). Figure 6 That is, the adjacent part 22 is restored from a curved plate shape to a flat plate shape.

[0100] In the preceding process (injection process), the cut portion 50 is pressed onto the indentation portion 21. Therefore, the raw material G is less likely to leak from the chamber 5M to the outside. Therefore, it is less likely for flash B to form on the composite component 1 for the fuel cell after this process (sulfurization process). In addition, flash B is less likely to be stretched.

[0101] [Effects] Next, the effects of the mold and the composite component for fuel cells in this embodiment will be explained. For example... Figure 8 As shown, the top surface 500 of the cut-off portion 50 is planar and extends in the horizontal direction (the extension direction of the parting line PL, orthogonal to the vertical direction (the opening and closing direction of the mold 5)). Therefore, compared to the case where the top surface 500 is curved or extends in a direction intersecting the horizontal direction, it is possible to prevent the top surface 500 from partially pressing against the spacer 2 during mold closing (the case where the top surface 500 and the spacer 2 are in contact on one side only). Therefore, it is possible to alleviate stress concentration on a portion of the top surface 500. Therefore, it is possible to suppress breakage of the cut-off portion 50 and improve durability. In addition, since the durability of the cut-off portion 50 is improved, the freedom of material selection for the spacer 2 can be increased. For example, the spacer 2 can be made of a material with a high Young's modulus (such as stainless steel).

[0102] Furthermore, in cases where the top surface 500 is not provided in the cutting section 50 (for example, Figure 8 Compared to the case where the pair of side surfaces (convex inner side surface 501 and convex outer side surface 502) are directly connected without passing through the top surface 500, the shape accuracy of the cut-off portion 50 (especially the height accuracy in the vertical direction) can be improved.

[0103] like Figure 8 As shown, the lateral width between a pair of side surfaces (convex inner side surface 501 and convex outer side surface 502) narrows from the top to the bottom (from the parting line PL to the top surface 500). Therefore, compared to the case where the lateral width between a pair of side surfaces is constant from the top to the bottom, or in other words, compared to the case where a pair of side surfaces extend in the vertical direction, stress concentration at the boundary between the top surface 500 and the side surfaces (in other words, the corner C2) can be mitigated during mold closing.

[0104] like Figure 5 As shown, the first mold 5D is a fixed mold, and the second mold 5U is a movable mold. That is, during the injection molding process, the first mold 5D is fixed when the mold 5 is opened and closed. An isolator 2 is provided in the first mold 5D. Therefore, the positional displacement of the isolator 2 during the opening and closing of the mold 5 can be suppressed.

[0105] like Figure 6 As shown, the cutting portion 50 is disposed on both sides of the cavity recess 51 in the left-right direction. Therefore, on both sides of the cavity recess 51 in the left-right direction (inner side and outer side of the frame), it is possible to suppress Figure 11 , Figure 12 The formation of flash B is shown. Furthermore, the stretching of flash B can be suppressed.

[0106] like Figure 1As shown, viewed from above (top view), the trace 21 extends in an endless ring around the pad 4. Figure 11 As shown, the trace portion 21 corresponds to the cut portion 50. The pad 4 corresponds to the cavity recess 51. Therefore, when viewed from above, the cut portion 50 extends in an endless ring around the cavity recess 51. That is, the cut portion 50 surrounds the cavity recess 51. Therefore, as Figure 9 As shown, leakage of the material G of the liner 4 can be suppressed throughout the circumference of the cavity using the recess 51, or in other words, the cavity 5M.

[0107] Figure 1 The surface area of ​​the isolation member 2 shown (the area of ​​the upper surface 2U) is... Figure 3 The ratio of the plate thickness (thickness in the vertical direction) of the separator 2 shown (= surface area / plate thickness) falls within the range of 30,000 to 3,125,000. That is, the separator 2 is plate-shaped. Therefore, compared to cases where this ratio is less than 30,000, it is possible to suppress the situation where the plate thickness relative to the surface area increases, leading to a larger fuel cell stack (laminated structure). Furthermore, compared to cases where this ratio exceeds 3,125,000, it is possible to suppress the situation where the plate thickness relative to the surface area decreases, leading to excessive deformation of the separator 2. In addition, the dimension of the above ratio is distance L. The unit of surface area is mm. 2 The unit for plate thickness is mm, and the unit for ratio is mm.

