Method for manufacturing a sheet for forming a membrane electrode assembly, method for manufacturing a membrane electrode assembly, set of sheets for forming a membrane electrode assembly, apparatus for manufacturing sheets for forming a membrane electrode assembly, and apparatus for manufacturing a membrane electrode assembly.

Abstract

To manufacture a high-quality membrane electrode assembly without occurrence of swell / shrinkage in an electrolyte membrane.SOLUTION: A multilayer substrate in which a lining material, a first film and a second film are laminated and which includes a rectangular half-cut part consisting of only the first and second films in a central portion and an electrolyte-side substrate in which an electrolyte membrane and a base film are laminated are adhered in such a manner that the electrolyte membrane covers an entire surface of the half-cut part. The base film is conveyed while being adsorbed and held, an ink for catalyst layer is applied onto the electrolyte membrane while using a mask part, which is formed by peeling the lining material and the half-cut part, as a mask. After drying, peeling of the first film is performed and after a coating body is acquired, the adsorbed and held state is cancelled. The base film of the coating body is peeled, and bonding is performed in such a manner that the electrolyte membrane of the coating body covers the entire half-cut part of a new multilayer substrate. The second film is adsorbed and held, the ink for catalyst layer is applied onto the electrolyte membrane in the similar procedure thereafter, a membrane electrode assembly 1 is acquired and then, the adsorbed and held state is cancelled.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a sheet for producing a membrane-electrode assembly (MEA: Membrane-Electrode Assembly), a method for manufacturing a membrane-electrode assembly, a set of sheets for producing a membrane-electrode assembly, a manufacturing apparatus for a sheet for producing a membrane-electrode assembly, and a manufacturing apparatus for a membrane-electrode assembly.

Background Art

[0002] In recent years, fuel cells have attracted attention as effective solutions to environmental and energy problems. A fuel cell is a device that oxidizes a fuel such as hydrogen using an oxidant such as oxygen and converts the accompanying chemical energy into electrical energy. Fuel cells are classified into alkaline, phosphoric acid, polymer, molten carbonate, solid oxide, etc. according to the type of electrolyte. Among these, polymer electrolyte fuel cells (hereinafter referred to as PEFCs) are expected to be applied as portable power sources, household power sources, and vehicle-mounted power sources because they operate at low temperatures, have high power density, and can be miniaturized and lightened.

[0003] The membrane-electrode assembly for PEFC is composed of a plurality of cells stacked, and in a single cell, a membrane-electrode assembly in which a pair of electrode catalyst layers (anode and cathode) are formed on both sides of an electrolyte membrane is joined. Furthermore, the membrane-electrode assembly is used for a membrane for obtaining hydrogen by water decomposition or as an electrochemical hydrogen pump, and its future development scope is wide. As a method for manufacturing a membrane-electrode assembly, a method of preparing an ink for a catalyst layer composed of carbon particles carrying a catalyst, a polymer electrolyte, and a solvent, and directly coating the ink for the catalyst layer on an electrolyte membrane, or a method of coating on an electrode transfer substrate or a gas diffusion layer and then thermocompression bonding to an electrolyte membrane is known.

[0004] When directly coating the ink for the catalyst layer on an electrolyte membrane, die coating is often used as the coating method to form the anode and cathode. After coating the ink for the catalyst layer, it is necessary to sufficiently remove the solvent in the electrode catalyst layer by drying or firing. Regardless of which of the above methods is adopted, defects caused by the coating of the catalyst layer ink often affect power generation performance. Examples include cracks, aggregates, and foreign matter contamination. If cracks occur in the membrane catalyst layer due to the swelling and shrinking of the electrolyte membrane, the electrolyte membrane becomes exposed, which reduces durability during power generation.

[0005] To eliminate the effects of swelling and shrinking of the electrolyte membrane, for example, in the technology described in Patent Document 1, an adsorption roller holding the electrolyte membrane is rotated at a predetermined speed to apply ink for the catalyst layer, and then the process proceeds to a drying step to manufacture the membrane electrode assembly. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] Patent No. 6517402 [Overview of the Initiative] [Problems that the invention aims to solve]

[0007] By the way, the manufacturing technology for the film electrode assembly shown in Patent Document 1 requires a predetermined drying time in the process of drying the catalyst layer ink in order to volatilize the solvent component of the catalyst layer ink coated on the electrolyte membrane. In order to increase the drying time in the process of drying the catalyst layer ink, it is necessary to either slow down the rotation speed (conveying speed) of the adsorption roller or increase the diameter of the adsorption roller to increase the length of the drying oven. However, slowing down the rotation speed of the suction roller may reduce the production efficiency of the membrane electrode assembly. Furthermore, increasing the diameter of the suction roller may increase the size of the equipment, leading to higher equipment costs.

