Method for manufacturing a fuel cell stack and fuel cell stack

Abstract

The present disclosure relates to a method of manufacturing a fuel cell stack and a fuel cell stack. The method of manufacturing a fuel cell stack (10) includes: a first manufacturing step of manufacturing a plurality of resin-frame-equipped membrane electrode structures (44) provided with resin seal members (98) extending in a linear shape on both surfaces of a resin frame member (54); a second manufacturing step of manufacturing a plurality of metal separators (46, 48); and a stacking step of stacking the plurality of resin-frame-equipped membrane electrode structures manufactured by the first manufacturing step and the plurality of metal separators manufactured by the second manufacturing step with each other in a manner in which end surfaces (66a, 82a) in a protruding direction of metal seal portions (66, 82) are in contact with the resin seal members.

Description

Technical Field

[0001] This disclosure relates to a method for manufacturing a fuel cell stack and the fuel cell stack itself. Background Technology

[0002] In recent years, in order to ensure that more people have access to appropriate, reliable, sustainable and advanced energy, research and development are underway on manufacturing methods for fuel cell stacks that contribute to energy efficiency.

[0003] For example, Patent Document 1 describes a method for manufacturing an integrally sealed separator, in which a sealing material is coated onto the surface of the separator of a fuel cell, and then the sealing material is fired to form a sealing member. In this method for manufacturing an integrally sealed separator, a mask fixture is used to prevent the escaping gas generated during the firing of the sealing material from adhering to the flow path of the separator.

[0004] Existing technical documents Patent documents Patent Document 1: Japanese Patent Application Publication No. 2022-15866 Summary of the Invention

[0005] The problem that the invention aims to solve We hope for better manufacturing methods for fuel cell stacks and better fuel cell stacks themselves.

[0006] The purpose of this disclosure is to address the aforementioned problems.

[0007] Solution for solving the problem The first aspect of this disclosure relates to a method for manufacturing a fuel cell stack, the fuel cell stack comprising a stack of multiple power-generating individual cells, each power-generating individual cell comprising: a membrane electrode structure with a resin frame, the membrane electrode structure having electrodes joined to both sides of an electrolyte membrane, a resin frame member disposed on the outer periphery of the membrane electrode structure in a manner protruding outward from the outer periphery of the membrane electrode structure; and a pair of metal spacers disposed on both sides of the membrane electrode structure with the resin frame and formed in a plate shape, wherein in the method for manufacturing the fuel cell stack, each of the pair of metal spacers has a metal sealing portion facing the resin frame member. The fuel cell stack is characterized by protrusion and linear extension, and elastic deformation due to the application of a fastening load in the stacking direction to the single-cell stack. The manufacturing method of the fuel cell stack includes: a first manufacturing step of manufacturing a plurality of membrane electrode structures with resin frames, wherein the membrane electrode structures with resin frames have linearly extending resin sealing members on both sides of the resin frame members; a second manufacturing step of manufacturing a plurality of metal spacers; and a stacking step of stacking the plurality of membrane electrode structures with resin frames manufactured in the first manufacturing step with the plurality of metal spacers manufactured in the second manufacturing step, such that the protruding end faces of the metal sealing portions contact the resin sealing members.

[0008] The second aspect of this disclosure relates to a method for manufacturing a fuel cell stack, the fuel cell stack comprising: a single-cell stack formed by stacking multiple single-cell power generation cells, each single-cell power generation cell comprising a membrane electrode structure formed by bonding electrodes to both sides of an electrolyte membrane, a pair of metal spacers disposed on both sides of the membrane electrode structure and formed in a plate shape; and a pair of insulating plates disposed on both sides of the stacking direction of the single-cell stack, wherein in the method for manufacturing the fuel cell stack, each of the pair of metal spacers located at both ends of the stacking direction of the single-cell stack, i.e., a pair of end metal spacers, has a metal sealing portion, the metal sealing portion protruding toward the insulating plate and extending linearly, and elastically deforming due to a fastening load applied to the single-cell stack in the stacking direction, the method for manufacturing the fuel cell stack comprising: a preparation step of preparing a pair of insulating plates provided with linearly extending end resin sealing members; and a stacking step of stacking the pair of insulating plates and the pair of end metal spacers together such that the end faces of the protruding directions of the metal sealing portions of the end metal spacers contact the end resin sealing members.

[0009] A third aspect of this disclosure relates to a fuel cell stack comprising a stack of multiple single-cell power-generating cells, each single-cell power-generating cell comprising: a membrane electrode structure with a resin frame having electrodes joined to both sides of an electrolyte membrane; a resin frame member disposed on the outer periphery of the membrane electrode structure protruding outward from the outer periphery of the membrane electrode structure; and a pair of metal spacers disposed on both sides of the membrane electrode structure with the resin frame and formed in a plate shape, wherein each of the metal spacers in the fuel cell stack has a metal sealing portion protruding toward the resin frame member and extending linearly, and elastically deforming due to a fastening load applied to the single-cell stack in the stacking direction; the membrane electrode structure with the resin frame has a resin sealing member disposed on both sides of the resin frame member, contacting the protruding end face of the metal sealing portion and extending linearly, the width dimension of the resin sealing member being greater than the spacing of the base portions of the metal sealing portions.

[0010] The fourth aspect of this disclosure relates to a fuel cell stack comprising: a single-cell stack consisting of a plurality of single-cell power-generating cells stacked on top of each other, each single-cell power-generating cell having a membrane electrode structure formed by bonding electrodes to both sides of an electrolyte membrane, a pair of metal spacers disposed on both sides of the membrane electrode structure and formed in a plate shape; and a pair of insulating plates disposed on both sides of the stacking direction of the single-cell stack, wherein in the fuel cell stack, the metal spacers located at the ends of the single-cell stack in the stacking direction, i.e., end metal spacers, have metal sealing portions that protrude toward the insulating plates and extend linearly, and are elastically deformable due to a fastening load applied to the single-cell stack in the stacking direction; an end resin sealing member extending linearly is provided on the surface of one of the pair of insulating plates facing the single-cell stack; the pair of insulating plates clamp the single-cell stack such that the end faces of the protruding directions of the metal sealing portions of the end metal spacers contact the end resin sealing members; the width dimension of the end resin sealing members is greater than the spacing of the base portions of the metal sealing portions of the end metal spacers.

[0011] The effects of the invention According to this disclosure, a better method for manufacturing fuel cell stacks and fuel cell stacks can be provided.

[0012] The above-described objectives, features, and advantages should be readily understood from the following description of the embodiments, which are illustrated with reference to the accompanying drawings. Attached Figure Description

[0013] Figure 1 This is a schematic cross-sectional view of a fuel cell stack.

[0014] Figure 2 It is along Figure 1 A partial sectional view of line II-II, omitted from the original text.

[0015] Figure 3 It is along Figure 1 A partial sectional view of line III-III, omitted from the original text.

[0016] Figure 4 This is a partially abbreviated exploded 3D view of a single-cell stack.

[0017] Figure 5 This is a plan view of the joining spacers as seen from the side of the first metal spacer.

[0018] Figure 6 yes Figure 2 A partially enlarged sectional view.

[0019] Figure 7 This is a plan view of the joining spacers as seen from the side of the second metal spacer.

[0020] Figure 8 This is a plan view of the membrane electrode structure with resin frame viewed from one side.

[0021] Figure 9 This is a plan view of the membrane electrode structure with resin frame viewed from the other side.

[0022] Figure 10 It is a plan view of one side of the insulation board.

[0023] Figure 11 This is a plan view of the other party's insulation board.

[0024] Figure 12 This is a flowchart illustrating a method for manufacturing a fuel cell stack.

[0025] Figure 13A as well as Figure 13B This is a flowchart illustrating a method for manufacturing a fuel cell stack.

[0026] Figure 14 It is a schematic diagram illustrating the first manufacturing process.

[0027] Figure 15 This is a schematic diagram illustrating the joining process.

[0028] Figure 16A This is a cross-sectional view illustrating the fuel cell stack involved in the comparative example. Figure 16B This is a cross-sectional view illustrating the fuel cell stack involved in this embodiment. Detailed Implementation

[0029] The method for manufacturing a sealed integrated spacer described in Patent Document 1 requires the preparation of a mask fixture, which necessitates the loading and unloading of the mask fixture relative to the spacer. This disclosure provides a method for manufacturing a fuel cell stack and a fuel cell stack that can reduce manufacturing costs.

