Membrane electrode assembly with protected edges
Patent Information
- Application Number
- CN202510751072.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Priority Date
- 2025-04-08
- Filing Date
- 2025-06-06
- Publication Date
- 2026-10-16
Smart Images
Figure CN122930930A_ABST
Abstract
Description
Technical Field
[0001] This disclosure relates to fuel cells, and more particularly to membrane electrode assemblies having protected edges. Background Technology
[0002] The information provided in this section is intended to generally present the background of this disclosure. The work of the currently named inventors, to the extent described in this section, and in aspects of the specification that would not otherwise be considered prior art at the time of filing, neither expressly nor implicitly acknowledges that it is prior art to this disclosure.
[0003] Fuel cells can be used to provide electricity to a load. A fuel cell includes an anode electrode layer, a cathode electrode layer, and a polymer electrolyte membrane (PEM). The polymer electrolyte membrane is disposed between the cathode and anode electrode layers. Molecular hydrogen (H2) is supplied to the anode electrode layer, and molecular oxygen (O2) is supplied to the cathode electrode layer. Hydrogen ions (H+) + Electrons pass through the PEM. - A current is generated through an external circuit, such as a load. Fuel cells can be used to power electric vehicles and / or stationary applications. While catalyst-coated membrane methods are more common, high-volume manufacturing methods, such as gas diffusion electrodes (GDE) in roll-to-roll processes or catalyst-coated on diffusion media (CCDM), are becoming increasingly prevalent. Summary of the Invention
[0004] A method for manufacturing a membrane electrode assembly includes: a) patch-coating a plurality of spaced-apart anode electrode layers on a first gas diffusion layer; b) patch-coating a plurality of spaced-apart cathode electrode layers on a second gas diffusion layer; c) slicing a continuous membrane into a plurality of membrane layers; d) stacking the plurality of membrane layers onto one of: a plurality of cathode electrode layers; and a plurality of anode electrode layers; and e) laminating a plurality of cathode electrode layers, a plurality of anode electrode layers, a plurality of membrane layers, and a plurality of gasket layers between the first gas diffusion layer and the second gas diffusion layer. The relative outer edges of the plurality of membrane layers, the plurality of cathode electrode layers, and the plurality of anode electrode layers are located inside the relative outer edges of the first gas diffusion layer and the second gas diffusion layer.
[0005] Among other features, prior to d), a plurality of anode electrode layers and a first gas diffusion layer are cut; and at least one of a plurality of cathode electrode layers and a second gas diffusion layer is cut.
[0006] Among other features, after d), the anode electrode layer and the first gas diffusion layer are cut; and at least one of the cathode electrode layer and the second gas diffusion layer is cut.
[0007] Among other features, the method includes aligning the relative outer edges of a plurality of film layers, a plurality of cathode electrode layers, and a plurality of anode electrode layers in the first and second lateral directions.
[0008] Among other features, the method includes aligning the relative outer edges of the plurality of film layers and the plurality of anodic electrode layers; and positioning the relative outer edge of the cathode electrode layer inside the outer edges of the plurality of film layers and the plurality of anodic electrode layers.
[0009] Among other features, multiple gasket layers are respectively arranged between multiple anode electrode layers and multiple film layers. Multiple gasket layers are respectively arranged between multiple cathode electrode layers and multiple film layers.
[0010] A method for manufacturing a membrane electrode assembly includes: a) longitudinally and continuously coating a plurality of anode electrode layers on a first gas diffusion layer; b) longitudinally and continuously coating a plurality of cathode electrode layers on a second gas diffusion layer; c) cutting the continuous membrane into a plurality of film layers; d) stacking the plurality of film layers onto one of: a plurality of cathode electrode layers; and a plurality of anode electrode layers; and e) laminating a plurality of cathode electrode layers, a plurality of anode electrode layers, a plurality of film layers, and a plurality of gasket layers between the first gas diffusion layer and the second gas diffusion layer. In a first direction, the relative outer edges of the plurality of film layers, the plurality of cathode electrode layers, and the plurality of anode electrode layers are located inside the relative outer edges of the first gas diffusion layer and the second gas diffusion layer.
[0011] Among other features, prior to d), a plurality of anode electrode layers and a first gas diffusion layer are cut; and at least one of a plurality of cathode electrode layers and a second gas diffusion layer is cut.
