Manufacturing method of film integrated gasket

Abstract

To provide a method for manufacturing a film-integrated gasket capable of suppressing molding defects.SOLUTION: There is provided a method for manufacturing a film-integrated gasket, which includes: a first step in which a first lower mold 310 and a first upper mold 320 are clamped in a state in which a resin film 120 is disposed between the first lower mold 310 and the first upper mold 320, and a molding material is filled into a first cavity 321 to mold a first gasket 131; and a second step in which a second lower mold 330 having a groove 331 at which the first gasket 131 is arranged and a second upper mold 340 are clamped in a state in which the resin film 120 integrally provided with the first gasket 131 is disposed between the second lower mold 330 and the second upper mold 340, and a molding material is filled into a second cavity 341 to mold a second gasket. A first opening width W32 is narrower than a second opening width W34.SELECTED DRAWING: Figure 3

Description

[Technical field]

[0001] The present invention relates to a method for producing a film-integrated gasket in which gaskets are integrally provided on both sides of a film. [Background technology]

[0002] A polymer electrolyte fuel cell is provided with an electrolyte membrane. A technique for reinforcing this electrolyte membrane with a resin film is known. A technique for integrally providing gaskets on both sides of a resin film to improve handling when assembling a fuel cell is also known. Such a conventional film-integrated gasket and its manufacturing method will be described with reference to Figs. 4 and 5. Fig. 4 is a partial cross-sectional view of a conventional film-integrated gasket. Fig. 5 is a manufacturing process diagram of a conventional film-integrated gasket, showing a partial cross-sectional view of a film-integrated gasket and a mold.

[0003] A film-integrated gasket 500 according to the conventional technology includes a resin film 510, and a first gasket 521 and a second gasket 522 which are provided on both sides of the resin film 510 integrally with the resin film 510. The second gasket 522 has the same dimensions and shape as the first gasket 521, and is provided along the first gasket 521 at a position directly behind the first gasket 521 with the resin film 510 interposed therebetween.

[0004] A manufacturing method of the film-integrated gasket 500 will be described with reference to Fig. 5. First, a first lower die 610 and an upper die 620 having a cavity 621 for forming the first gasket 521 are clamped together with the resin film 510 disposed between the first lower die 610 and the upper die 620 (see Fig. 5(a)). Then, a molding material is filled into the cavity 621 to form the first gasket 521. Thereafter, the die is opened, and the resin film 510 integrally formed with the first gasket 521 is taken out.

[0005] Next, second lower mold 630 having groove 631 in which first gasket 521 is disposed and upper mold 620 having cavity 621 for molding second gasket 522 are clamped together with resin film 510 integrally provided with first gasket 521 disposed between second lower mold 630 and upper mold 620 (see FIG. 5(b)). Then, molding material is filled into cavity 621 to mold second gasket 522. Thereafter, the mold is opened and resin film 510 integrally formed with first gasket 521 and second gasket 522 is taken out.

[0006] As described above, the same mold or a mold having the cavity 621 of the same size and shape is used for the upper mold 620 having the cavity 621 for molding the first gasket 521 and the second gasket 522. In contrast, for the lower mold, when molding the first gasket 521, a first lower mold 610 is used in which at least a portion of the upper surface facing the cavity 621 of the upper mold 620 is configured as a flat surface. Then, when molding the second gasket 522, a second lower mold 630 is used which has a groove 631 in which the first gasket 521 is disposed so that the first gasket 521 does not interfere.

[0007] To prevent interference between the groove 631 and the first gasket 521, a gap is formed between both side surfaces and the bottom surface of the groove 631 and the first gasket 521. Therefore, an opening width W63 of the groove 631 on the resin film side in a direction perpendicular to the extension direction of the groove 631 is configured to be wider than an opening width W62 of the cavity 621 on the resin film side in a direction perpendicular to the extension direction of the cavity 621. Therefore, the second gasket 521 is configured to be wider than the opening width W63 of the cavity 621 on the resin film side in a direction perpendicular to the extension direction of the cavity 621. When the mold is clamped to mold cavity 522, gaps S are formed between first gasket 521 and both side surfaces of groove 631. As a result, the above-mentioned gaps S are present directly behind both sides of cavity 621 in upper mold 620, via resin film 510. Therefore, since resin film 510 is flexible, the pressing force of upper mold 620 against resin film 510 is likely to be insufficient in the circled X portion in the figure. Therefore, burrs are likely to be generated, making post-processing difficult, or molding defects such as leakage of molding material may occur.