[0030] The following description, using the accompanying drawings, illustrates a method for manufacturing a fuel cell stack 10 according to an embodiment of the present disclosure, as well as the fuel cell stack 10 itself. Figure 1 This is a schematic cross-sectional view of the fuel cell stack 10.

[0031] Figure 1 The fuel cell stack 10 shown is, for example, mounted on a fuel cell vehicle (not shown). Furthermore, the fuel cell stack 10 can also be mounted on equipment other than vehicles. The fuel cell stack 10 can also be used as a stationary power source.

[0032] like Figure 1 As shown, the fuel cell stack 10 includes a stack body 12 and a housing assembly 14. The stack body 12 has a single cell stack 18 formed by stacking multiple power generating single cells 16, a pair of terminal blocks 20 and 22, and a pair of insulating plates 24 and 26.

[0033] The single-cell power generation unit 16 generates electricity through an electrochemical reaction between an oxidant gas and a fuel gas. The oxidant gas is an oxygen-containing gas. Air can be used as an example of the oxidant gas. Hydrogen can be used as an example of the fuel gas. The fuel cell stack 10 is configured, for example, with the stacking direction (direction A) of the single-cell stack 18 along the horizontal direction. Alternatively, the fuel cell stack 10 can be configured with the stacking direction of the single-cell stack 18 along the direction of gravity.

[0034] Figure 2 It is along Figure 1 A partially omitted sectional view of line II-II. (See attached image.) Figure 1 as well as Figure 2 As shown, the terminal block 20 is disposed at one end of the single-cell stack 18 in the stacking direction (the end in the A1 direction). The insulating plate 24 is disposed adjacent to the terminal block 20 in the A1 direction.

[0035] Figure 3 It is along Figure 1 A partially omitted sectional view of line III-III. (See attached image.) Figure 1 as well as Figure 3 As shown, the terminal block 22 is disposed at the other end (the end in the A2 direction) of the single-cell stack 18 in the stacking direction. The insulating plate 26 on the other side is disposed adjacent to the terminal block 22 in the A2 direction.

[0036] Figures 1 to 3In this configuration, each terminal block 20, 22 is formed into a rectangular shape (quadrilateral) from a conductive metal material. Terminal blocks 20, 22 are used to extract the electricity generated by the single-cell stack 18 (multiple power-generating single cells 16) to the outside. Each insulating plate 24, 26 is formed into a rectangular shape (quadrilateral) from an electrically insulating resin material.

[0037] like Figure 1 As shown, housing assembly 14 includes a cylindrical peripheral housing 28 and a pair of end panels 30, 32. End panels 30 are bolted to the peripheral housing 28 by a plurality of bolts 33 in a manner that closes an opening in the A1 direction of the peripheral housing 28. End panels 30 are in contact with an insulating plate 24 (see reference). Figure 2 ).

[0038] The end panel 32 is bolted to the peripheral wall housing 28 by a plurality of bolts 34 in a manner that closes the opening in the A2 direction of the peripheral wall housing 28. The end panel 32 contacts the insulating plate 26 (see reference). Figure 3 The end panel 32 is fastened to the peripheral housing 28 by bolts 34, thereby clamping the single-cell stack 18 with a pair of insulating plates 24, 26. That is, the single-cell stack 18 is subjected to a fastening load in the stacking direction.

[0039] Figure 4 This is a partially abbreviated exploded 3D view of the single-cell stack 18. (See image below.) Figure 4 As shown, the power-generating single cell 16 has a horizontally elongated rectangular shape. The size and shape of the power-generating single cell 16 can be appropriately set.

[0040] Each individual power-generating cell 16 has a plurality of through holes 36 formed therethrough to allow fluid to flow along the stacking direction of the cell stack 18. The plurality of through holes 36 are also formed in the insulating plate 24 and the end face plate 30 (see reference). Figure 10 Furthermore, multiple connecting holes 36 are not formed on the insulating plate 26 and the end face plate 32 (see reference). Figure 11 ).

[0041] The plurality of connecting holes 36 include an oxidant gas supply connecting hole 38a, an oxidant gas discharge connecting hole 38b, a cooling medium supply connecting hole 40a, a cooling medium discharge connecting hole 40b, a fuel gas supply connecting hole 42a, and a fuel gas discharge connecting hole 42b.

[0042] At one end of the power generation cell 16 along its long side (the end in the B1 direction), an oxidant gas supply connection hole 38a, a cooling medium supply connection hole 40a, and a fuel gas discharge connection hole 42b are arranged along the short side direction (the C direction) of the power generation cell 16. At the other end of the power generation cell 16 along its long side (the end in the B2 direction), a fuel gas supply connection hole 42a, a cooling medium discharge connection hole 40b, and an oxidant gas discharge connection hole 38b are arranged along the C direction.

[0043] Oxidant gas flows towards A2 through oxidant gas supply connection hole 38a. Oxidant gas flows towards A1 through oxidant gas discharge connection hole 38b. Cooling medium flows towards A2 through cooling medium supply connection hole 40a. Cooling medium flows towards A1 through cooling medium discharge connection hole 40b. Fuel gas flows towards A2 through fuel gas supply connection hole 42a. Fuel gas flows towards A1 through fuel gas discharge connection hole 42b.

[0044] The configuration, shape, and size of the multiple connecting holes 36 can be set appropriately.

[0045] like Figures 2 to 4 As shown, the power-generating single cell 16 includes a membrane electrode structure 44 with a resin frame and a pair of metal spacers 46 and 48 formed in a plate shape. Hereinafter, one of the metal spacers 46 and 48, the metal spacer 46, will sometimes be referred to as the "first metal spacer 46", and the other of the metal spacers 46 and 48 will be referred to as the "second metal spacer 48". The first metal spacer 46 and the second metal spacer 48 form a bonding spacer 50 that is joined together by a plurality of bonding lines (not shown).

[0046] The membrane electrode structure 44 with a resin frame has a membrane electrode assembly (MEA) 52 and a resin frame member 54. Electrodes 58 and 60 are joined to both sides of the electrolyte membrane 56, thereby forming the membrane electrode structure 52. Hereinafter, one of the pair of electrodes 58 and 60, electrode 58, is sometimes referred to as the "cathode electrode 58", and the other of the pair of electrodes 58 and 60 is referred to as the "anode electrode 60".

[0047] Electrolyte membrane 56 is, for example, a solid polymer electrolyte membrane. A solid polymer electrolyte membrane is, for example, a membrane containing water-based perfluorosulfonic acid. Electrolyte membrane 56 can also be a fluorinated electrolyte membrane.

[0048] like Figure 2 as well as Figure 3As shown, a cathode electrode 58 is bonded to one side 56a of the electrolyte membrane 56. An anode electrode 60 is bonded to the other side 56b of the electrolyte membrane 56. The electrolyte membrane 56 is held between the cathode electrode 58 and the anode electrode 60. Detailed illustrations are omitted, but each electrode 58, 60 includes an electrode catalyst layer bonded to the electrolyte membrane 56 and a gas diffusion layer stacked on the electrode catalyst layer.

[0049] like Figure 4 As shown, the resin frame member 54 is disposed on the outer periphery of the membrane electrode structure 52, protruding outward from the outer periphery of the membrane electrode structure 52. The resin frame member 54 is formed in a quadrilateral ring shape. That is, a quadrilateral through hole 62 is formed in the center of the resin frame member 54 (see reference). Figure 2 as well as Figure 3 The resin frame member 54 is formed in a sheet shape. Multiple connecting holes 36 are formed in each of the resin frame member 54, the first metal spacer 46, and the second metal spacer 48.

[0050] Figure 5 This is a plan view of the joining spacer 50 as seen from the side of the first metal spacer 46. (See diagram below.) Figure 5 As shown, an oxidant gas flow path 64 extending in the B direction is formed on the surface of the first metal spacer 46 facing the membrane electrode structure 44 with resin frame (hereinafter referred to as "surface 46a"). The oxidant gas flow path 64 is integrally formed with the first metal spacer 46 by stamping (see reference). Figure 2 as well as Figure 3 The oxidant gas flow path 64 is connected to the oxidant gas supply connection hole 38a and the oxidant gas discharge connection hole 38b. The oxidant gas flow path 64 supplies oxidant gas to the cathode electrode 58 (power generation area).