[0108] The aforementioned spacer 2, with a surface area / plate thickness ratio falling between 30,000 and 3,125,000, is thin and prone to moderate deformation. Therefore, as... Figure 7 , Figure 8 As shown, during mold closing, the shape accuracy of the mold surface 50U of the second mold 5U is easily reflected (transferred) onto the upper surface 2U of the spacer 2. For example, to improve the durability of the cut-off portion 50, the second mold 5U, which has the cut-off portion 50, can be hardened to increase its hardness. However, if hardening is performed, deformation such as "warping" can easily occur in the second mold 5U. That is, the shape accuracy of the second mold 5U can easily decrease. Therefore, if the liner 4 is formed on the thin plate-shaped spacer 2 (the easily deformable spacer 2) using the second mold 5U after hardening, there is a risk of a decrease in the shape accuracy of the spacer 2.

[0109] In this respect, according to the mold 5 of this embodiment, the durability of the cut portion 50 can be improved without specifically performing processing on the mold 5 to increase hardness (processing that may reduce shape accuracy). Therefore, even if the spacer 2 is in the form of a thin plate, in other words, even if the spacer 2 is easily deformable, the reduction in the shape accuracy of the spacer 2 can be suppressed.

[0110] Figure 1 The surface area of ​​the isolation element 2 shown is... Figure 3The ratio of the vertical thickness of the gasket 4 shown (= surface area / vertical thickness) falls within the range of 5000 to 500000. Therefore, compared to cases where this ratio is less than 5000, it is possible to suppress the situation where the vertical thickness of the gasket 4 increases relative to the surface area, thus preventing the fuel cell stack from becoming larger. Furthermore, compared to cases where this ratio exceeds 500000, it is possible to suppress the situation where the vertical thickness of the gasket 4 decreases relative to the surface area, thus preventing the elastic deformation of the gasket 4 from decreasing; in other words, it is possible to suppress the situation where the sealing performance deteriorates. In addition, the dimension of the above ratio is distance L. The unit of surface area is mm. 2 The unit for thickness in the vertical direction is mm, and the unit for ratio is mm.

[0111] With the Young's modulus of the material of the second mold 5U being 100%, the Young's modulus of the material of the spacer 2 falls within the range of 80% to 150%. Therefore, compared to the case where the Young's modulus of the material of the spacer 2 is less than 80%, the reduction in the rigidity of the spacer 2 can be suppressed. Furthermore, even if the rigidity of the spacer 2 is high, the durability of the cut-off portion 50 can be ensured. Additionally, compared to the case where the Young's modulus of the material of the spacer 2 exceeds 150%, the excessive increase in the rigidity of the spacer 2 can be suppressed.

[0112] The spacer 2 is made of stainless steel. Therefore, the oxide coating of stainless steel can suppress corrosion of the spacer 2. In addition, compared with the case where the spacer 2 is made of a material with low Young's modulus (such as titanium), the rigidity of the spacer 2 can be improved. Furthermore, even with the high rigidity of the spacer 2, the durability of the cut-off portion 50 can be improved.

[0113] like Figure 8 As shown, corner portions C2 are respectively provided at the boundaries of the top surface 500 and the inner convex surface 501, and at the boundaries of the top surface 500 and the outer convex surface 502. Therefore, compared with the case where rounded chamfer portions (curved chamfer portions) are provided at the boundaries of the top surface 500 and the inner convex surface 501, and at the boundaries of the top surface 500 and the outer convex surface 502, the shape accuracy of the cut portion 50 can be improved.

[0114] like Figure 8 As shown, the inner convex side surface 501 and the outer convex side surface 502 are both planar. Therefore, the width between the pair of side surfaces (inner convex side surface 501 and outer convex side surface 502) gradually narrows in the direction from the parting line PL towards the top surface 500. Therefore, during mold closing, it can alleviate the situation where stress concentrates on a part of the side surface.

[0115] like Figure 8As shown, the angle θ2 between the inner convex side surface 501 and the outer convex side surface 502 is an obtuse angle. Therefore, compared with the case where the angle θ2 is less than 90°, when the mold is closed, the stress concentration at the boundary between the top surface 500 and the side surface (inner convex side surface 501, outer convex side surface 502) can be mitigated. In other words, the stress concentration at the corner C2 can be mitigated.