[0008] The same problem can arise not only when manufacturing a film-integrated gasket to be provided in a fuel cell, but also when manufacturing a film-integrated gasket in which a gasket is integrally provided on both sides of a flexible film. [Prior art documents] [Patent documents]

[0009] [Patent Document 1] JP 2010-67371 A [Patent Document 2] JP 2009-99531 A [Patent Document 3] JP 2006-344541 A Summary of the Invention [Problem to be solved by the invention]

[0010] An object of the present invention is to provide a method for producing a film-integrated gasket that can suppress molding defects. [Means for solving the problem]

[0011] The present invention employs the following means to solve the above problems.

[0012] That is, the manufacturing method of a film-integrated gasket of the present invention is a manufacturing method of a film-integrated gasket having a first gasket integrally provided on one surface of a film, and a second gasket integrally provided on the other surface of the film at a position directly behind the first gasket so as to be aligned with the first gasket, a first step of clamping a first lower die and a first upper die having a first cavity for molding a first gasket with the film disposed between the first lower die and the first upper die, filling the first cavity with a molding material, and molding a first gasket; a second step of clamping a second lower mold having a groove in which the first gasket is disposed and a second upper mold having a second cavity for molding the second gasket, with the film with the first gasket integrally provided therewith disposed between the second lower mold and the second upper mold, filling a molding material into the second cavity, and molding the second gasket; The first cavity is characterized in that a first opening width on the film side in a direction perpendicular to the extension direction of the first cavity is narrower than a second opening width on the film side in a direction perpendicular to the extension direction of the second cavity.

[0013] According to the present invention, the width of the film side of the first gasket formed by the first cavity is narrower than the width of the second opening in the second cavity. This allows the groove width of the groove in the second lower mold to be narrowed. As a result, it is possible to narrow or eliminate gaps formed directly behind both sides of the second cavity in the second upper mold via the film.

[0014] The second opening width may be equal to or greater than a third opening width of the groove on the side of the film in a direction perpendicular to the extension direction of the groove.

[0015] This makes it possible to prevent the formation of gaps directly behind the portions on both sides of the second cavity in the second upper mold via the film.

[0016] The center of the third opening width is located directly behind the center of the second opening width via the film.

[0017] This prevents any gaps from being formed directly behind the portions on both sides of the second cavity in the second upper mold via the film.

[0018] The film may be a resin film that reinforces an electrolyte membrane provided in a fuel cell.

[0019] The above configurations may be combined as much as possible. Effect of the Invention

[0020] As described above, according to the present invention, molding defects can be suppressed. [Brief description of the drawings]

[0021] [Figure 1] FIG. 1 is a plan view of a film-integrated gasket according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a partial cross-sectional view of a fuel cell including a film integrated gasket according to an embodiment of the present invention. [Diagram 3] FIG. 3 is a manufacturing process diagram of a film-integrated gasket according to an embodiment of the present invention. [Figure 4] FIG. 4 is a partial cross-sectional view of a film-integrated gasket according to the prior art. [Diagram 5] FIG. 5 is a manufacturing process diagram of a film-integrated gasket according to the prior art. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] The following describes in detail the embodiments of the present invention with reference to the drawings. However, the dimensions, materials, shapes, and relative positions of the components described in the embodiments are not intended to limit the scope of the present invention unless otherwise specified. In the following embodiments, a film-integrated gasket used in a fuel cell is described as an example.