[0051] The first metal spacer 46 has a metal sealing portion 66 (hereinafter sometimes referred to as "first metal sealing portion 66") that protrudes toward the resin frame member 54 and extends in a linear manner. The first metal sealing portion 66 prevents the leakage of reactive gases (oxidant gases and fuel gases) and cooling media to the outside. The first metal sealing portion 66 is integrally formed with the first metal spacer 46 by stamping.

[0052] Figure 6 yes Figure 2 A partially enlarged sectional view. For example... Figure 6 As shown, the first metal seal portion 66 is formed in a trapezoidal shape that tapers at its front end in the protruding direction of the first metal seal portion 66. The first metal seal portion 66 elastically deforms due to the application of a fastening load in the stacking direction to the single cell stack 18. The first metal seal portion 66 includes a pair of first sealing sides 68 and a first sealing top 70.

[0053] A pair of first sealing sides 68 are arranged facing each other. The spacing between the pair of first sealing sides 68 gradually narrows towards the first sealing top 70. The first sealing top 70 connects the protruding ends of the pair of first sealing sides 68. The protruding end face 66a of the first metal sealing part 66 is flat.

[0054] like Figure 5 As shown, the first metal sealing part 66 includes a plurality of first connecting hole sealing parts 72a~72f and a first flow path sealing part 74. The plurality of first connecting hole sealing parts 72a~72f individually surround the plurality of connecting holes 36.

[0055] Specifically, the first connecting hole sealing part 72a surrounds the oxidant gas supply connecting hole 38a. The first connecting hole sealing part 72b surrounds the oxidant gas discharge connecting hole 38b. The first connecting hole sealing part 72c surrounds the cooling medium supply connecting hole 40a. The first connecting hole sealing part 72d surrounds the cooling medium discharge connecting hole 40b. The first connecting hole sealing part 72e surrounds the fuel gas supply connecting hole 42a. The first connecting hole sealing part 72f surrounds the fuel gas discharge connecting hole 42b.

[0056] Multiple first connecting hole sealing portions 72a, 72b, 72e, and 72f are located inside the first flow path sealing portion 74. An oxidant gas supply channel 76 is provided in the first connecting hole sealing portion 72a. The oxidant gas supply channel 76 connects the oxidant gas supply connecting hole 38a with the oxidant gas flow path 64. An oxidant gas discharge channel 78 is provided in the first connecting hole sealing portion 72b. The oxidant gas discharge channel 78 connects the oxidant gas discharge connecting hole 38b with the oxidant gas flow path 64.

[0057] Figure 7 This is a plan view of the joining spacer 50 as seen from the side of the second metal spacer 48. (See attached image.) Figure 7 As shown, a fuel gas flow path 80 extending in the B direction is formed on the surface of the second metal spacer 48 facing the membrane electrode structure 44 with resin frame (hereinafter referred to as "surface 48a"). The fuel gas flow path 80 is integrally formed with the second metal spacer 48 by stamping (see reference). Figure 2 as well as Figure 3 The fuel gas flow path 80 is connected to the fuel gas supply connection hole 42a and the fuel gas discharge connection hole 42b. The fuel gas flow path 80 supplies fuel gas to the anode electrode 60 (power generation area).

[0058] The second metal spacer 48 has a metal sealing portion 82 (hereinafter sometimes referred to as "second metal sealing portion 82") that protrudes toward the resin frame member 54 and extends in a linear manner. The second metal sealing portion 82 prevents the leakage of reactive gases (oxidant gases and fuel gases) and cooling media to the outside. The second metal sealing portion 82 is integrally formed with the second metal spacer 48 by stamping.

[0059] like Figure 6 As shown, the second metal seal portion 82 is formed in a trapezoidal shape that tapers at its front end in the protruding direction of the second metal seal portion 82. The second metal seal portion 82 elastically deforms due to the application of a fastening load in the stacking direction to the single-cell stack 18. The second metal seal portion 82 includes a pair of second sealing sides 84 and a second sealing top 86.

[0060] A pair of second sealing sides 84 are arranged facing each other. The spacing between the pair of second sealing sides 84 gradually narrows towards the second sealing top 86. The second sealing top 86 connects the protruding ends of the pair of second sealing sides 84. The protruding end face 82a of the second metal sealing part 82 is flat.

[0061] like Figure 7 As shown, the second metal sealing part 82 includes a plurality of second connecting hole sealing parts 88a~88f and a second flow path sealing part 90. The plurality of second connecting hole sealing parts 88a~88f individually surround the plurality of connecting holes 36.

[0062] Specifically, the second connecting hole sealing part 88a surrounds the oxidant gas supply connecting hole 38a. The second connecting hole sealing part 88b surrounds the oxidant gas discharge connecting hole 38b. The second connecting hole sealing part 88c surrounds the cooling medium supply connecting hole 40a. The second connecting hole sealing part 88d surrounds the cooling medium discharge connecting hole 40b. The second connecting hole sealing part 88e surrounds the fuel gas supply connecting hole 42a. The second connecting hole sealing part 88f surrounds the fuel gas discharge connecting hole 42b.

[0063] Multiple second connecting hole sealing portions 88a, 88b, 88e, and 88f are located inside the second flow path sealing portion 90. A fuel gas supply passage 92 is provided in the second connecting hole sealing portion 88e. The fuel gas supply passage 92 connects the fuel gas supply connecting hole 42a to the fuel gas flow path 80. A fuel gas discharge passage 94 is provided in the second connecting hole sealing portion 88f. The fuel gas discharge passage 94 connects the fuel gas discharge connecting hole 42b to the fuel gas flow path 80.

[0064] like Figures 2 to 4As shown, a cooling medium flow path 96 is formed between the back surface 46b of the first metal spacer 46 and the back surface 48b of the second metal spacer 48, which is in fluid communication with the cooling medium supply communication hole 40a and the cooling medium discharge communication hole 40b. The cooling medium flow path 96 is formed by overlapping the back surface shape of the first metal spacer 46, on which the oxidant gas flow path 64 is formed, with the back surface shape of the second metal spacer 48, on which the fuel gas flow path 80 is formed.

[0065] Figure 8 This is a plan view of the membrane electrode structure 44 with resin frame viewed from one side. Figure 9 This is a plan view of the membrane electrode structure 44 with resin frame, viewed from the other side. (See diagram below.) Figure 8 as well as Figure 9 As shown, resin sealing members 98 extending in a linear shape are provided on both sides of the resin frame member 54. The resin sealing member 98 is a thin film-shaped miniature seal. The resin sealing member 98 has a linear first resin sealing member 100 provided on one side 54a of the resin frame member 54 and a second resin sealing member 102 provided on the other side 54b of the resin frame member 54.

[0066] like Figure 6 As shown, the first resin sealing member 100 has a plane 100a facing the first metal spacer 46. The end face 66a of the protruding direction of the first metal sealing portion 66 is in airtight and liquidtight contact with the first resin sealing member 100. The width dimension L1 of the first resin sealing member 100 is greater than the spacing L2 of the base of the first metal sealing portion 66. The width direction of the first resin sealing member 100 is a direction orthogonal to the extension direction and the thickness direction of the first resin sealing member 100.

[0067] Due to the fastening load, the protruding end face 66a of the first metal sealing portion 66 is pressed against the plane 100a of the first resin sealing member 100. Therefore, a recess 100r corresponding to the first sealing top 70 is formed in the plane 100a of the first resin sealing member 100. The thickness d1 of the portion of the plane 100a in the first resin sealing member 100 without the recess is, for example, thicker than the thickness d2 of the resin frame member 54. Furthermore, the thickness d1 may be less than or equal to the thickness d2.

[0068] like Figure 8 As shown, the first resin sealing member 100 has a plurality of first connecting hole resin sealing members 104a~104f and a first flow path resin sealing member 106. The plurality of first connecting hole resin sealing members 104a~104f individually surround the plurality of connecting holes 36.

[0069] Specifically, the first connecting hole resin sealing member 104a surrounds the oxidant gas supply connecting hole 38a. The first connecting hole resin sealing member 104b surrounds the oxidant gas discharge connecting hole 38b. The first connecting hole resin sealing member 104c surrounds the cooling medium supply connecting hole 40a. The first connecting hole resin sealing member 104d surrounds the cooling medium discharge connecting hole 40b. The first connecting hole resin sealing member 104e surrounds the fuel gas supply connecting hole 42a. The first connecting hole resin sealing member 104f surrounds the fuel gas discharge connecting hole 42b. Multiple first connecting hole resin sealing members 104a, 104b, 104e, and 104f are located inside the first flow path resin sealing member 106.