[0116] like Figure 8 As shown, the intersection angle θ2 falls within the range of 120° to 150°. Therefore, compared to the case where the intersection angle θ2 is less than 120°, stress concentration at the corner C2 can be mitigated during mold closing. Furthermore, compared to the case where the intersection angle θ2 exceeds 150°, the increase in the lateral width of the cut-off portion 50 can be suppressed. In other words, the cut-off portion 50 can be miniaturized.

[0117] like Figure 8 As shown, the tilt angle α2 of the inner convex surface 501 relative to the vertical direction and the tilt angle β2 of the outer convex surface 502 relative to the vertical direction are both 60° or more. Therefore, compared with the case where the tilt angles α2 and β2 are less than 60°, the stress concentration at the corner C2 can be mitigated during mold closing.

[0118] like Figure 8 As shown, the tilt angle α2 is the same as the tilt angle β2. Therefore, it is possible to [properly] the X-direction central axis (specifically, the axis passing through the cut section 50) relative to the cut section 50. Figure 8 The axis extending vertically from the center of the cut-off portion 50 in the left-right direction is aligned with the axis extending vertically. Figure 7 The stress distribution on both sides (inside and outside the frame) is equalized by the axis parallel to the central axis A in the X direction.

[0119] like Figure 8 As shown, the second mold 5U includes a deformation-absorbing recess 52. The deformation-absorbing recess 52 is located on the right side (outer side in the X direction) of the cut portion 50. The deformation-absorbing recess 52 can absorb the deformation of the spacer 2 when the top surface 500 is pressed against the spacer 2. That is, when the mold is closed, if the top surface 500 of the cut portion 50 is pressed against the upper surface 2U of the spacer 2, the spacer 2 may elastically deform. Specifically, the spacer 2 may float from the mold surface 50D of the first mold 5D. In this respect, the composite component 1 for fuel cells according to this embodiment can accommodate the deformed portion (adjacent portion 22) of the spacer 2 in the deformation-absorbing recess 52. Therefore, the cutting depth (engagement amount) D of the cut portion 50 relative to the appearance of the spacer 2 can be increased.

[0120] like Figure 8As shown, the width (X-direction width) between the inner concave side 521 and the outer concave side 522 of the deformation-absorbing recess 52 narrows from the bottom to the top (from the parting line PL to the bottom surface 520). Therefore, when the adjacent portion 22 elastically deforms from a flat plate shape to a curved plate shape (a curved plate shape bulging from the bottom to the top), the adjacent portion 22 can be easily accommodated in the deformation-absorbing recess 52.

[0121] like Figure 8 As shown, the cut-off portion 50 and the deformation-absorbing recess 52 are arranged adjacent to each other in the left-right direction. From the left side (inner side in the X direction) to the right side (outer side in the X direction), the convex outer surface 502 of the cut-off portion 50 and the concave inner surface 521 of the deformation-absorbing recess 52 are smoothly connected in a planar manner. Therefore, compared with the case where the boundary between the convex outer surface 502 and the concave inner surface 521 is angular, the case where stress concentration at the boundary can be mitigated.

[0122] Figure 10 The Y-direction protrusion (vertical protrusion) E of the top surface 500 relative to the parting line PL is set to 20 μm. That is, the Y-direction protrusion E falls within the range of 10 μm or more and 100 μm or less. Therefore, compared to the case where the Y-direction protrusion E is less than 10 μm, it is possible to suppress the material G of the gasket 4 from passing through the boundary between the cut portion 50 and the trace portion 21. Therefore, it is possible to suppress the leakage of material G from the cavity 5M to the outside. That is, it is possible to improve the sealing performance. In addition, compared to the case where the Y-direction protrusion E is less than 10 μm, it is possible to improve the machining accuracy of the mold 5. In addition, compared to the case where the Y-direction protrusion E exceeds 100 μm, it is possible to suppress the case where the top surface 500 excessively bites into the spacer 2. Therefore, it is possible to suppress the breakage of the cut portion 50 and the spacer 2.