[0012] Among other features, after d), the anode electrode layer and the first gas diffusion layer are cut; and at least one of the cathode electrode layer and the second gas diffusion layer is cut.
[0013] Among other features, the method includes aligning the relative outer edges of a plurality of cathode electrode layers and a plurality of anode electrode layers in a second direction transverse to the first direction; and positioning the relative outer edges of the plurality of film layers inside the outer edges of the plurality of cathode electrode layers and the plurality of anode electrode layers in the second direction.
[0014] Among other features, multiple gasket layers are respectively arranged between multiple anode electrode layers and multiple film layers. Multiple gasket layers are respectively arranged between multiple cathode electrode layers and multiple film layers.
[0015] A membrane electrode assembly includes a first gas diffusion layer; an anode electrode layer disposed adjacent to the first gas diffusion layer; a gasket layer; a membrane layer; a cathode electrode layer; and a second gas diffusion layer disposed adjacent to the cathode electrode layer. The relative outer edges of the membrane layers are located inside the corresponding relative outer edges of the first and second gas diffusion layers.
[0016] Among other features, one set of opposite outer edges of the film layer is aligned with the corresponding outer edges of the cathode and anode electrode layers. Another set of opposite outer edges of the film layer is aligned with the corresponding outer edges of the cathode and anode electrode layers.
[0017] Among other features, a set of opposing outer edges of the film layer are located inside the corresponding outer edge of at least one of the cathode electrode layer and the anode electrode layer.
[0018] Among other features, another set of relative outer edges of the film layer is located inside the corresponding outer edge of at least one of the cathode electrode layer and the anode electrode layer.
[0019] Among other features, a set of opposite outer edges of the film layer are located outside the first and second opposite outer edges of the cathode electrode layer.
[0020] Among other features, a set of opposing outer edges of the film layer are aligned in a first direction with the corresponding outer edges of the cathode electrode layer and the anode electrode layer. In a second direction transverse to the first direction, another set of opposing outer edges of the film layer is located inside the corresponding outer edge of the cathode electrode layer.
[0021] The present invention discloses the following solutions:
[0022] Option 1. A method for manufacturing a membrane electrode assembly, comprising:
[0023] a) Multiple anode electrode layers spaced apart from each other are coated in patches on the first gas diffusion layer;
[0024] b) Coating multiple cathode electrode layers spaced apart from each other onto the second gas diffusion layer in sections;
[0025] c) Cutting a continuous membrane into multiple membrane layers;
[0026] d) Stack the plurality of film layers onto one of the following:
[0027] The plurality of cathode electrode layers; and
[0028] The plurality of anode electrode layers; and
[0029] e) Laminating the plurality of cathode electrode layers, the plurality of anode electrode layers, the plurality of film layers, and the plurality of gasket layers between the first gas diffusion layer and the second gas diffusion layer, respectively.
[0030] The relative outer edges of the plurality of film layers, the plurality of cathode electrode layers, and the plurality of anode electrode layers are located inside the relative outer edges of the first gas diffusion layer and the second gas diffusion layer.
[0031] Option 2. The method according to Option 1, further comprising, before d), cutting at least one of the following:
[0032] The plurality of anode electrode layers and the first gas diffusion layer; and
[0033] The plurality of cathode electrode layers and the second gas diffusion layer.
[0034] Option 3. The method according to Option 1, further comprising, after d), cutting at least one of the following:
[0035] The anode electrode layer and the first gas diffusion layer; and
[0036] The cathode electrode layer and the second gas diffusion layer.
[0037] Option 4. The method according to Option 1, further comprising aligning the relative outer edges of the plurality of film layers, the plurality of cathode electrode layers and the plurality of anode electrode layers in the first and second lateral directions.
[0038] Option 5. The method according to Option 1 further includes:
[0039] Align the relative outer edges of the plurality of film layers and the plurality of anode electrode layers; and
[0040] The relative outer edges of the cathode electrode layer are located inside the outer edges of the plurality of film layers and the plurality of anode electrode layers.
[0041] Option 6. According to the method of Option 1, wherein the plurality of gasket layers are respectively arranged between the plurality of anode electrode layers and the plurality of film layers.