[0070] Multiple first connecting hole resin sealing members 104a~104f contact with multiple first connecting hole sealing portions 72a~72f of the first metal spacer 46. The first flow path resin sealing member 106 contacts the first flow path sealing portion 74 (see reference). Figure 6 This prevents the leakage of reactive gases (oxidant gases and fuel gases) and cooling media between the membrane electrode structure 44 with resin frame and the first metal spacer 46.

[0071] like Figure 9 As shown, the second resin sealing member 102 is formed in the form of a film. The second resin sealing member 102 has a plane 102a facing the second metal spacer 48.

[0072] like Figure 6 As shown, the protruding end face 82a of the second metal sealing portion 82 is in airtight and liquidtight contact with the second resin sealing member 102. The width dimension L3 of the second resin sealing member 102 is greater than the distance L4 at the base of the second metal sealing portion 82. The width direction of the second resin sealing member 102 is orthogonal to the extension direction and the thickness direction of the second resin sealing member 102.

[0073] Due to the fastening load, the protruding end face 82a of the second metal sealing portion 82 is pressed against the plane 102a of the second resin sealing member 102. Therefore, a recess 102r corresponding to the second sealing top 86 is formed in the plane 102a of the second resin sealing member 102. The thickness d3 of the portion of the plane 102a in the second resin sealing member 102 without the recess is thicker than the thickness d2. Furthermore, the thickness d3 can be less than or equal to the thickness d2. The thickness d3 can be the same as the thickness d1, or it can be a different thickness than the thickness d1.

[0074] like Figure 9As shown, the second resin sealing member 102 has a plurality of second connecting hole resin sealing members 108a~108f and a second flow path resin sealing member 110. The plurality of second connecting hole resin sealing members 108a~108f individually surround the plurality of connecting holes 36.

[0075] Specifically, the second connecting hole resin sealing member 108a surrounds the oxidant gas supply connecting hole 38a. The second connecting hole resin sealing member 108b surrounds the oxidant gas discharge connecting hole 38b. The second connecting hole resin sealing member 108c surrounds the cooling medium supply connecting hole 40a. The second connecting hole resin sealing member 108d surrounds the cooling medium discharge connecting hole 40b. The second connecting hole resin sealing member 108e surrounds the fuel gas supply connecting hole 42a. The second connecting hole resin sealing member 108f surrounds the fuel gas discharge connecting hole 42b. Multiple second connecting hole resin sealing members 108a, 108b, 108e, and 108f are located inside the second flow path resin sealing member 110.

[0076] Multiple second-connecting-hole resin sealing members 108a~108f contact the multiple second-connecting-hole sealing portions 88a~88f of the second metal spacer 48. The second flow path resin sealing member 110 contacts the second flow path sealing portion 90 (see reference). Figure 6 This prevents the leakage of reactive gases (oxidant gases and fuel gases) and cooling media between the membrane electrode structure 44 with resin frame and the second metal spacer 48.

[0077] like Figure 6 , Figure 8 as well as Figure 9 As shown, when viewed from the thickness direction of the resin frame member 54, the first resin sealing member 100 and the second resin sealing member 102 extend in a linear manner while overlapping each other. Furthermore, as... Figure 6 As shown, the first end 100e of the first resin sealing member 100 in the width direction is located at a position offset in the plane direction of the resin frame member 54 relative to the second end 102e of the second resin sealing member 102 in the width direction. That is, the first end 100e and the second end 102e do not overlap each other in the stacking direction (direction A) of the single cell stack 18.

[0078] With this structure, the first end 100e of the first resin sealing member 100 is located at a position offset relative to the second end 102e of the second resin sealing member 102 in the planar direction of the resin frame member 54. Therefore, stress concentration at the end of the resin sealing member 98 can be suppressed when a fastening load is applied to the single-cell laminate 18. As a result, damage to the resin frame member 54 can be suppressed.

[0079] Figure 10This is a plan view of one side of the insulating plate 24. (See diagram below.) Figure 2 as well as Figure 10 As shown, an end resin sealing member 112 (hereinafter sometimes referred to as "first end resin sealing member 112") is provided on the surface 24a of the insulating plate 24 facing the single cell stack 18. The first end resin sealing member 112 is a thin film-shaped miniature seal.

[0080] like Figure 2 As shown, the first end resin sealing member 112 has a plane 112a facing the single-cell laminate 18. The end face 82a of the protruding direction of the second metal sealing portion 82 of the metal spacer 48, i.e., the end metal spacer 48e, located at one end (the end in the A1 direction) of the single-cell laminate 18, is in airtight and liquidtight contact with the first end resin sealing member 112. Hereinafter, the end metal spacer 48e is sometimes referred to as the "second end metal spacer 48e".

[0081] The width dimension L5 of the first end resin sealing member 112 is greater than the distance L4 between the base of the second metal sealing portion 82 of the second end metal spacer 48e. The width direction of the first end resin sealing member 112 is orthogonal to the extension direction and the thickness direction of the first end resin sealing member 112.

[0082] Due to the fastening load, the protruding end face 82a of the second metal sealing portion 82 of the second end metal spacer 48e is pressed against the plane 112a of the first end resin sealing member 112. Therefore, a recess 112r corresponding to the second sealing top 86 is formed in the plane 112a of the first end resin sealing member 112. The thickness d4 of the portion of the plane 112a in the first end resin sealing member 112 without the recess can be the same as the thickness d1, or it can be the same as the thickness d3. The thickness d4 can also be a thickness different from both the thickness d1 and the thickness d3.

[0083] like Figure 10 As shown, the first end resin sealing member 112 has a plurality of first end connecting hole resin sealing members 114a~114f and a first end flow path resin sealing member 116. The plurality of first end connecting hole resin sealing members 114a~114f individually surround the plurality of connecting holes 36.

[0084] Specifically, the first end connecting hole resin sealing member 114a surrounds the oxidant gas supply connecting hole 38a. The first end connecting hole resin sealing member 114b surrounds the oxidant gas discharge connecting hole 38b. The first end connecting hole resin sealing member 114c surrounds the cooling medium supply connecting hole 40a. The first end connecting hole resin sealing member 114d surrounds the cooling medium discharge connecting hole 40b. The first end connecting hole resin sealing member 114e surrounds the fuel gas supply connecting hole 42a. The first end connecting hole resin sealing member 114f surrounds the fuel gas discharge connecting hole 42b. Multiple first end connecting hole resin sealing members 114a, 114b, 114e, and 114f are located inside the first end flow path resin sealing member 116.

[0085] Multiple first-end connecting hole resin sealing members 114a~114f contact with multiple second connecting hole sealing portions 88a~88f of the second-end metal spacer 48e. First-end flow path resin sealing member 116 contacts the second flow path sealing portion 90 of the second-end metal spacer 48e (see reference). Figure 2 This prevents the reaction gases (oxidant gases and fuel gases) and cooling media from leaking between the insulating plate 24 and the second end metal spacer 48e.

[0086] Figure 11 This is a plan view of the insulating plate 26 on the other side. (See diagram below.) Figure 3 as well as Figure 11 As shown, an end resin sealing member 118 (hereinafter sometimes referred to as "second end resin sealing member 118") is provided on the surface 26a of the insulating plate 26 facing the single cell stack 18. The second end resin sealing member 118 is a thin film-shaped miniature seal.

[0087] like Figure 3 As shown, the second end resin sealing member 118 has a plane 118a facing the single-cell stack 18. The end face 66a of the protruding direction of the metal spacer 46 located at the other end (the end in the A2 direction) of the single-cell stack 18, namely the end metal spacer 46e, is in airtight and liquid-tight contact with the second end resin sealing member 118. Hereinafter, the end metal spacer 46e is sometimes referred to as the "first end metal spacer 46e".

[0088] The width dimension L6 of the second end resin sealing member 118 is greater than the distance L2 between the base of the first metal sealing portion 66 of the first end metal spacer 46e. The width direction of the second end resin sealing member 118 is orthogonal to the extension direction and the thickness direction of the second end resin sealing member 118.