[0123] like Figure 10 As shown, the X-direction width (left-right direction width) F of the top surface 500 is set to 70 μm. That is, the X-direction width F falls within the range of 10 μm or more and 500 μm or less. Therefore, compared to the case where the X-direction width F is less than 10 μm, it is possible to suppress the material G of the gasket 4 from passing through the boundary between the cut portion 50 and the trace portion 21. Therefore, it is possible to suppress the leakage of material G from the chamber 5M to the outside. That is, it is possible to improve the sealing performance. In addition, compared to the case where the X-direction width F exceeds 500 μm, it is possible to reduce the pressing area of ​​the top surface 500 relative to the spacer 2. Therefore, it is possible to suppress the breakage of the cut portion 50 and the spacer 2.

[0124] like Figure 8As shown, the cutting portion 50 is arranged separated from the cavity recess 51 to the right (outward in the X direction) at a predetermined interval. That is, the cutting portion 50 is offset to the right from the cavity recess 51. Therefore, compared with the case where the cutting portion 50 is arranged adjacent to the cavity recess 51, stress concentration at the boundary between the cutting portion 50 and the cavity recess 51 can be alleviated during mold closing.

[0125] like Figure 4 As shown, the lateral width between a pair of sides (inner side 211 and outer side 212 of the trace portion 21) of the composite component 1 for fuel cells narrows from the top to the bottom (from the top surface 2U to the bottom surface 210). Therefore, compared to the case where the lateral width between a pair of sides is constant from the top to the bottom, it can alleviate the concentration of residual stress at the boundary between the bottom surface 210 and the sides (inner side 211 and outer side 212 of the trace portion), in other words, it can alleviate the concentration of residual stress at the corner C1.

[0126] Furthermore, the composite component 1 for the fuel cell in this embodiment uses the mold 5 of this embodiment (e.g., Figure 9 As shown, a mold 5) is manufactured with a pair of cutting portions 50 on both sides (inner and outer sides of the frame) of the recess 51 in the left and right directions of the cavity. Therefore, as Figure 2 As shown, the generation of flash B can be suppressed on both sides (inner and outer sides of the frame) in the left and right directions of the pad 4. Furthermore, the stretching of flash B can be suppressed. Additionally, the area occupied by flash B in the upper surface 2U can be reduced.

[0127] like Figure 12 As shown, the bottom surface 210 of the trace portion 21 is formed by the top surface 500 of the cutting portion 50, the concave inner side surface 211 of the trace portion 21 is formed by the convex inner side surface 501 of the cutting portion 50, the concave outer side surface 212 of the trace portion 21 is formed by the convex outer side surface 502 of the cutting portion 50, and the corner C1 of the trace portion 21 is formed by the corner C2 of the cutting portion 50.

[0128] The top surface 500 of the cut-off portion 50 is planar and extends horizontally. Therefore, compared to the case where the top surface 500 is curved or extends in a direction intersecting the horizontal direction, it is possible to prevent the top surface 500 from partially pressing against the spacer 2 during mold closing (the case where the top surface contacts the spacer 2 on one side only). Therefore, it is possible to alleviate the situation where stress concentrates on a portion of the top surface 500; in other words, it is possible to alleviate the situation where residual stress concentrates on a portion of the bottom surface 210 of the trace portion 21. In addition, compared to the case where the top surface 500 is not provided in the cut-off portion 50, the shape accuracy of the cut-off portion 50, in other words, the trace portion 21, can be improved.

[0129] The X-direction width (left-right direction width) W2 between the pair of side surfaces (convex inner side surface 501, convex outer side surface 502) of the cut-off portion 50 narrows from the parting line PL toward the top surface 500. Therefore, compared to the case where the X-direction width W2 between the pair of side surfaces is constant along the direction from the parting line toward the top surface, the stress concentration at the corner C2 of the cut-off portion 50 can be mitigated during mold closing. Therefore, the concentration of residual stress at the corner C1 of the trace portion 21 can be suppressed.

[0130] <Second Implementation> The difference between the mold and fuel cell composite component of this embodiment and the mold and fuel cell composite component of the first embodiment is that the cut-off portion and the recessed portion of the chamber are arranged adjacent to each other in the left-right direction. Additionally, the convex inner side of the cut-off portion extends into the interior of the recessed portion of the chamber. Here, only the differences will be described.