[0042] Option 7. According to the method of Option 1, wherein the plurality of gasket layers are respectively arranged between the plurality of cathode electrode layers and the plurality of film layers.
[0043] Option 8. A method for manufacturing a membrane electrode assembly, comprising:
[0044] a) A plurality of anode electrode layers are continuously coated longitudinally on the first gas diffusion layer;
[0045] b) A plurality of cathode electrode layers are longitudinally and continuously coated on the second gas diffusion layer;
[0046] c) Cutting a continuous membrane into multiple membrane layers;
[0047] d) Stack the plurality of film layers onto one of the following:
[0048] The plurality of cathode electrode layers; and
[0049] The plurality of anode electrode layers; and
[0050] e) Laminating the plurality of cathode electrode layers, the plurality of anode electrode layers, the plurality of film layers, and the plurality of gasket layers between the first gas diffusion layer and the second gas diffusion layer.
[0051] The relative outer edges of the plurality of film layers, the plurality of cathode electrode layers and the plurality of anode electrode layers in the first direction are located inside the relative outer edges of the first gas diffusion layer and the second gas diffusion layer.
[0052] Option 9. The method according to Option 8, further comprising, before d), cutting at least one of the following:
[0053] The plurality of anode electrode layers and the first gas diffusion layer; and
[0054] The plurality of cathode electrode layers and the second gas diffusion layer.
[0055] Option 10. The method according to Option 8, further comprising, after d), cutting at least one of the following:
[0056] The anode electrode layer and the first gas diffusion layer; and
[0057] The cathode electrode layer and the second gas diffusion layer.
[0058] Option 11. The method according to Option 8, further comprising:
[0059] Align the relative outer edges of the plurality of cathode electrode layers and the plurality of anode electrode layers in a second direction transverse to the first direction; and
[0060] In the second direction, the relative outer edges of the plurality of film layers are located inside the outer edges of the plurality of cathode electrode layers and the plurality of anode electrode layers.
[0061] Option 12. The method according to Option 8, wherein the plurality of gasket layers are respectively disposed between the plurality of anode electrode layers and the plurality of film layers.
[0062] Option 13. The method according to Option 8, wherein the plurality of gasket layers are respectively disposed between the plurality of cathode electrode layers and the plurality of film layers.
[0063] Option 14. A membrane electrode assembly, comprising:
[0064] First gas diffusion layer;
[0065] An anode electrode layer is arranged adjacent to the first gas diffusion layer;
[0066] gasket layer;
[0067] membrane;
[0068] Cathode electrode layer; and
[0069] The second gas diffusion layer is arranged adjacent to the cathode electrode layer.
[0070] The relative outer edges of the film layer are located inside the corresponding relative outer edges of the first gas diffusion layer and the second gas diffusion layer.
[0071] Option 15. The membrane electrode assembly according to Option 14, wherein a set of opposite outer edges of the membrane layer are aligned with the corresponding outer edges of the cathode electrode layer and the anode electrode layer.
[0072] Option 16. The membrane electrode assembly according to Option 15, wherein another set of opposite outer edges of the membrane layer are aligned with the corresponding outer edges of the cathode electrode layer and the anode electrode layer.
[0073] Option 17. The membrane electrode assembly according to Option 14, wherein a set of opposing outer edges of the membrane layer are located inside the corresponding outer edge of at least one of the cathode electrode layer and the anode electrode layer.
[0074] Option 18. The membrane electrode assembly according to Option 17, wherein another set of opposite outer edges of the membrane layer is located inside the corresponding outer edge of at least one of the cathode electrode layer and the anode electrode layer.
[0075] Option 19. The membrane electrode assembly according to Option 14, wherein a set of opposite outer edges of the membrane layer are located outside the first and second opposite outer edges of the cathode electrode layer.
[0076] Option 20. The membrane electrode assembly according to Option 14, wherein:
[0077] In the first direction, a set of opposing outer edges of the film layer are aligned with the corresponding outer edges of the cathode electrode layer and the anode electrode layer.
[0078] In a second direction transverse to the first direction, another set of opposite outer edges of the film layer are located inside the corresponding outer edges of the cathode electrode layer.