[0089] Due to the fastening load, the protruding end face 66a of the first metal sealing portion 66 of the first end metal spacer 46e is pressed against the plane 118a of the second end resin sealing member 118. Therefore, a recess 118r corresponding to the first sealing top 70 is formed in the plane 118a of the second end resin sealing member 118. The thickness d5 of the portion of the plane 118a in the second end resin sealing member 118 without the recess is, for example, the same as the thickness d4. That is, the thickness d5 can also be the same as the thickness d1, or the same as the thickness d3. The thickness d5 can also be a thickness different from both thickness d1 and thickness d3. The thickness d5 can also be a thickness different from thickness d4.

[0090] like Figure 11 As shown, the second end resin sealing member 118 has a plurality of second end connecting hole resin sealing members 120a~120f and a second end flow path resin sealing member 122.

[0091] Multiple second-end connecting hole resin sealing members 120a~120f contact with multiple first connecting hole sealing portions 72a~72f of the first-end metal spacer 46e. Second-end flow path resin sealing member 122 contacts the first flow path sealing portion 74 of the first-end metal spacer 46e (see reference). Figure 3 This prevents the leakage of reactive gases (oxidant gases and fuel gases) and cooling media between the insulating plate 26 and the first end metal spacer 46e.

[0092] Next, the operation of the fuel cell stack 10 will be explained.

[0093] When the fuel cell stack 10 is operated (started), an oxidant gas pump (not shown) is driven, thereby supplying oxidant gas to the oxidant gas supply connection port 38a. Figure 4 As shown, the oxidant gas flowing through the oxidant gas supply connection hole 38a is guided to the oxidant gas flow path 64 of each power generation cell 16. The oxidant gas flows along the B direction in the oxidant gas flow path 64 and is thus supplied to the cathode electrode 58.

[0094] Additionally, an injector (not shown) is driven, thereby supplying fuel gas to the fuel gas supply connection port 42a. The fuel gas flowing through the fuel gas supply connection port 42a is guided to the fuel gas flow path 80 of each power generation cell 16. The fuel gas flows in the fuel gas flow path 80 along direction B and is thus guided to the anode electrode 60.

[0095] In each membrane electrode structure 52, the oxidant gas supplied to the cathode electrode 58 and the fuel gas supplied to the anode electrode 60 are consumed through an electrochemical reaction to generate electricity.

[0096] The oxidant exhaust gas flowing through the oxidant gas flow path 64 is directed to the oxidant gas exhaust connection hole 38b. The oxidant exhaust gas flowing through the oxidant gas exhaust connection hole 38b flows in the A1 direction and is thus discharged to the outside of the single cell stack 18.

[0097] Fuel exhaust flowing through fuel gas flow path 80 is directed to fuel gas discharge connection hole 42b. Fuel exhaust flowing through fuel gas discharge connection hole 42b flows in the A1 direction and is discharged to the outside of single cell stack 18.

[0098] Furthermore, when the fuel cell stack 10 is started, a cooling medium pump (not shown) is driven to supply cooling medium to the cooling medium flow path 96. The cooling medium flowing through the cooling medium supply connection hole 40a flows through the cooling medium flow path 96 of each power generation cell 16, thereby cooling each power generation cell 16 and then being discharged to the cooling medium discharge connection hole 40b. The cooling medium flowing through the cooling medium discharge connection hole 40b flows in the A1 direction and is thus discharged to the outside of the cell stack 18.

[0099] Next, the manufacturing method of the fuel cell stack 10 will be explained. Figures 12 to 13B This is a flowchart illustrating a method for manufacturing a fuel cell stack 10. Figure 14 It is a schematic diagram illustrating the first manufacturing process. Figure 15 This is a schematic diagram illustrating the joining process.

[0100] like Figure 12 As shown, the manufacturing method of fuel cell stack 10 includes a first manufacturing process, a second manufacturing process, a preparation process, and a stacking process.

[0101] In step S1, a first manufacturing process is performed. In this first manufacturing process, a plurality of membrane electrode structures 44 with resin frames are manufactured. Each membrane electrode structure 44 with a resin frame has resin sealing members 98 extending linearly on both sides of the resin frame member 54. For example... Figure 13A As shown, in the first manufacturing process, in step S11, a resin sealing formation process is performed to form resin sealing components 98 on both sides of the resin sheet 200.

[0102] That is, such as Figure 13B As shown, in the resin seal forming process, in step S21, a coating process is performed to coat both sides of the resin sheet 200 with sealant 202. In this embodiment, when the first manufacturing process is performed, as... Figure 14 As shown, the resin sheet 200 wound on the unwind roller 300 is fed to the screen printing apparatus 302 in a roll-to-roll manner. Furthermore, Figure 14 In the example, illustrations of conveyor rollers, etc., are omitted.

[0103] In the screen printing apparatus 302, a sealing material 202 is applied to both sides of a resin sheet 200 fed from the unwinding roller 300 by screen printing. The coating process is not limited to screen printing; the sealing material 202 can be applied to both sides of the resin sheet 200 by any appropriate method.

[0104] In the coating process, the sealing material 202 is simultaneously coated on both sides of the resin sheet 200. Alternatively, in the coating process, the sealing material 202 may be coated on one side of the resin sheet 200, and then coated on the other side. The sealing material 202 coated on the resin sheet 200 in the coating process has a shape corresponding to the shape of the resin sealing member 98.

[0105] However, when resin sealing members 98 are provided on the protruding end faces 66a and 82a of the metal sealing portions 66 and 82 of the metal spacers 46 and 48, high-precision positioning of the metal sealing portions 66 and 82 is required during the coating process. Furthermore, when the metal spacers 46 and 48 are not subjected to a tightening load, the protruding end faces 66a and 82a of the metal sealing portions 66 and 82 are not flat but curved surfaces, making the coating of the sealing material 202 difficult. Also, the width dimension of the sealing material 202 is limited to or less than the width dimension of the end faces 66a and 82a.

[0106] However, in this embodiment, the sealing material 202 is applied linearly to the resin sheet 200 during the coating process, thus eliminating the need for high-precision positioning of the resin sheet 200 relative to the screen printing apparatus 302 (coating apparatus). Furthermore, the sealing material 202 is applied to the flat surface of the resin sheet 200, making the application of the sealing material 202 easier. Also, the width of the sealing material 202 is not limited to the width of the end faces 66a and 82a in the protruding direction of the metal sealing portions 66 and 82. After the coating process, the process proceeds to step S22.

[0107] In step S22, a hardening process is performed to harden the sealing material 202, thereby obtaining the resin sealing member 98. That is, the resin sheet 200 fed from the screen printing device 302 is heated by the heating device 304. In this case, the sealing material 202 hardens due to heat, thereby obtaining the resin sealing member 98.

[0108] In other words, the sealing material 202 coated on one side of the resin sheet 200 hardens, thereby obtaining the first resin sealing member 100. Furthermore, the sealing material 202 coated on the other side of the resin sheet 200 hardens, thereby obtaining the second resin sealing member 102. Moreover, in this embodiment, a sealing material 202 that hardens below the temperature at which the resin sheet 200 shrinks is used. Therefore, it is possible to suppress the shrinkage of the resin sheet 200 due to heat and to obtain the resin sealing member 98.

[0109] Furthermore, in this embodiment, the resin seal forming process includes a coating process and a curing process, thus enabling efficient and effective formation of the resin seal member 98 on both sides of the resin frame member 54. Afterwards, proceed to step S12.

[0110] In step S12, the resin sheet 200 on which the resin sealing member 98 is formed is trimmed, thereby forming a resin frame member 54 provided with the resin sealing member 98. That is, the resin sheet 200 fed from the heating device 304 is trimmed by the processing device 306. Specifically, the processing device 306 cuts the resin sheet 200 to a size that is the same as the outer dimensions of the resin frame member 54. In addition, the processing device 306 forms a through hole 62 and a plurality of connecting holes 36 in the resin sheet 200. Thus, the resin frame member 54 provided with the resin sealing member 98 can be obtained. Then, the process proceeds to step S13.