[0008] The present invention has been made in view of the above-mentioned points, and aims to provide a method for manufacturing a membrane electrode assembly sheet, a method for manufacturing a membrane electrode assembly, a set of membrane electrode assembly sheets, a manufacturing apparatus for membrane electrode assembly sheets, and a manufacturing apparatus for membrane electrode assembly, which can be produced without causing swelling and shrinkage of the electrolyte membrane, while improving production efficiency and reducing equipment costs. [Means for solving the problem]

[0009] To solve the problem, the present invention provides a method for manufacturing a sheet for forming a membrane electrode assembly, comprising the steps of: preparing a laminated substrate having a rectangular shape in plan view, in which a backing material, a first film, and a second film are laminated in that order, and the first film and the second film are provided with cuts that divide only the first film and the second film into a rectangular central portion which is a half-cut portion and a surrounding portion; and preparing an electrolyte side substrate having a rectangle larger than the half-cut portion in plan view, in which an electrolyte membrane and a base film are laminated; and bonding the laminated substrate and the electrolyte side substrate so that the second film and the electrolyte membrane face each other and the electrolyte membrane covers the entire surface of the half-cut portion to obtain a coated substrate.

[0010] Furthermore, the present invention relates to a method for manufacturing a membrane electrode assembly, comprising the steps of: preparing a laminated substrate having a rectangular shape in plan view, wherein a backing material, a first film, and a second film are laminated in that order, and the first film and the second film are provided with cuts that divide only the first film and the second film into a rectangular central portion which is a half-cut portion and a peripheral portion; and preparing an electrolyte side substrate having a rectangle larger than the half-cut portion in plan view, wherein an electrolyte membrane and a base film are laminated; and preparing a second film and an electrolyte membrane. The process involves: obtaining a first coated substrate by bonding a laminated substrate and an electrolyte-side substrate so that they face each other and the electrolyte membrane covers the entire surface of the half-cut portion; adsorbing the base film of the first coated substrate to an adsorption device to hold the first coated substrate by adsorption; transporting the substrate while maintaining the adsorption and holding state, peeling off the backing material and half-cut portion of the laminated substrate contained in the first coated substrate, forming a mask portion surrounding the exposed electrolyte membrane; transporting the substrate while maintaining the adsorption and holding state, applying catalyst layer ink onto the electrolyte membrane using the mask portion as a mask, and then drying it. The process involves transporting the material while maintaining the adsorption and holding state, peeling off only the first film of the mask portion to obtain the coated material, releasing the adsorption and holding state, preparing a new laminated substrate, peeling off the base film of the coated material, bonding the new laminated substrate and the coated material so that the second film of the new laminated substrate and the electrolyte membrane of the coated material face each other and the electrolyte membrane covers the entire half-cut portion of the new laminated substrate to obtain a second coated substrate, and adsorbing the second film of the second coated substrate to hold the second coated substrate in the adsorption device. The present invention provides a method for manufacturing a membrane electrode assembly, comprising the steps of: transporting the second coating substrate while maintaining an adsorbed and held state, peeling off the backing material and half-cut portion of the laminated substrate contained in the second coating substrate to form a mask portion surrounding the exposed electrolyte membrane; transporting the substrate while maintaining an adsorbed and held state, applying catalyst layer ink onto the electrolyte membrane using the mask portion as a mask, and then drying it; transporting the substrate while maintaining an adsorbed and held state, peeling off the first film of the mask portion to obtain a membrane electrode assembly, and then releasing the adsorbed and held state.