[0131] Figure 13 This is a partial cross-sectional view of the mold according to this embodiment. Furthermore, regarding... Figure 8 Corresponding parts are indicated by the same reference numerals. For example... Figure 13 As shown, the cutting portion 50 and the cavity recess 51 are arranged adjacent to each other in the left-right direction (X direction). The convex inner surface 501 of the cutting portion 50 crosses the parting line PL from the lower right side to the upper left side. The convex inner surface 501 extends from the top surface 500 into the interior of the cavity recess 51. In other words, the left end of the convex inner surface 501 of the cutting portion 50 overlaps with the right end of the opening edge of the cavity recess 51.

[0132] The mold 5 and the composite component for fuel cells in this embodiment have the same effect on the common parts as those in the mold and the composite component for fuel cells in the first embodiment. According to the mold 5 of this embodiment, compared with the case where the inner convex side surface 501 does not cross the parting line PL (does not extend into the interior of the cavity recess 51), stress concentration at the opening edge of the cavity recess 51 can be mitigated during mold closing.

[0133] <Third Implementation Method> The difference between the mold and the composite component for fuel cells in this embodiment and those in the first embodiment is the absence of a deformation-absorbing recess. Here, only the difference will be explained.

[0134] Figure 14 This is a partial cross-sectional view of the mold according to this embodiment. Furthermore, regarding... Figure 8 Corresponding parts are indicated by the same reference numerals. For example... Figure 14 As shown, no [something] is provided on the right side (outer side in the X direction) of the cut-off section 50. Figure 8The deformation-absorbing recess 52 is shown. The mold 5 and fuel cell composite component of this embodiment have the same effect on the common parts as those of the mold and fuel cell composite component of the first embodiment. According to the mold 5 of this embodiment, compared to the case where the deformation-absorbing recess is provided in the second mold 5U, the surface shape of the mold surface 50U can be simplified.

[0135] <Fourth Implementation> The differences between the mold and fuel cell composite component of this embodiment and those of the first embodiment are that the cut-off portion and the recessed portion for the chamber are arranged adjacent to each other in the left-right direction. Additionally, the convex inner surface of the cut-off portion extends into the interior of the recessed portion for the chamber. Furthermore, the deformation-absorbing recess is not provided. Here, only these differences will be described.

[0136] Figure 15 This is a partial cross-sectional view of the mold according to this embodiment. Furthermore, regarding... Figure 8 Corresponding parts are indicated by the same reference numerals. For example... Figure 15 As shown, the cutting portion 50 and the cavity recess 51 are arranged adjacent to each other in the left-right direction (X direction). The convex inner surface 501 of the cutting portion 50 crosses the parting line PL from the lower right side to the upper left side. The convex inner surface 501 extends from the top surface 500 into the interior of the cavity recess 51. In other words, the left end of the convex inner surface 501 of the cutting portion 50 overlaps with the right end of the opening edge of the cavity recess 51. No cutting portion is provided on the right side (outer side in the X direction). Figure 8 The shown is a recessed portion 52 for absorbing deformation.

[0137] The mold 5 and the composite component for fuel cells in this embodiment have the same effect on the common parts as those in the mold and the composite component for fuel cells in the first embodiment. According to the mold 5 of this embodiment, compared to the case where the convex inner surface 501 does not cross the parting line PL (does not extend into the interior of the cavity recess 51), stress concentration at the opening edge of the cavity recess 51 can be mitigated during mold closing. Furthermore, compared to the case where a deformation-absorbing recess is provided in the second mold 5U, the surface shape of the mold surface 50U can be simplified.

[0138] <Other> The embodiments of the mold and composite component for fuel cells disclosed herein have been described above. However, the embodiments are not particularly limited to the above-described manner. Various modifications and improvements can also be made by those skilled in the art.

[0139] exist Figure 16 The image shows a partial top view of a composite component for a fuel cell according to other embodiments. Furthermore, regarding... Figure 2Corresponding parts are indicated by the same reference numerals. For example... Figure 16 As shown, the pad placement portion 20, in other words, the pad 4, extends in a straight line and a strip shape. The mark portion 21 surrounds the pad placement portion 20 in an endless ring around its entire circumference. That is, the cutting portion 50 of the mold 5 surrounds the pad placement portion 20 in an endless ring around its entire circumference. Therefore, in the aforementioned injection process, leakage of the material G of the pad 4 can be suppressed along the entire circumference of the cavity recess 51, in other words, the cavity 5M. In this way, the extension shape of the pad 4 (such as...) Figure 1 As shown, the shape viewed from above (from a top-down perspective) is not particularly limited. It can be strip-shaped (straight lines, curves, or shapes formed by appropriate combinations of these shapes), block-shaped (circular, elliptical, droplet-shaped, polygonal (triangles, quadrilaterals, hexagons, etc.), irregular, etc.), or frame-shaped (circular frame, elliptical frame, polygonal frame).