[0111] In step S13, a joining process is performed, in which the inner peripheral end of the resin frame member 54, which is provided with the resin sealing member 98, is joined to the membrane electrode structure 52. Specifically, as follows... Figure 15 As shown, an electrolyte membrane 56, a cathode electrode 58, and an anode electrode 60 are prepared in advance. In this embodiment, the electrolyte membrane 56 is pre-bonded to the anode electrode 60. During the bonding process, the inner peripheral end of the resin frame member 54 is clamped by the cathode electrode 58 and the anode electrode 60 such that the electrolyte membrane 56 is positioned in the through hole 62 of the resin frame member 54. The cathode electrode 58 and the anode electrode 60 are bonded to the resin frame member 54 with an adhesive (not shown). Thus, a membrane electrode structure 44 with a resin frame is obtained. Moreover, the bonding process is not limited to the method described above.

[0112] In this embodiment, the bonding process is performed after the coating and curing processes, so the volatile components of the sealing material 202 will not adhere to the electrodes 58, 60, etc. during the curing process. Therefore, it is not necessary to prepare a mask component or the like to protect the power generation area during the curing process. As a result, the membrane electrode structure 44 with a resin frame can be manufactured at low cost.

[0113] In addition, Figure 12 In step S2, a second manufacturing process is performed to manufacture multiple metal spacers 46 and 48. Specifically, multiple joining spacers 50 are manufactured by joining the first metal spacer 46 and the second metal spacer 48 together with the first metal spacer 46 overlapping. The second manufacturing process can also be performed simultaneously with the first manufacturing process.

[0114] In addition, in step S3, a preparation process is performed to prepare a pair of insulating plates 24 and 26 with end resin sealing members 112 and 118 extending in a linear shape. Specifically, an insulating plate 24 with a first end resin sealing member 112 and an insulating plate 26 with a second end resin sealing member 118 are prepared. The first end resin sealing member 112 and the second end resin sealing member 118 can be formed by the same method as the resin sealing formation process (screen printing) and the curing process described above. In addition, a plurality of connecting holes 36 in the insulating plate 24 can be formed by the same method as the processing process (trimming) described above. The preparation process can also be performed simultaneously with the first manufacturing process and the second manufacturing process. After this, the process proceeds to step S4.

[0115] In step S4, a stacking process is performed. Specifically, for example, firstly, the end panel 30 is fastened to one end of the peripheral housing 28 using bolts 33. Then, on the end panel 30 and inside the peripheral housing 28, the insulating plate 24, the terminal block 20, multiple individual power generating cells 16 (single cell stack 18), the terminal block 22, and the insulating plate 26 are stacked in sequence. Afterward, the end panel 32 is fastened to the other end of the peripheral housing 28 using multiple bolts 34, thereby applying a fastening load to the single cell stack 18. That is, the single cell stack 18 is clamped by a pair of insulating plates 24 and 26.

[0116] In the lamination process, multiple membrane electrode structures 44 with resin frames and multiple bonding spacers 50 are stacked together in such a way that the end face 66a of the first metal sealing part 66 in the protruding direction contacts the first resin sealing member 100 and the end face 82a of the second metal sealing part 82 in the protruding direction contacts the second resin sealing member 102.

[0117] Furthermore, in the lamination process, the insulating plate 24 and the second end metal spacer 48e are laminated such that the protruding end face 82a of the second end metal sealing portion 82 of the second end metal spacer 48e contacts the first end resin sealing member 112. Also, in the lamination process, the first end metal spacer 46e and the insulating plate 26 are laminated such that the protruding end face 66a of the first end metal sealing portion 66 of the first end metal spacer 46e contacts the second end resin sealing member 118. Thus, the fuel cell stack 10 is manufactured. Thereafter, Figure 12 The processing shown is complete.

[0118] However, in the fuel cell stack 10, due to manufacturing tolerances and assembly tolerances of the bonding spacer 50, the first metal seal 66 and the second metal seal 82 may sometimes be misaligned in the planar direction during the stacking process. This section explains the sealing function in such cases.

[0119] Figure 16AThis is a cross-sectional view of the fuel cell stack 400 involved in the comparative example. Figure 16B This is a cross-sectional view illustrating the fuel cell stack 10 according to this embodiment. Figure 16A As shown, in the comparative example of the fuel cell stack 400, the first resin sealing member 100 is fixed to the protruding end face 66a of the first metal sealing portion 66 of the first metal spacer 46, and the second resin sealing member 102 is fixed to the protruding end face 82a of the second metal sealing portion 82 of the second metal spacer 48.

[0120] Figure 16A This example illustrates a fuel cell stack 400 according to a comparative example, where the first metal sealing portion 66 and the second metal sealing portion 82 sandwich the resin frame member 54, resulting in a positional offset of only a distance L7 in the planar direction. In this case, the first resin sealing member 100 and the resin frame member 54 are sealed within a sealing width W1. The sealing width W1 is smaller than the width of the protruding end face 66a of the first metal sealing portion 66. Furthermore, the second resin sealing member 102 and the resin frame member 54 are sealed within a sealing width W2. The sealing width W2 is smaller than the width of the protruding end face 82a of the second metal sealing portion 82.

[0121] Figure 16BThis embodiment illustrates an example where, in the fuel cell stack 10, the first metal sealing portion 66 and the second metal sealing portion 82 sandwich the resin frame member 54, resulting in a positional offset of only a distance L8 in the planar direction. Distance L8 is the same length as distance L7. In this case, the first metal sealing portion 66 and the first resin sealing member 100 are sealed within a sealing width W3. The sealing width W3 is approximately the same as the width of the end face 66a in the protruding direction of the first metal sealing portion 66, and is wider than the sealing width W1. Furthermore, the second metal sealing portion 82 and the second resin sealing member 102 are sealed within a sealing width W4. The sealing width W4 is approximately the same as the width of the end face 82a in the protruding direction of the second metal sealing portion 82, and is wider than the sealing width W2. Alternatively, a portion of the first metal sealing portion 66 (including the portion containing the first sealing top 70) may be pressed into the resin frame member 54 side relative to the plane 100a of the first resin sealing member 100 (or may be buried). In this case, a recess 100r corresponding to a portion of the first metal sealing portion 66 is formed in the plane 100a of the first resin sealing member 100. Alternatively, a portion of the second metal sealing portion 82 (including the portion containing the second sealing top 86) may be pressed into the side of the resin frame member 54 relative to the plane 102a of the second resin sealing member 102 (or may be buried). In this case, a recess 102r corresponding to a portion of the second metal sealing portion 82 is formed in the plane 102a of the second resin sealing member 102. Furthermore, the center of the first sealing top 70 in the width direction may be offset relative to the center of the first resin sealing member 100 in the width direction. Similarly, the center of the second sealing top 86 in the width direction may be offset relative to the center of the second resin sealing member 102 in the width direction.

[0122] In this embodiment, the narrowing of the sealing width due to the positional offset between the first metal sealing part 66 and the second metal sealing part 82 in the planar direction can be suppressed.

[0123] According to this embodiment, the resin sealing member 98 is disposed on the resin frame member 54 instead of the metal spacers 46 and 48, so there is no need to install the mask member when manufacturing the metal spacers 46 and 48. As a result, the manufacturing cost of the fuel cell stack 10 can be reduced.

[0124] Furthermore, according to this embodiment, the resin sealing member 98 is disposed on the insulating plates 24 and 26 instead of on the end metal spacers 46e and 48e, so a mask member is not required when manufacturing the end metal spacers 46e and 48e. As a result, the manufacturing cost of the fuel cell stack 10 can be reduced.

[0125] According to this embodiment, after the resin sealing member 98 is formed on the resin sheet 200, a processing step and a joining step are performed, so that the resin sealing member 98 can be easily disposed on the resin frame member 54.

[0126] In this embodiment, when the single-cell stack 18 is subjected to a fastening load, the width dimensions L1 and L3 of the resin sealing member 98 are greater than the distance L2 and L4 between the bases of the metal sealing portions 66 and 82. Therefore, during the lamination process, the metal sealing portions 66 and 82 can easily contact the resin sealing member 98. In other words, during the lamination process, the permissible offset in the planar direction between the membrane electrode structure 44 with the resin frame and the metal spacers 46 and 48 can be relatively large. Therefore, the lamination process can be performed simply.

[0127] Furthermore, when the single-cell laminate 18 is subjected to a fastening load, the width dimensions L5 and L6 of the end resin sealing members 112 and 118 are greater than the distance L2 and L4 between the bases of the metal sealing portions 66 and 82. Therefore, during the lamination process, the metal sealing portions 66 and 82 can easily contact the end resin sealing members 112 and 118. In other words, during the lamination process, the permissible offset in the planar direction between the end metal spacers 46e and 48e and the insulating plates 24 and 26 can be relatively large. Therefore, the lamination process can be performed simply.