[0079] Further applicability of this disclosure will become apparent from the detailed description, claims, and drawings. The detailed description and specific examples are intended for illustrative purposes only and are not intended to limit the scope of this disclosure. Attached Figure Description
[0080] This disclosure will be more fully understood from the detailed embodiments and the accompanying drawings, in which:
[0081] Figure 1A This is a functional block diagram of an example of a membrane electrode assembly according to the present disclosure;
[0082] Figure 1B This is a functional block diagram of an example of a fuel cell stack according to the present disclosure, which includes multiple membrane electrode assemblies arranged between adjacent bipolar plates;
[0083] Figure 2 This is a plan view illustrating an example of a continuous gas diffusion electrode layer having a segmented coated cathode electrode layer according to the present disclosure;
[0084] Figure 3 This is a plan view illustrating an example of a continuous film layer being cut into discrete film layers according to the present disclosure;
[0085] Figure 4 and Figure 5 An example of a film layer laminated onto a cathode electrode layer / gas diffusion layer (GDL) according to the present disclosure is shown;
[0086] Figure 6A and Figure 6B Examples of lamination of the film layer / cathode electrode layer / GDL, anode electrode layer / GLD and gasket layer according to the present disclosure are shown;
[0087] Figure 7 It is a cross-section of an example of a membrane electrode assembly according to this disclosure after lamination in the machine and / or transverse machine direction;
[0088] Figure 8 It is a cross-section of an example of a membrane electrode assembly according to this disclosure after lamination in the machine and / or transverse machine direction;
[0089] Figure 9 This is a flowchart illustrating an example of a method for manufacturing a membrane electrode assembly according to the present disclosure;
[0090] Figure 10 This is a plan view illustrating an example of a continuous gas diffusion electrode layer having a continuously coated cathode electrode layer according to the present disclosure;
[0091] Figure 11 This is a plan view illustrating an example of a continuous film layer being cut into discrete film layers according to the present disclosure;
[0092] Figure 12 and Figure 13 An example of a film layer laminated onto a cathode electrode layer / gas diffusion layer (GDL) according to the present disclosure is shown;
[0093] Figure 14 Examples of lamination of the film layer / cathode electrode layer / GDL, anode electrode layer / GDL and gasket layer according to the present disclosure are shown;
[0094] Figure 15 This is a cross-section of an example of a membrane electrode assembly according to the present disclosure after lamination in the machine direction;
[0095] Figure 16 This is a cross-section of an example of a membrane electrode assembly according to this disclosure after lamination in the transverse machine direction; and
[0096] Figure 17 This is a flowchart of another example of a method for manufacturing a membrane electrode assembly according to the present disclosure.
[0097] In the accompanying drawings, reference numerals may be used repeatedly to identify similar and / or identical elements. Detailed Implementation
[0098] Although the membrane electrode assembly is described below in the context of fuel cells for vehicles, the membrane electrode assembly can be used in other applications, such as fuel cells for stationary applications and other electrochemical cells for hydrogen production, such as PEM water electrolyzers.
[0099] Membrane electrode assemblies can be manufactured using high-volume roll-to-roll fabrication and the gas diffusion electrode (GDE) method. Conventional membrane electrode assemblies manufactured using the GDE method experience external contamination due to their edge design. In these designs, the relative outer edges of the gas diffusion layer (GDL), anode electrode layer, cathode electrode layer, and membrane layer are aligned. In other words, these layers maintain the same external dimensions.
[0100] The membrane electrode assembly is arranged between bipolar plates made of metal such as stainless steel. Corrosion of the bipolar plates can lead to the formation of metal ions such as iron (Fe). 2+ Release. Although the hydrophobic gas diffusion layer repels water, and thus restricts Fe... 2+ The path into the MEA, but the exposed membrane at the edge is Fe. 2+ Access the path provided by MEA. 2+ (A known Fenton reagent) accelerates undesirable reactions, such as the decomposition of hydrogen peroxide into hydroxyl radicals (●OH), which leads to rapid degradation of the membrane and reduced durability.
[0101] Although hydroxyl radical scavengers such as Ce are added to the membrane 3+ and / or Mn 2+ It provided some relief, but Fe 2+ Reaching the MEA leads to membrane failure. In some instances, the gasket is positioned between the anode and the membrane (resulting in a cathode larger than the anode). Free radical scavenger cations (Ce)3+ and Mn 2+ Driven by the potential gradient, it tends to build up under the gaskets, anode electrode layers, cathode electrode layers, and film layers at the outer edge of the GDL, leading to additional performance or durability issues.