[0140] Regarding the cross-sectional shape of pad 4 (e.g.) Figure 3 As shown, the shape of the direction orthogonal to the extension direction of the pad 4 is not particularly limited. For example, it can also be a rectangle, trapezoid, arc, V, C, U, or a shape formed by appropriate combination of these shapes.

[0141] From Figure 12 The presence, shape, size, and quantity of the protruding burr B in the padding configuration 20 shown are not particularly limited. For example... Figure 16 As shown, the flash B may not extend from the padding section 20. Flash B may extend from one location on the padding section 20. Flash B may extend from multiple locations on the padding section 20. Flash B may extend from the entire padding section 20. Flash B may reach the cut section 50 (marked section 21), or it may not reach the cut section 50 (marked section 21). Flash B may also extend beyond the cut section 50.

[0142] There are no particular limitations on the relative positional relationship between the padding configuration section 20 and the cutting section 50 (mark section 21). For example... Figure 11 As shown, the cutting portion 50 can also be disposed on both the inner and outer sides of the frame-shaped padding portion 20. Alternatively, the cutting portion 50 can be disposed only on the inner side of the frame-shaped padding portion 20. Or, the cutting portion 50 can be disposed only on the outer side of the frame-shaped padding portion 20. That is, the cutting portion 50 can be disposed on at least one of the outer or inner side of the frame-shaped padding portion 20.

[0143] The extended shape of the trace portion 21 (the cut portion 50 and the deformation absorption recess 52 are also the same) (such as Figure 1As shown, the shape viewed from above (when viewed from above) is not particularly limited. It can be strip-shaped (straight line, curved line, or a shape formed by appropriately combining these shapes), block-shaped (circular, elliptical, droplet-shaped, polygonal (triangle, quadrilateral, hexagonal, etc.), irregular shape, etc.), or frame-shaped (circular frame, elliptical frame, polygonal frame).

[0144] The cross-sectional shape of the trace portion 21 (the cut portion 50 and the deformation absorption recess 52 are also the same) (e.g. Figure 3 As shown, the shape of the direction orthogonal to the extension direction of the pad 4 is not particularly limited. For example, it can be a rectangle, trapezoid, arc, V, C, U, or a shape formed by appropriate combination of these shapes.

[0145] The extension shape of the padding configuration portion 20 (the cavity recess 51 and the padding 4 are the same) can be the same as or different from the extension shape of the trace portion 21 (the cut portion 50 and the deformation absorption recess 52 are the same). For example, the padding configuration portion 20 and the trace portion 21 can extend together in a frame shape. Alternatively, the padding configuration portion 20 can extend in a straight line, and the trace portion 21 can extend around the padding configuration portion 20 in a frame shape (endless ring shape).

[0146] The number of padding configuration sections 20 (including the cavity recess 51 and the padding 4) can be the same as or different from the number of trace sections 21 (including the cut section 50 and the deformation absorption recess 52). A single trace section 21 can be configured for a single padding configuration section 20. Multiple trace sections 21 can be configured for a single padding configuration section 20. A single trace section 21 can also be configured for multiple padding configuration sections 20. For example, a single frame-shaped trace section 21 can be configured to surround multiple island-shaped padding configuration sections 20.

[0147] right Figure 8 The Y-direction protrusion E, X-direction widths F, W1, W2, tilt angles α1, α2, β1, β2, and intersection angles θ1, θ2 shown are not specifically limited. Tilting angles α1, α2, β1, β2 can be greater than 60° or less than 60°. Tilting angles α1 and β1 can be the same or different. Tilting angles α2 and β2 can be the same or different. Intersection angles θ1 and θ2 can be within the range of 120° to 150°, or they can be outside this range. Intersection angles θ1 and θ2 can be obtuse, right, or acute.