[0128] The following notes are also disclosed regarding the above-described embodiments.

[0129] (Postscript 1) In the method for manufacturing the fuel cell stack 10 disclosed herein, the fuel cell stack includes a single-cell stack 18 formed by stacking multiple power-generating single cells 16. Each power-generating single cell includes: a membrane electrode structure 44 with a resin frame, having a membrane electrode structure 52 formed by bonding electrodes 58 and 60 to both sides of an electrolyte membrane 56; a resin frame member 54 disposed on the outer periphery of the membrane electrode structure in a manner that protrudes outward from the outer periphery of the membrane electrode structure; and a pair of metal spacers 46 and 48 disposed on both sides of the membrane electrode structure with a resin frame and formed in a plate shape. In the method for manufacturing the fuel cell stack, each of the pair of metal spacers has a metal sealing portion 66 and 82, the metal sealing portion facing the resin frame. The resin frame member protrudes and extends linearly, and elastically deforms due to the application of a fastening load in the stacking direction to the single cell stack. The manufacturing method of the fuel cell stack includes: a first manufacturing step S1, manufacturing a plurality of membrane electrode structures with resin frames, wherein the membrane electrode structures with resin frames are provided with resin sealing members 98 extending linearly on both sides of the resin frame member; a second manufacturing step S2, manufacturing a plurality of metal spacers; and a stacking step S4, stacking the plurality of membrane electrode structures with resin frames manufactured in the first manufacturing step and the plurality of metal spacers manufactured in the second manufacturing step together such that the end faces 66a, 82a of the protruding direction of the metal sealing portion contact the resin sealing member.

[0130] With this structure, the resin sealing component is placed within the resin frame component instead of the metal spacer, thus eliminating the need for a mask component during the manufacturing of the metal spacer. This allows for a reduction in the manufacturing cost of the fuel cell stack.

[0131] (Postscript 2) In the fuel cell stack manufacturing method described in Appendix 1, the first manufacturing step may include: a resin sealing forming step S11, in which the resin sealing member is formed on both sides of the resin sheet 200; a processing step S12, in which the resin sheet on which the resin sealing member is formed is trimmed to form the resin frame member provided with the resin sealing member; and a joining step S13, in which the inner peripheral end of the resin frame member provided with the resin sealing member is joined to the membrane electrode structure.

[0132] Based on this structure, after the resin sealing member is formed on the resin sheet, processing and joining processes are performed, thus enabling the resin sealing member to be easily placed on the resin frame member.

[0133] (Note 3) In the method for manufacturing a fuel cell stack described in Appendix 2, the resin sealing forming process may also include: a coating process S21, in which a sealing material 202 is coated on both sides of the resin sheet; and a curing process S22, in which the sealing material is cured after the coating process to obtain the resin sealing member.

[0134] Based on this structure, resin sealing components can be formed efficiently on both sides of the resin frame component.

[0135] (Note 4) In any of the manufacturing methods of the fuel cell stack described in Notes 1 to 3, the dimensions L1 and L3 in the width direction of the resin sealing member may be greater than the interval L2 and L4 at the base of the metal sealing portion when the single cell stack is subjected to the fastening load.

[0136] With this structure, the metal sealing portion can easily contact the resin sealing component during the lamination process. In other words, during the lamination process, the permissible offset in the planar direction between the membrane electrode structure with resin frame and the metal spacer can be relatively large. Therefore, the lamination process can be performed simply.

[0137] (Note 5) In any of the fuel cell stack manufacturing methods described in Appendices 1 to 4, the resin sealing member may have a linear first resin sealing member 100 disposed on one side surface 54a of the resin frame member; and a linear second resin sealing member 102 disposed on the other side surface 54b of the resin frame member. When viewed from the thickness direction of the resin frame member, the first resin sealing member and the second resin sealing member extend linearly in an overlapping state, and the width direction end of the first resin sealing member, i.e., the first end 100e, is located at a position offset in the planar direction of the resin frame member relative to the width direction end of the second resin sealing member, i.e., the second end 102e.

[0138] With this structure, the first end of the first resin sealing member is located at a position offset relative to the second end of the second resin sealing member in the planar direction of the resin frame member. Therefore, stress concentration at the end of the resin sealing member can be suppressed when a fastening load is applied to the single-cell laminate. As a result, damage to the resin frame member can be suppressed.

[0139] (Note 6) In any of the manufacturing methods of the fuel cell stack described in Appendices 1 to 5, the fuel cell stack may also include a pair of insulating plates 24, 26 disposed on both sides of the stacking direction of the single cell stack. The manufacturing method of the fuel cell stack includes a preparation step in which a pair of insulating plates provided with end resin sealing members 112, 118 extending in a linear shape are prepared. In the stacking step, the pair of insulating plates are stacked with the single cell stack in such a way that the end face of the protruding direction of the metal sealing portion of the metal spacer at the end of the stacking direction of the single cell stack, i.e., the end metal spacer 46e, 48e, is in contact with the end resin sealing member.

[0140] With this structure, the end resin sealing member is placed on the insulating plate instead of the end metal spacer, thus eliminating the need for a mask member during the manufacturing of the end metal spacer. This allows for a reduction in the manufacturing cost of the fuel cell stack.

[0141] (Note 7) In the fuel cell stack manufacturing method described in Appendix 6, the width dimensions L5 and L6 of the end resin sealing member may be greater than the interval between the base portions of the metal sealing portion when the single cell stack is subjected to the fastening load.

[0142] With this structure, the metal sealing portion can easily contact the end resin sealing member during the lamination process. In other words, during the lamination process, the permissible offset between the end metal spacer and the insulating plate in the planar direction can be relatively large. Therefore, the lamination process can be performed simply.

[0143] (Note 8) In the method for manufacturing a fuel cell stack disclosed herein, the fuel cell stack comprises: a single-cell stack formed by stacking multiple single-cell power generation cells, each single-cell power generation cell comprising a membrane electrode structure formed by bonding electrodes to both sides of an electrolyte membrane, a pair of metal spacers disposed on both sides of the membrane electrode structure and formed in a plate shape; and a pair of insulating plates disposed on both sides of the stacking direction of the single-cell stack. In the method for manufacturing the fuel cell stack, each of the pair of metal spacers located at both ends of the stacking direction of the single-cell stack, i.e., a pair of end metal spacers, has a metal sealing portion. The metal sealing portion protrudes toward the insulating plate and extends linearly, and elastically deforms due to a fastening load applied to the single-cell stack in the stacking direction. The method for manufacturing the fuel cell stack includes: a preparation step of preparing a pair of insulating plates provided with linearly extending end resin sealing members; and a stacking step of stacking a pair of insulating plates and a pair of end metal spacers together such that the end face of the protruding direction of the metal sealing portion of the end metal spacer contacts the end resin sealing member.

[0144] With this structure, the resin sealing component is placed on the insulating plate instead of the end metal spacer, thus eliminating the need for a mask component during the manufacturing of the end metal spacer. This allows for a reduction in the manufacturing cost of the fuel cell stack.

[0145] (Note 9) The fuel cell stack disclosed herein comprises a single-cell stack consisting of multiple power-generating single cells stacked on top of each other. Each power-generating single cell comprises: a membrane electrode structure with a resin frame, having a membrane electrode structure formed by bonding electrodes to both sides of an electrolyte membrane; a resin frame member disposed on the outer periphery of the membrane electrode structure in a manner protruding outward from the outer periphery of the membrane electrode structure; and a pair of metal spacers disposed on both sides of the membrane electrode structure with the resin frame and formed in a plate shape. In the fuel cell stack, each of the pair of metal spacers has a metal sealing portion, which protrudes toward the resin frame member and extends linearly, and is elastically deformable due to a fastening load applied to the single-cell stack in the stacking direction. The membrane electrode structure with the resin frame has a resin sealing member disposed on both sides of the resin frame member, contacting the protruding end face of the metal sealing portion and extending linearly. The width dimension of the resin sealing member is greater than the spacing of the base portions of the metal sealing portions.

[0146] Based on this structure, the same effect as that described in Appendix 1 and Appendix 4 can be achieved.