[0102] The membrane electrode assembly according to this disclosure includes a membrane layer and an electrode layer having a smaller size (relatively outer edges recessed relative to a first and / or second set of relative outer edges of the GDL). In a first manufacturing method, anode and cathode electrode layers are coated on the GDL in a spaced-out manner using a block coating method. Uncoated areas of the GDL are located at the relative outer edges along the machine direction and in the transverse machine direction. The membrane layer is dimensionally cut and laminated onto the electrode layer / GDL such that the relative outer edges of the GDL are larger and located outside the relative outer edges of the membrane and electrode layers in both the machine and transverse machine directions. The membrane layer may be the same size as or larger than the electrode layer but smaller than the GDL.
[0103] In another method, the electrode layer is continuously coated onto the GDL layer using a roll-to-roll method. Uncoated GDL regions are located at opposite edges along the machine direction. The film layer is cut and laminated onto the electrode layer / GDL. The opposite outer edges of the GDL are larger than the opposite outer edges of the electrode layer and film layer in the machine direction, and are located outside the opposite outer edges of the electrode layer and film layer in the machine direction. The opposite outer edges of the electrode and film layers are aligned in the machine direction. In the transverse machine direction, the opposite outer edges of the film layer are located inside the cathode electrode layer.
[0104] Using these methods, manufacturing can be completed via roll-to-roll or discrete manufacturing methods.
[0105] Now for reference Figure 1A The fuel cell 10 includes an anode electrode layer 20, a membrane layer 28, and a cathode electrode layer 36. Gas diffusion layers 40 and 44 are arranged adjacent to the anode electrode layer 20 and the cathode electrode layer 36, respectively. Molecular hydrogen (H2) is supplied to the gas diffusion layer 40 of the anode electrode layer 20. Molecular oxygen (O2) is supplied to the gas diffusion layer 44 of the cathode electrode layer 36. A hydrogen oxidation reaction (HOR) occurs at the anode electrode layer 20, where hydrogen (H2) is decomposed into protons (H+). + ) and electrons (e - ). Film layer 28 will hold hydrogen ions (H) + Electrons are transferred to the cathode electrode layer 36. - The oxygen reduction reaction (ORR) occurs at the cathode electrode layer 36, passing through an external circuit 46, such as a load or battery pack, to produce molecular oxygen (O2) and hydrogen ions (H2O). + ) and electrode layer (e - The reaction forms water (H2O).
[0106] Cathode (reduction): 2H + +2e - +1 / 2O2(g)→H2O(l); and anode (oxidation):H2(g)→2H + +2e - .
[0107] Overall: 2H₂(g) + O₂(g) → 2H₂O(l)
[0108] Now for reference Figure 1B MEAs 10-1, 10-2, ..., and 10-F are located between adjacent bipolar plates 60-1, 60-2, ..., and 60-B, where F and B are integers greater than 1. In some instances, bipolar plates 60-1, 60-2, ..., and 60-B include channels, ports, and a central window (not shown) (some of which are aligned with the ports and windows of the gasket layers described further below). In some instances, the bipolar plates are made of stainless steel, which is a source of iron ions or other metal ions during corrosion.
[0109] Now for reference Figure 2-9 This illustrates a method for manufacturing membrane electrode assemblies. Figure 2 In this process, a block coating method is used to coat spaced-apart cathode electrode layers 118 onto a continuous gas diffusion layer (GDL) 114. The edge regions 119 of the GDL 114 are not coated in either the machine direction or the transverse machine direction. Figure 3 In this process, the continuous film layer 122 is cut and sized to form discrete film layers 124. In some instances, film layers 124 are coupled to cathode electrode layer 118 (or anode electrode layer 132) in the machine direction (arrow 127) and / or transverse machine direction (arrow 129) (e.g., as shown in the image). Figure 7 The films shown have the same dimensions. In other examples, the film layer 124 is larger than the cathode electrode layer 118 in the machine direction and / or the transverse machine direction, but smaller than the GDL 114 (as shown). Figure 8 (As shown).