[0011] Furthermore, the set of membrane electrode assembly formation sheets according to the present invention is a set of membrane electrode assembly formation sheets used in the above-mentioned method for manufacturing a membrane electrode assembly, and is characterized by comprising: a sheet of laminated substrate having a rectangular shape in plan view, wherein a backing material, a first film, and a second film are laminated in that order, and the first film and the second film are provided with cuts that divide only the first film and the second film into a rectangular central half-cut portion and a surrounding portion; and an electrolyte side substrate sheet having a rectangle larger than the half-cut portion in plan view, wherein an electrolyte membrane and a base film are laminated together.

[0012] Furthermore, the present invention provides a manufacturing apparatus for a membrane electrode assembly sheet, comprising the steps of: preparing a laminated substrate having a rectangular shape in plan view, wherein a backing material, a first film, and a second film are laminated in that order, and the first film and the second film are provided with cuts that divide only the first film and the second film into a rectangular central portion which is a half-cut portion and a surrounding portion; and preparing an electrolyte side substrate having a rectangle larger than the half-cut portion in plan view, wherein an electrolyte membrane and a base film are laminated; and bonding the laminated substrate and the electrolyte side substrate so that the second film and the electrolyte membrane face each other and the electrolyte membrane covers the entire surface of the half-cut portion to obtain a coated substrate.

[0013] Furthermore, the present invention relates to a manufacturing apparatus for a membrane electrode assembly, comprising the steps of: preparing a laminated substrate having a rectangular shape in plan view, wherein a backing material, a first film, and a second film are laminated in this order, and the first film and the second film are provided with cuts that divide only the first film and the second film into a rectangular central portion which is a half-cut portion and a peripheral portion; and preparing an electrolyte side substrate having a rectangle larger than the half-cut portion in plan view, wherein an electrolyte membrane and a base film are laminated; and preparing the second film and the electrolytic The process involves: obtaining a first coated substrate by bonding the laminated substrate and the electrolyte-side substrate such that the base film faces the electrolyte film and the electrolyte film covers the entire surface of the half-cut portion; adsorbing the base film of the first coated substrate onto an adsorption device to hold the first coated substrate on an adsorption device; transporting the substrate while maintaining the adsorption and holding state, peeling off the backing material and the half-cut portion of the laminated substrate contained in the first coated substrate, forming a mask portion surrounding the exposed electrolyte film; and transporting the substrate while maintaining the adsorption and holding state, using the mask portion as a mask. The process involves applying catalyst layer ink onto the electrolyte membrane and drying it, transporting the material while maintaining the adsorption and retention state, peeling off only the first film from the mask portion to obtain a coated body, then releasing the adsorption and retention state, preparing a new laminated substrate, peeling off the base film from the coated body, and bonding the new laminated substrate and the coated body such that the second film of the new laminated substrate and the electrolyte membrane of the coated body face each other and the electrolyte membrane covers the entire half-cut portion of the new laminated substrate. A step of obtaining a work substrate; a step of adsorbing the second film of the second coated substrate onto an adsorption device to hold the second coated substrate on an adsorption device; a step of transporting the second coated substrate while maintaining the adsorption-held state, peeling off the backing material and the half-cut portion of the laminated substrate contained in the second coated substrate, and forming a mask portion surrounding the exposed electrolyte membrane; a step of transporting while maintaining the adsorption-held state, applying catalyst layer ink onto the electrolyte membrane using the mask portion as a mask, and then drying it; and a step of transporting while maintaining the adsorption-held state.After peeling the first film of the mask portion to obtain the membrane electrode assembly, a step of releasing the adsorbed and held state is performed, and a manufacturing apparatus for the membrane electrode assembly is provided.

Effects of the Invention

[0014] According to the present invention, a high-quality membrane electrode assembly can be manufactured without causing swelling and shrinkage in the electrolyte membrane, while improving production efficiency and reducing device costs.