[0148] There are no particular limitations on the shapes of the bottom surface 210, the inner concave side surface 211 of the trace portion, the outer concave side surface 212 of the trace portion, the top surface 500, the inner convex side surface 501, and the outer convex side surface 502. They can be planar, curved, or a combination of these shapes. Rounded chamfers can also be used instead of corners C1 and C2. The shape of the deformation-absorbing recess 52 can be applied to the shape of the trace portion 21 and the cut portion 50 as described above. Figure 12 The deformation of the adjacent portions 22 during mold closing may remain in the separator 2 after mold opening, or it may not remain in the separator 2 after mold opening. That is, the deformation of the adjacent portions 22 during mold closing may be plastic deformation or elastic deformation.

[0149] right Figure 5 The configuration direction (opening and closing direction of mold 5) of the first mold 5D and the second mold 5U shown in the diagram is not particularly limited. It can be vertical, horizontal, or a direction intersecting the vertical and horizontal directions. In the injection molding process, the first mold 5D can be a fixed mold and the second mold 5U can be a movable mold. Conversely, the first mold 5D can also be a movable mold and the second mold 5U can be a fixed mold.

[0150] There are no specific limitations on the material of mold 5. It can be corrosion-resistant steel, carbon tool steel, alloy tool steel, high-speed tool steel, as-rolled steel, pre-hardened steel, quenched steel, quenched and tempered steel, aging-treated steel, etc. There are also no specific limitations on the material of separator 2. It can be any conductive, non-corrosive resin or metal. Examples include stainless steel, titanium, copper, magnesium, aluminum, carbon, graphite, ceramics, and conductive resins (thermoplastic or thermosetting resins containing carbon, graphite, polyacrylonitrile-based carbon fibers, etc.).

[0151] There are no particular limitations on the material of the gasket 4. It can be an elastomer that possesses insulation and rubber elasticity after curing. It only needs to have flowability during the stage of raw material G (before curing). Gasket 4 may also contain crosslinking agents, co-crosslinking agents, processing aids, softeners, reinforcing materials, etc., in addition to rubber components. Preferred rubber components include silicone rubbers other than VMQ (PVMQ (phenyl vinyl methyl silicone rubber), FVMQ (fluorovinyl methyl silicone rubber), EPDM (ethylene propylene diene rubber), FKM (fluororubber), etc. When using liquid silicone rubber as raw material G, there are no particular limitations on the type of liquid silicone rubber. It can be a one-component or two-component type. Furthermore, it can be a room temperature curing type or a heat curing type.

[0152] In the above embodiments, a composite component for a fuel cell is described as an example of a composite component for an electrochemical device according to this disclosure. However, there is no particular limitation on the type of electrochemical device. An electrochemical device is any device that converts chemical energy into electrical energy or electrical energy into chemical energy. Examples of electrochemical devices include fuel cells, secondary batteries, and water electrolysis devices.

[0153] In the above embodiments, as an example of a method for manufacturing a composite component for an electrochemical device according to the present disclosure, a method for manufacturing a composite component for a fuel cell having an injection process and a vulcanization process (crosslinking process) is described. However, the method for manufacturing a composite component for an electrochemical device according to the present disclosure is not particularly limited. For example, a method for manufacturing a composite component for an electrochemical device having an injection process and a vulcanization integration process may also be used. In this case, it is also possible to form the gasket in the injection process and vulcanize and cure the gasket in the vulcanization integration process by laminating the gasket on a substrate, thereby integrating the gasket with the substrate.

[0154] Explanation of reference numerals in the attached figures: 1: Composite component for fuel cell (composite component for electrochemical device); 2: Separator (substrate); 2D: Lower surface; 2U: Upper surface (surface); 20: Gasket placement part; 21: Trace part; 210: Bottom surface; 211: Inner recess of trace part; 212: Outer recess of trace part; 22: Adjacent part; 23: Manifold; 24: Protrusion; 4: Gasket; 5: Mold; 5D: First mold; 50D: Mold surface; 5M: Chamber; 5U: Second mold; 50U: Mold surface; 50: Cut-off part; 500: Top surface; 501: Inner convex surface; 502: Outer convex surface Surface; 51: Recess for cavity; 52: Recess for deformation absorption; 520: Bottom surface; 521: Inner side of the recess; 522: Outer side of the recess; 53: Protrusion for manifold; 54: Recess; α1: Inclined angle; α2: Inclined angle; β1: Inclined angle; β2: Inclined angle; θ1: Intersection angle; θ2: Intersection angle; A: Central axis in the X direction; B: Flash; C1: Corner; C2: Corner; D: Cutting depth of appearance; E: Protrusion in the Y direction; F: Width in the X direction; G: Raw material; H: Frame; PL: Parting line; W1: Width in the X direction; W2: Width in the X direction.