[0023] (Example) A manufacturing method of a film-integrated gasket according to an embodiment of the present invention will be described with reference to Figures 1 to 3. Figure 1 is a plan view of a film-integrated gasket according to an embodiment of the present invention. Figure 2 is a part of a cross-sectional view of a fuel cell equipped with a film-integrated gasket according to an embodiment of the present invention, and the cross-sectional view of the film-integrated gasket in the figure corresponds to the cross-sectional view AA in Figure 1. Figure 3 is a manufacturing process diagram of a film-integrated gasket according to an embodiment of the present invention, showing a part of a cross-sectional view of the film-integrated gasket and a mold.

[0024] <Fuel cell> A fuel cell including a film-integrated gasket according to this embodiment will be described with reference to FIG. 2. Generally, a fuel cell is configured as a cell stack consisting of a plurality of unit cells. FIG. 2 shows a cross-sectional view of a portion of a cell stack consisting of a plurality of unit cells. The cell stack is configured such that a film-integrated gasket 100 integrally including an MEA (Membrane Electrode Assembly) 110 and a separator 200 are alternately stacked. The film-integrated gasket 100 and a pair of separators 200 provided on both sides thereof form a unit cell 10. FIG. 2 shows only one unit cell.

[0025] The MEA 110 includes an electrolyte membrane 111 and a pair of gas diffusion layers 112 provided on both sides of the electrolyte membrane 111. In addition, in the separator 200, on the surface facing the gas diffusion layer 112, flow paths (not shown) are formed through which a fuel gas, an oxidant gas, a coolant, and the like flow.

[0026] In this embodiment, a resin film 120 that reinforces the electrolyte membrane 111 is provided integrally with the MEA 110. The resin film 120 is composed of a pair of films 121, 122 so as to support both sides of the electrolyte membrane 111. Suitable materials for the resin film 120 include resin materials such as PEN (polyethylene naphthalate) and PI (polyimide).

[0027] A first gasket 131 and a second gasket 132 are provided between the resin film 120 and the separator 200 to prevent leakage of fuel gas, oxidant gas, coolant, and the like. In this embodiment, the first gasket 131 and the second gasket 132 are provided integrally with the resin film 120. A member in which the first gasket 131 and the second gasket 132 are provided integrally with the resin film 120 in this manner can be called a "film-integrated gasket." Suitable materials for the first gasket 131 and the second gasket 132 include rubber materials such as EPDM (ethylene propylene rubber) and VMQ (vinyl methyl silicone rubber).

[0028] <Film integrated gasket> The film-integrated gasket 100 provided in the fuel cell will be described in more detail. As described above, the film-integrated gasket 100 includes the MEA 110 and the resin film 120 that is integrally provided with the MEA 110. The resin film 120 is provided with a plurality of manifolds 101. The manifolds 101 are provided to distribute fuel gas, oxidant gas, coolant, and the like to each cell.

[0029] In order to prevent the fuel gas and the like from leaking to the outside, a first gasket 131 and a second gasket 132 are provided integrally with the resin film 120 around the area where the MEA 110 is provided and around the manifold 101, respectively. In Fig. 1, the area where the second gasket 132 is provided is indicated by a thick line.

[0030] The first gasket 131 is provided on one surface of the resin film 120, integrally with the resin film 120. The second gasket 132 is provided on the other surface of the resin film 120, directly behind the first gasket 131, integrally with the resin film 120 so as to be aligned with the first gasket 131. However, depending on the structure of the cell stack, the second gasket 132 may be provided directly behind the entire area in which the first gasket 131 is provided, or may be provided directly behind a portion of the area. The width W1 of the first gasket 131 on the resin film 120 side in a direction perpendicular to the direction in which the first gasket 131 extends is configured to be narrower than the width W2 of the second gasket 132 on the resin film 120 side in a direction perpendicular to the direction in which the second gasket 132 extends. Furthermore, the center of width W2 of second gasket 132 is configured to be located directly behind the center of width W1 of first gasket 131 via resin film 120. However, the present invention does not exclude the case where the center of W2 is not located directly behind the center of W1 via resin film 120. In order to improve sealing performance, first gasket 131 in this embodiment is provided with seal protrusion 131a on the side in contact with separator 200, the width of which is narrower than width W1 on the resin film 120 side. Second gasket 132 is also provided with similar seal protrusion 132a.