[0110] exist Figure 4 and Figure 5 In this process, film layer 124 is aligned and laminated onto cathode electrode layer 118 / GDL 114. For example, film layer 124 may be aligned with one or both edges of cathode electrode layer 118. A similar method is used to plate spaced anode electrode layers 132 in blocks onto gas diffusion layer (GDL) 128.
[0111] exist Figure 6A In this process, the film layer 124, the cathode electrode layer 118, and the anode electrode layer 132 have the same dimensions in both the machine and transverse machine directions. Figure 6BIn this configuration, the cathode electrode layer 118 is the same size as or narrower than the film layer 124 and the anode electrode layer 132 in both the machine direction and the transverse machine direction. Film layer 124 / cathode electrode layer 118 / GDL 114, gasket layer 133 (including port 136 and window 138), and anode electrode layer 132 / GDL 128 are laminated together. In some embodiments, the gasket layer contains an adhesive layer at its edge facing the film.
[0112] exist Figure 7 In this example, the cross-section of the membrane electrode assembly is shown in a machine and / or transverse machine orientation. The edges of the cathode electrode layer 118, membrane layer 124, and anode electrode layer 132 are aligned and arranged inwards from the outer edges of GDLs 114 and 128. In some examples, GDLs 114 and 128 are significantly thicker than membrane layer 124 and the electrode layers (GDLs range from 5 to 15 times thicker than the electrodes and membrane layers). GDLs 114 and 128 are also compressible materials. (e.g., Sigracet...) TM The 39BB GDL has an uncompressed thickness of approximately ~300 μm and a compressed thickness of ~220 μm @ 1 MPa. As a result, when the membrane electrode assembly is compressed between the bipolar plates, GDLs 114 and 128 protect the edges of the electrode layers and the membrane layers. In this example, a gasket layer 133 is located between the membrane layer 124 and the anode electrode layer 132. Furthermore, the adhesive in the gasket facing the membrane bonds to the membrane and the uncoated GDL edges, forming protected edges. As can be understood, the gasket layer 133 may be located between the membrane layer 124 and the cathode electrode layer 118.
[0113] exist Figure 8 In this example, the cross-section of the membrane electrode assembly is shown in the machine and / or transverse machine direction. In this example, the edges of the cathode electrode layer 118, the membrane layer 124, and the anode electrode layer 132 are arranged inwards from the outer edges of GDLs 114 and 128. As previously described, GDLs 114 and 128 protect the edges of the electrode layers and the membrane layer when the membrane electrode assembly is compressed between the bipolar plates. In some examples, the outer edge of the cathode electrode layer 118 is arranged inwards from the membrane layer 124 and the anode electrode layer 132 in the machine and transverse machine direction. In some examples, the width of the cathode electrode layer 118 is greater than or equal to the width of the window 138. By limiting the size of the cathode electrode with respect to the sub-gasket window and by extending the anode electrode, it is advantageous to accommodate metal cations (including Ce). 3+ and Mn 2+ The potential gradient for the accumulation of free radical scavengers is reduced. This prevents metal cations from accumulating below the sub-shield and near the GDL edge, while providing protection to external Fe through the protected edge. 2+ Protection.
[0114] exist Figure 9The diagram illustrates a method for manufacturing a membrane electrode assembly. At 170, a cathode electrode layer 118, spaced apart from each other, is coated on a continuous gas diffusion layer (GDL) 114 using a block coating method. An anode electrode layer 132, spaced apart on a gas diffusion layer (GDL) 128, is coated in a similar block method. At 174, the continuous membrane layer 122 is sized and cut into discrete membrane layers 124. At 178, membrane layers 124 are aligned with and laminated onto the cathode electrode layer 118 (which is disposed on the GDL 114). At 182, membrane layers 124 / cathode electrode layer 118 / GDL 114, gasket layer 133 (including port 136 and window 138), and anode electrode layer 132 / GDL 128 are laminated together.
[0115] While one example of a discrete method is shown, using advanced positioning techniques, discrete film components can be laminated on segmented coating rollers in similar stacks and sizes, followed by slitting and lamination with sub-wafers. In some instances, the method can be implemented using a roll-to-roll approach.