Brief Description of the Drawings

[0015] [Figure 1] It is a diagram showing a membrane electrode assembly for a fuel cell according to the present invention. [Figure 2] It is a diagram showing a manufacturing apparatus for a membrane electrode assembly for a fuel cell according to the present invention. [Figure 3] It is a diagram showing an adsorption device according to the present invention, (a) is a diagram showing an adsorption portion and a pedestal portion formed of a porous material, and (b) is a diagram showing a blocking plate arranged around the adsorption portion. [Figure 4] It is a diagram showing the operation of a suction mechanism according to the present invention. [Figure 5] It is a diagram showing an electrolyte membrane supply device of a loader according to the present invention. [Figure 6] It is a diagram showing an adhesive peeling roller of a loader according to the present invention. [Figure 7] It is a diagram showing a mechanism constituting a coating portion according to the present invention. [Figure 8] It is a diagram showing a transfer plate moving mechanism for moving an adsorption device to a coating portion according to the present invention. [Figure 9] It is a diagram showing the internal structure of a drying furnace according to the present invention. [Figure 10] It is a diagram showing a state in which an external suction means is connected to an adsorption device housed in a drying furnace according to the present invention. [Figure 11] It is a diagram showing an appearance inspection portion according to the present invention. [Figure 12] It is a diagram showing an unloader according to the present invention. [Figure 13]This is a perspective view illustrating the manufacturing method of a laminated substrate. [Figure 14] This is a cross-sectional process diagram showing an example of the manufacturing process for a membrane electrode assembly for a fuel cell according to the present invention. [Figure 15] This is a continuation of the manufacturing process for the membrane electrode assembly for fuel cells shown in Figure 14. [Figure 16] This is a continuation of the manufacturing process for the membrane electrode assembly for fuel cells shown in Figure 15. [Figure 17] This is a continuation of the manufacturing process for the membrane electrode assembly for fuel cells shown in Figure 16. [Modes for carrying out the invention]

[0016] Next, embodiments of the present invention will be described with reference to the drawings. In the following drawings, identical or similar parts are denoted by the same or similar reference numerals. However, it should be noted that the drawings are schematic, and the relationship between thickness and planar dimensions, the ratio of the thickness of each layer, etc., may differ from reality. Therefore, specific thicknesses and dimensions should be determined by referring to the following explanation. Furthermore, it should be noted that there are parts where the relationships and ratios of dimensions differ between drawings.

[0017] Furthermore, the following embodiments illustrate apparatuses and methods for embodying the technical concept of the present invention, and the technical concept of the present invention does not limit the materials, shapes, structures, arrangements, etc., of the components to those described below. The technical concept of the present invention can be modified in various ways within the technical scope defined by the claims described in the patent claims. The terms indicating direction, such as "up," "down," "left," "right," "bottom," "front," "back," "long direction," and "short direction," used in the following explanation refer to the directions shown in the attached drawings.

[0018] [Membrane electrode assembly for fuel cells] Figure 1 shows the membrane electrode assembly according to the present invention applied to a membrane electrode assembly for a fuel cell. Note that the membrane electrode assembly according to the present invention is not limited to membrane electrode assemblies for fuel cells; it can also be applied, for example, to membrane electrode assemblies in hydrogen-related electrodes. As shown in Figure 1, the membrane electrode assembly for fuel cell (hereinafter also simply referred to as the membrane electrode assembly) 1 comprises an electrolyte membrane (polymer electrolyte membrane) 2, an anode electrode catalyst layer 3 provided on one surface of the electrolyte membrane 2 (the upper surface of the electrolyte membrane 2 in Figure 1), and a cathode electrode catalyst layer 3 provided on the other surface of the electrolyte membrane 2 (the lower surface of the electrolyte membrane 2 in Figure 1). Here, in Figure 1, a structure in which the anode electrode catalyst layer 3 is formed on one surface of the electrolyte membrane 2 is referred to as workpiece 4 or coated body C, a structure in which the cathode electrode catalyst layer 3 is formed on the other surface of the electrolyte membrane 2 is also referred to as workpiece 4 or coated body C, and a structure in which the electrode catalyst layers 3 are formed on both sides of the electrolyte membrane 2 is referred to as workpiece 4 or membrane electrode assembly 1a. The electrolyte membrane 2 may be, for example, a polymer electrolyte membrane having ionic conductivity and proton conductivity.

[0019] [Manufacturing equipment] Figure 2 shows a manufacturing apparatus 10 for manufacturing a membrane electrode assembly 1. In the first manufacturing step, the manufacturing apparatus 10 manufactures a workpiece 4 by providing one of the electrode catalyst layers 3 for the anode or cathode on one side of the electrolyte membrane 2. In the second manufacturing step, the manufacturing apparatus 10 forms the workpiece 4 by providing the other electrode catalyst layer 3 for the anode or cathode on the other side of the electrolyte membrane 2, which already has one electrode catalyst layer 3 on one side. In this way, the manufacturing apparatus 10 manufactures the membrane electrode assembly 1 by performing two manufacturing steps to form the workpiece 4 on one side and the other side of the electrolyte membrane 2.