[0031] <Manufacturing method for film-integrated gaskets> A manufacturing method of the film-integrated gasket 100 according to this embodiment will be described with reference to Fig. 3. This embodiment includes an insert molding step (first step) of molding a first gasket 131 using the resin film 120 as an insert part, and an insert molding step (second step) of molding a second gasket 132 using the resin film 120 integrally provided with the first gasket 131 as an insert part.

[0032] FIG. 3(a) shows the first step. The mold for insert molding used in the first step includes a first lower mold 310 and a first upper mold 320. The first upper mold 320 is provided with a first cavity 321 for molding the first gasket 131. At least a portion of the upper surface of the first lower mold 310 that faces the first cavity 321 of the first upper mold 320 is configured as a flat surface. Using the mold configured as above, the mold is clamped with the resin film 120 disposed between the first lower mold 310 and the first upper mold 320. Then, the molding material is filled into the first cavity 321, and the first gasket 131 is molded.

[0033] After the first step described above, the mold is opened, and the resin film 120 with the first gasket 131 integrally formed therewith is taken out.

[0034] FIG. 3(b) shows the second step. The mold for insert molding used in the second step includes a second lower mold 330 and a second upper mold 340. The second upper mold 340 is provided with a second cavity 341 for molding the second gasket 132. The second lower mold 330 is provided with a groove 331 in which the first gasket 131 is disposed. Using the mold configured as above, the mold is clamped in a state in which the resin film 120 with the first gasket 131 integrally provided thereon is disposed between the second lower mold 330 and the second upper mold 340. The mold is clamped in a state in which the first gasket 131 is disposed in the groove 331. After the mold is clamped, the second cavity 341 is filled with a molding material, and the second gasket 132 is molded.

[0035] After the second step described above, the mold is opened, and the resin film 120 in which the first gasket 131 and the second gasket 132 are integrally formed is taken out. After that, post-treatment such as deburring is performed as necessary, and the film-integrated gasket 100 can be obtained.

[0036] Here, the opening width of first cavity 321 of first upper mold 320 on the resin film 120 side in a direction perpendicular to the extension direction of first cavity 321 is defined as a first opening width W32. Also, the opening width of second cavity 341 of second upper mold 340 on the resin film 120 side in a direction perpendicular to the extension direction of second cavity 341 is defined as a second opening width W34. Furthermore, the opening width of groove 331 of second lower mold 330 on the resin film 120 side in a direction perpendicular to the extension direction of groove 331 is defined as a third opening width W33.

[0037] In this case, the first opening width W32 is smaller than the second opening width W34. The width W1 of the first gasket 131 formed by the first cavity 321 is approximately equal to the first opening width W32. The width W2 of the second gasket 132 formed by the second cavity 341 is approximately equal to the second opening width W34.

[0038] In this embodiment, the second opening width W34 is greater than or equal to the third opening width W33. Furthermore, the center of the third opening width W33 is located at a position directly behind the center of the second opening width W34 via the resin film 120 (see FIG. 3(b)).

[0039] <Advantages of the manufacturing method of the film-integrated gasket according to this embodiment> According to the manufacturing method of this embodiment, the first opening width W32 is smaller than the second opening width W34. As a result, the groove width of the groove 331 in the second lower mold 330 (the third opening width W 33) can be narrowed. Therefore, it is possible to narrow the gap formed directly behind both sides of second cavity 341 in second upper die 340 through resin film 120, or to eliminate such a gap. Therefore, it is possible to prevent the pressing force of both sides of second cavity 341 in second upper die 340 against resin film 120 from becoming insufficient. This makes it possible to prevent the occurrence of burrs and leakage of molding material, and thus molding defects.

[0040] In this embodiment, since the second opening width W34 is configured to be greater than or equal to the third opening width W33, it is possible to prevent gaps from being formed directly behind both side portions of the second cavity 341 in the second upper mold 340 through the resin film 120.