[0116] Now for reference Figure 10-17 This illustrates a method for manufacturing membrane electrode assemblies. Figure 10 In this process, continuous coating is used to coat a continuous cathode electrode layer (which later separates into discrete cathode electrode layers 218) on a continuous gas diffusion layer (GDL) 214. Uncoated GDL regions 219 are positioned along their opposite edges in the machine direction. The anode electrode layer is manufactured using a similar method. Figure 11 In this process, the continuous film layer 222 is sized and cut into discrete film layers 224. In some instances, film layer 224 is the same size as cathode electrode layer 218 in a cross-section transverse to the machine direction. In some instances, film layer 224 is smaller than cathode electrode layer 218 in a cross-section transverse to the transverse machine direction (it is smaller than GDL 214).
[0117] exist Figure 12 and Figure 13 In this process, film layer 224 is aligned and laminated onto cathode electrode layer 218 / GDL 214. For example, opposite edges of film layer 224 may be aligned with opposite edges of cathode electrode layer 218 in the machine direction and offset inward in the transverse machine direction. A similar method is used for continuously coating anode electrode layers 232 spaced apart on gas diffusion layer (GDL) 228.
[0118] exist Figure 14 and Figure 15 In this structure, film 224 / cathode electrode layer 218 / GDL 214, gasket layer 233 (including port 236 and window 238), and anode electrode layer 232 / GDL 228 are laminated together. Figure 15The image shows a cross-section of the membrane electrode assembly in the machine direction. The outer edges of the cathode electrode layer 218, membrane layer 224, and anode electrode layer 232 are aligned and arranged inwardly from their respective outer edges. A window 238 of the gasket layer 233 is located between the membrane layer 224 and the anode electrode layer 232 (or cathode electrode layer 218). In some instances, as viewed in a transverse cross-section in the machine direction, the outer edge of the cathode layer 218 is arranged inside the membrane layer 224 and the anode electrode layer 232. In some instances, the outer edge of the cathode layer 218 coincides with the edge of the gasket window 238. This prevents the peroxide scavenger metal cations (Ce) from escaping in the machine direction. 3+ and Mn 2+ Accumulation below the sub-wafer near the edge of the GDL reduces the size of the cathode electrode relative to the anode electrode.
[0119] exist Figure 16 In the diagram, the cross-section of the membrane electrode assembly is shown in the transverse machine direction. The relative outer edges of the membrane layer 224 are arranged inward from the relative outer edges of the cathode electrode layer 218, the anode electrode layer 232, and GDLs 214 and 228.
[0120] In some instances, GDL 214 and 228 are significantly thicker and compressible, and the sub-gaskets have an adhesive layer along the window edge on the membrane-facing surface. During MEA lamination and during stack compression, the uncoated GDL edge adheres to the gasket in the machine direction, providing ventilation for external Fe. 2+ Protection. Because the electrode edges adhere to the sub-gasket, and the electrode edges expose Fe... 2+ Therefore, partial protection is achieved in the transverse machine direction. Although compared to a membrane, Fe... 2+ Migration into the MEA via the electrode edge will be slower. In some instances, the protected machine-oriented edge is located at the cathode inlet port, where Fe... 2+ Its prevalence may be high.
[0121] exist Figure 17The diagram illustrates a method for manufacturing a membrane electrode assembly. At 270, a continuous coating is used to coat a continuous cathode layer (which is then cut into cathode electrode layers 118) on a continuous gas diffusion layer (GDL) 114. A similar method is used to coat an anode electrode layer 232 on a gas diffusion layer (GDL) 228. At 274, the continuous membrane layer 222 is cut into discrete membrane layers 224 of the same size as or smaller than the cathode electrode layers 218 and anode electrode layers 232. At 278, membrane layers 224 are aligned with and laminated onto the cathode electrode layer 218 (which is disposed on GDL 214). At 282, membrane 224 / cathode electrode layer 218 / GDL 214, gasket layer 233 (including port 236 and window 238), and anode electrode layer 232 / GDL 228 are laminated together.