[0147] (Postscript 10) The fuel cell stack disclosed herein comprises: a single-cell stack consisting of multiple single-cell power-generating cells stacked on top of each other; each single-cell power-generating cell having a membrane electrode structure formed by bonding electrodes to both sides of an electrolyte membrane; a pair of metal spacers disposed on both sides of the membrane electrode structure and formed in a plate shape; and a pair of insulating plates disposed on both sides of the stacking direction of the single-cell stack. In the fuel cell stack, the metal spacers located at the ends of the single-cell stack in the stacking direction, i.e., end metal spacers, have metal sealing portions. The metal sealing portions protrude toward the insulating plates and extend linearly, and elastically deform due to the single-cell stack being subjected to a fastening load in the stacking direction. An end resin sealing member extending linearly is provided on the surface of one of the pair of insulating plates facing the single-cell stack. The pair of insulating plates clamp the single-cell stack such that the end faces of the protruding directions of the metal sealing portions of the end metal spacers contact the end resin sealing members. The width dimension of the end resin sealing members is greater than the spacing of the base portions of the metal sealing portions of the end metal spacers.

[0148] Based on this structure, the same effect as that described in Appendix 7 and Appendix 8 can be achieved.

[0149] This disclosure has been described in detail, but it is not limited to the embodiments described above. Various additions, substitutions, modifications, and partial deletions can be made to these embodiments without departing from the spirit of this disclosure, or without departing from the content of the claims and the spirit of this disclosure derived from their equivalents. Furthermore, these embodiments can also be combined. For example, the order of each action and each process in the above embodiments is only one example and is not limited thereto. The same applies to the use of numerical values ​​or mathematical formulas in the description of the above embodiments.

Claims

1. A method for manufacturing a fuel cell stack, the fuel cell stack comprising a stack of multiple power-generating individual cells, wherein each power-generating individual cell comprises: A membrane electrode structure with a resin frame, comprising a membrane electrode structure formed by bonding electrodes to both sides of an electrolyte membrane, and a resin frame member disposed on the outer periphery of the membrane electrode structure in a manner protruding outward from the outer periphery of the membrane electrode structure; and A pair of metal spacers, disposed on both sides of the membrane electrode structure with resin frame and formed as plates, In the method for manufacturing the fuel cell stack, Each of the pair of metal spacers has a metal sealing portion that protrudes towards the resin frame member and extends linearly, and elastically deforms due to a fastening load applied in the stacking direction to the single-cell stack. The method for manufacturing the fuel cell stack includes: In the first manufacturing process, a plurality of the membrane electrode structures with resin frames are manufactured, wherein the membrane electrode structures with resin frames are provided with resin sealing members extending in a linear shape on both sides of the resin frame members. The second manufacturing process involves manufacturing multiple of the aforementioned metal spacers; as well as In the stacking process, the multiple membrane electrode structures with resin frames manufactured in the first manufacturing process are stacked with the multiple metal spacers manufactured in the second manufacturing process in such a way that the protruding end face of the metal sealing part contacts the resin sealing member.

2. The method for manufacturing a fuel cell stack according to claim 1, characterized in that, The first manufacturing process includes: The resin sealing forming process forms the resin sealing component on both sides of the resin sheet; The processing steps include trimming the resin sheet on which the resin sealing member is formed, thereby forming the resin frame member on which the resin sealing member is provided; and In the joining process, the inner peripheral end of the resin frame member, which is provided with the resin sealing member, is joined to the membrane electrode structure.

3. The method for manufacturing a fuel cell stack according to claim 2, characterized in that, The resin seal forming process includes: In the coating process, a sealing material is coated on both sides of the resin sheet; and The hardening process, following the coating process, hardens the sealing material to obtain the resin sealing member.

4. The method for manufacturing a fuel cell stack according to any one of claims 1 to 3, characterized in that, When the single-cell stack is subjected to the fastening load, the width dimension of the resin sealing member is greater than the spacing of the base of the metal sealing portion.

5. The method for manufacturing a fuel cell stack according to any one of claims 1 to 3, characterized in that, The resin sealing member has: A linear first resin sealing member is disposed on one side of the resin frame member; and A linear second resin sealing member is provided on the other side of the resin frame member. When viewed from the thickness direction of the resin frame member, the first resin sealing member and the second resin sealing member extend in a linear manner while overlapping each other, and the first end of the width direction of the first resin sealing member is located at a position offset in the planar direction of the resin frame member relative to the second end of the width direction of the second resin sealing member.

6. The method for manufacturing a fuel cell stack according to any one of claims 1 to 3, characterized in that, The fuel cell stack includes a pair of insulating plates disposed on both sides of the stacking direction of the single cell stack. The method for manufacturing the fuel cell stack includes a preparation step, which involves preparing a pair of insulating plates having end resin sealing members extending in a linear shape. In the lamination process, a pair of insulating plates are laminated to the single-cell laminate in such a way that the end face of the metal sealing portion of the metal spacer located at the end of the lamination direction of the single-cell laminate contacts the end resin sealing member.

7. The method for manufacturing a fuel cell stack according to claim 6, characterized in that, When the single-cell stack is subjected to the fastening load, the width dimension of the end resin sealing member is greater than the spacing of the base of the metal sealing portion.

8. A method for manufacturing a fuel cell stack, the fuel cell stack comprising: A stack of single-cell power-generating cells, comprising multiple single-cell power-generating cells stacked on top of each other, wherein each single-cell power-generating cell includes a membrane electrode structure formed by bonding electrodes to both sides of an electrolyte membrane, and a pair of metal spacers disposed on both sides of the membrane electrode structure and formed into plates; and A pair of insulating plates are arranged on both sides of the stacking direction of the single-cell stack. In the method for manufacturing the fuel cell stack, Each of the pair of metal spacers located at both ends of the single-cell stack along the stacking direction has a metal sealing portion. The metal sealing portion protrudes towards the insulating plate and extends linearly, and elastically deforms due to the applied fastening load along the stacking direction on the single-cell stack. The method for manufacturing the fuel cell stack includes: Preparation process: Prepare a pair of insulating plates with end resin sealing members extending in a linear shape; as well as In the lamination process, a pair of insulating plates and a pair of end metal spacers are laminated together such that the end face of the protruding direction of the metal sealing portion of the end metal spacer contacts the end resin sealing member.

9. A fuel cell stack comprising a stack of multiple power-generating individual cells, wherein each power-generating individual cell comprises: A membrane electrode structure with a resin frame, comprising a membrane electrode structure formed by bonding electrodes to both sides of an electrolyte membrane, and a resin frame member disposed on the outer periphery of the membrane electrode structure in a manner protruding outward from the outer periphery of the membrane electrode structure; and A pair of metal spacers, disposed on both sides of the membrane electrode structure with resin frame and formed as plates, In the fuel cell stack, Each of the pair of metal spacers has a metal sealing portion that protrudes towards the resin frame member and extends linearly, and elastically deforms due to a fastening load applied in the stacking direction to the single-cell stack. The membrane electrode structure with a resin frame has a resin sealing member disposed on both sides of the resin frame member, contacting the protruding end face of the metal sealing part and extending in a linear shape. The width dimension of the resin sealing member is greater than the spacing at the base of the metal sealing part.

10. A fuel cell stack, comprising: A stack of single-cell power-generating cells, comprising multiple single-cell power-generating cells stacked on top of each other, wherein each single-cell power-generating cell includes a membrane electrode structure formed by bonding electrodes to both sides of an electrolyte membrane, and a pair of metal spacers disposed on both sides of the membrane electrode structure and formed into plates; and A pair of insulating plates are arranged on both sides of the stacking direction of the single-cell stack. In the fuel cell stack, The metal spacer located at the end of the single-cell stack in the stacking direction, i.e., the end metal spacer, has a metal sealing portion that protrudes toward the insulating plate and extends linearly, and elastically deforms due to the application of a fastening load in the stacking direction to the single-cell stack. A linearly extending end resin sealing member is provided on the surface of the pair of insulating plates facing the single-cell stack. The single-cell stack is clamped by the pair of insulating plates in such a manner that the end face of the protruding direction of the metal sealing portion of the end metal spacer contacts the end resin sealing member. The width dimension of the end resin sealing member is greater than the spacing at the base of the metal sealing portion of the end metal spacer.

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