Claims

1. A mold for forming a gasket onto a thin sheet-like substrate disposed within the mold, comprising a mold for preventing the embedding of a cut portion from the gasket's flash, characterized in that, The X-direction is defined as the extension direction of the parting line of the mold, the Y-direction as the opening and closing direction of the mold, the side of the cavity for forming the liner in the X-direction is defined as the inner side of the X-direction, and the side of the X-direction opposite to the inner side of the X-direction is defined as the outer side of the X-direction. The mold has the following features: A first mold, which is configured for the substrate; and The second mold is configured to face the first mold in the Y direction, and has the cutting portion and a cavity recess disposed inside the cutting portion in the X direction and dividing the cavity. The cutting portion has: a planar top surface that protrudes toward the substrate relative to the parting line and extends along the X direction; a convex inner surface disposed on the inner side of the top surface in the X direction; and a convex outer surface disposed on the outer side of the top surface in the X direction. The width in the X direction between the inner convex side surface and the outer convex side surface narrows in the direction from the parting line toward the top surface.

2. The mold of claim 1, wherein The inner convex side and the outer convex side are respectively planar.

3. The mold of claim 2, wherein, The angle between the inner convex side surface and the outer convex side surface is an obtuse angle.

4. The mold of claim 3, wherein The angle between the two points is greater than 120° and less than 150°.

5. The mold of claim 2, wherein The inclination angle of the inner convex side surface relative to the Y direction is the same as the inclination angle of the outer convex side surface relative to the Y direction.

6. The mold according to claim 1, characterized in that, The convex inner surface extends from the top surface across the parting line into the interior of the recessed portion of the cavity.

7. The mold according to claim 1, characterized in that, The second mold has a deformation-absorbing recess, which is disposed on the outer side of the cut portion in the X direction to absorb the deformation of the substrate when the top surface is pressed onto the substrate.

8. The mold according to claim 7, characterized in that, The deformation-absorbing recess has: a planar bottom surface that is recessed into the interior of the second mold relative to the parting line and extends along the X direction; an inner recessed side surface disposed on the inner side of the bottom surface in the X direction; and an outer recessed side surface disposed on the outer side of the bottom surface in the X direction. The width in the X direction between the inner concave side and the outer concave side narrows in the direction from the parting line toward the bottom surface.

9. The mold according to claim 8, characterized in that, The cut-off portion is arranged adjacent to the deformation-absorbing recess. From the inner side in the X direction toward the outer side in the X direction, the convex outer side and the concave inner side are smoothly connected.

10. The mold according to claim 1, characterized in that, The top surface protrudes more than 10 μm and less than 100 μm in the Y direction relative to the parting line.

11. The mold according to claim 1, characterized in that, The width of the top surface in the X direction is more than 10 μm and less than 500 μm.

12. The mold according to claim 1, characterized in that, The cutting portion is arranged to separate from the recess in the cavity and move outward in the X direction at predetermined intervals.

13. A composite component for an electrochemical device, comprising a substrate and a pad disposed on the surface of the substrate, characterized in that, With the extension direction of the surface defined as the X direction, the lamination direction of the substrate and the gasket defined as the Y direction, the side closer to the gasket in the X direction defined as the inner side in the X direction, and the side opposite to the inner side in the X direction defined as the outer side in the X direction. The substrate has a concave mark on its surface and a pad placement portion disposed inside the mark in the X direction for the pad to be placed. The trace portion has: a planar bottom surface; an inner recessed side surface disposed on the inner side of the bottom surface in the X direction; and an outer recessed side surface disposed on the outer side of the bottom surface in the X direction. The width in the X direction between the inner side and the outer side of the recessed mark narrows from the surface toward the bottom surface.

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