[0122] The foregoing description is illustrative in nature and is in no way intended to limit this disclosure, its application, or its use. The broad teachings of this disclosure can be implemented in many forms. Therefore, although this disclosure includes specific examples, its true scope should not be so limited, as other modifications will become apparent upon examination of the drawings, description, and appended claims. It should be understood that one or more steps within the method may be performed in a different order (or simultaneously) without altering the principles of this disclosure. Furthermore, although each embodiment is described above as having certain features, any one or more of those features described with respect to any embodiment of this disclosure may be implemented in any other embodiment and / or combined with features in any other embodiment, even if such combination is not explicitly described. In other words, the described embodiments are not mutually exclusive, and permutations and combinations of one or more embodiments with each other still exist within the scope of this disclosure.
[0123] Spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers, etc.) are described using various terms, including “connection,” “joint,” “coupled,” “adjacent,” “closely adjacent,” “above,” “under,” and “set.” Unless explicitly described as “direct,” the relationship between the first and second elements described in the foregoing disclosure can be a direct relationship, where no other intermediary element exists between the first and second elements, or an indirect relationship, where one or more intermediary elements exist between the first and second elements (spatially or functionally). As used herein, the phrase at least one of A, B, and C should be interpreted as meaning the logic of using non-exclusive OR (A OR B OR C), and should not be interpreted as meaning “at least one A, at least one B, and at least one C.”
Claims
1. A method for manufacturing a membrane electrode assembly, comprising: a) Multiple anode electrode layers spaced apart from each other are coated in patches on the first gas diffusion layer; b) Coating multiple cathode electrode layers spaced apart from each other onto the second gas diffusion layer in sections; c) Cutting a continuous membrane into multiple membrane layers; d) Stack the plurality of film layers onto one of the following: The plurality of cathode electrode layers; and The plurality of anode electrode layers; and e) Laminating the plurality of cathode electrode layers, the plurality of anode electrode layers, the plurality of film layers, and the plurality of gasket layers between the first gas diffusion layer and the second gas diffusion layer, respectively. The relative outer edges of the plurality of film layers, the plurality of cathode electrode layers, and the plurality of anode electrode layers are located inside the relative outer edges of the first gas diffusion layer and the second gas diffusion layer.
2. The method of claim 1, further comprising, prior to d), cutting at least one of the following: The plurality of anode electrode layers and the first gas diffusion layer; and The plurality of cathode electrode layers and the second gas diffusion layer.
3. The method of claim 1, further comprising, after d), cutting at least one of the following: The anode electrode layer and the first gas diffusion layer; and The cathode electrode layer and the second gas diffusion layer.
4. The method of claim 1, further comprising aligning the opposite outer edges of the plurality of film layers, the plurality of cathode electrode layers and the plurality of anode electrode layers in the first and second lateral directions.
5. The method of claim 1, further comprising: Align the relative outer edges of the plurality of film layers and the plurality of anode electrode layers; and The relative outer edges of the cathode electrode layer are located inside the outer edges of the plurality of film layers and the plurality of anode electrode layers.
6. The method according to claim 1, wherein the plurality of gasket layers are respectively disposed between the plurality of anode electrode layers and the plurality of film layers.
7. The method according to claim 1, wherein the plurality of gasket layers are respectively disposed between the plurality of cathode electrode layers and the plurality of film layers.
8. A method for manufacturing a membrane electrode assembly, comprising: a) A plurality of anode electrode layers are continuously coated longitudinally on the first gas diffusion layer; b) A plurality of cathode electrode layers are longitudinally and continuously coated on the second gas diffusion layer; c) Cutting a continuous membrane into multiple membrane layers; d) Stack the plurality of film layers onto one of the following: The plurality of cathode electrode layers; and The plurality of anode electrode layers; and e) Laminating the plurality of cathode electrode layers, the plurality of anode electrode layers, the plurality of film layers, and the plurality of gasket layers between the first gas diffusion layer and the second gas diffusion layer. The relative outer edges of the plurality of film layers, the plurality of cathode electrode layers and the plurality of anode electrode layers in the first direction are located inside the relative outer edges of the first gas diffusion layer and the second gas diffusion layer.
9. The method of claim 8, further comprising, prior to d), cutting at least one of the following: The plurality of anode electrode layers and the first gas diffusion layer; and The plurality of cathode electrode layers and the second gas diffusion layer.
10. The method of claim 8, further comprising, after d), cutting at least one of the following: The anode electrode layer and the first gas diffusion layer; and The cathode electrode layer and the second gas diffusion layer.