[0041] In this embodiment, the second opening width W34≧the third opening width W33 is satisfied, and the center of the third opening width W33 is located at a position directly behind the center of the second opening width W34 via the resin film 120. As a result, even if the second opening width W34=the third opening width W33 is set, no gaps are formed directly behind the portions on both sides of the second cavity 341 in the second upper mold 340 via the resin film 120.

[0042] In this way, by preventing gaps from being created directly behind both side portions of second cavity 341 in second upper mold 340 through resin film 120, the pressing force of both side portions of second cavity 341 in second upper mold 340 against resin film 120 can be sufficiently increased.

[0043] (others) In the above embodiment, the configuration in which the second opening width W34≧the third opening width W33 is shown. However, if at least the first opening width W32<the second opening width W34 is satisfied, the groove width (the third opening width W33) of the groove 331 in the second lower mold 330 can be narrowed. Therefore, compared to the case in which the first opening width W32=the second opening width W34, the gap formed directly behind the second cavity 341 on both sides of the second upper mold 340 through the resin film 120 can be narrowed, and molding defects can be suppressed.

[0044] In this embodiment, the second opening width W34≧the third opening width W33 is satisfied, and the center of the third opening width W33 is located at a position directly behind the center of the second opening width W34 through the resin film 120. If the positional relationship of the opening width centers is not configured in this way, a gap may be formed directly behind one side of the second cavity 341 in the second upper mold 340 through the resin film 120. However, if the second opening width W34≧the third opening width W33 is satisfied, such a gap can be narrowed, making it possible to suppress molding defects.

[0045] In this embodiment, a film-integrated gasket provided in a fuel cell is shown as an example of a film-integrated gasket. However, the film-integrated gasket according to the present invention is not limited to fuel cells and can be applied to various devices. Furthermore, the material of the film is not limited to resin material. In particular, the present invention can be suitably applied to a manufacturing method of a film-integrated gasket made of a highly flexible film. [Explanation of symbols]

[0046] 10 Single Cell 100 Film integrated gasket 101 Manifold 110 MEA 111 Electrolyte membrane 112 Gas diffusion layer 120 Resin Film 121,122 Films 131 First Gasket 131a Seal protrusion 132 Second gasket 132a Seal protrusion 200 Separator 310 First Lower Die 320 First upper die 321 1st cavity 330 Second Lower Die 331 Groove 340 No. 2 Upper Die 341 2nd Cavity W32 First opening width W33 Third opening width W34 Second opening width

Claims

1. A method for producing a film-integrated gasket, comprising the steps of: providing a first gasket integrally on one surface of a film; and providing a second gasket integrally on the other surface of the film at a position directly behind the first gasket so as to be aligned with the first gasket, the method comprising the steps of: a first step of clamping a first lower die and a first upper die having a first cavity for molding a first gasket with the film disposed between the first lower die and the first upper die, filling the first cavity with a molding material, and molding a first gasket; a second step of clamping a second lower mold having a groove in which the first gasket is disposed and a second upper mold having a second cavity for molding the second gasket, with the film with the first gasket integrally provided thereon disposed between the second lower mold and the second upper mold, filling a molding material into the second cavity, and molding the second gasket; having A method for manufacturing a film-integrated gasket, characterized in that a first opening width on the film side of a first cavity in a direction perpendicular to the extension direction of the first cavity is narrower than a second opening width on the film side of a second cavity in a direction perpendicular to the extension direction of the second cavity.

2. 2. The method for producing a film-integrated gasket according to claim 1, wherein the second opening width is equal to or larger than a third opening width of the groove on the film side in a direction perpendicular to the extension direction of the groove.

3. 3. The method for producing a film-integrated gasket according to claim 2, wherein the center of the third opening width is located at a position directly behind the center of the second opening width via the film.

4. 4. The method for producing a film-integrated gasket according to claim 1, wherein the film is a resin film that reinforces an electrolyte membrane provided in a fuel cell.

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