[0020] In the manufacturing apparatus 10 shown in Figure 2, a transport path 11 is installed as a planar endless circulation path, and multiple adsorption devices 12 are transported in one direction along this transport path 11. A loader 13, a half-cut peeling section 13a, a peeling inspection section 13b, a coating section 14, a drying oven 15, a mask peeling section 15a, an appearance inspection section 16, and an unloader 17 are installed along the transport path 11 from the upstream side to the downstream side. Furthermore, a bonding device 131 is located near the loader 13. The bonding device 131 bonds the laminated substrate A stored in storage area 131a to the electrolyte-side substrate B stored in storage area 131b, or the laminated substrate A stored in storage area 131a to the coated body C stored in storage area 131c. Furthermore, the manufacturing apparatus 10 is equipped with a control unit 50 that manages the entire apparatus.

[0021] [Adsorption device] Figures 3(a) and 3(b) show the adsorption device 12. As shown in Figure 3(a), the adsorption device 12 comprises a transport case 18 with a bottomed box shape and a rectangular opening 18a, a base portion 19 housed inside the transport case 18, and an adsorption portion 20 made of a porous material having numerous pores, which is positioned to cover the upper surface 19a of the base portion 19. The transport case 18 is made of a synthetic resin or the like that has heat resistance and impact resistance. As disclosed in Figure 4(a) illustrating the suction mechanism 30 described later, a first suction pipe 21a and a second suction pipe 21b are connected to the bottom of the transport case 18, and a check valve 22 is interposed between these first and second suction pipes 21a and 21b. The adsorption portion 20 is formed from at least one porous material selected from metal, nonwoven fabric, paper, ceramics, stone, resin, and glass. The adsorption portion 20 may also be made of a single ceramic material, or it may be formed by layering multiple of the aforementioned porous materials.

[0022] The base portion 19 is also made of at least one of the following materials: metal, nonwoven fabric, paper, ceramics, stone, resin, and glass. This base portion 19 may be made of a single piece of stone, for example, or it may be formed in a rectangular parallelepiped shape by layering several of the aforementioned materials. As shown in Figure 3(a), the base portion 19 has a main suction passage 23 formed inside along the bottom of the transport case 18, and multiple branch suction passages 24 are formed branching from the main suction passage 23 and opening on the upper surface 19a, and the first and second suction pipes 21a and 21b connected to the transport case 18 are connected to the main suction passage 23. Note that the main suction passage 23 and branch suction passages 24 formed in the base portion 19 are merely means of forming a suction flow path. Furthermore, the material used for the adsorption part 20 may be a single material, in which case there is no bonding with other materials and therefore no effect from thermal shrinkage.

[0023] Furthermore, as shown in Figure 3(b), a rectangular frame-shaped closure plate 25 is arranged to cover the outer periphery of the upper surface of the adsorption unit 20. The shape (rectangular) of the opening 25a of the closure plate 25 is set to be the same as the shape of the electrolyte membrane 2 that is adsorbed by the adsorption unit 20. However, the shape of the opening 25a of the closure plate 25 does not have to be the same as the shape of the electrolyte membrane 2. Moreover, even without the transport case 18, the porous material on the surface and the base unit 19 may be bonded together with resin to create a multilayer structure. In this case, the adhesive may be applied in dots, and spacers may be present in the areas where the adhesive is applied, with the areas without adhesive serving as the main suction path.

[0024] When the suction mechanism 30, described later, is connected to at least one of the first and second suction pipes 21a and 21b and performs a suction operation, the multiple branch suction passages 24 become negative pressure via the main suction passage 23, the portion of the suction unit 20 surrounded by the closing plate 25 becomes the suction surface 20a, and the workpiece placed on the suction surface 20a is picked up. Even if the first and second suction pipes 21a and 21b are disconnected from the suction mechanism 30, the check valve 22 maintains the negative pressure state in the main suction passage 23 and the branch suction passages 24. Furthermore, when the suction device 12 that has picked up a workpiece moves between adjacent devices of the manufacturing apparatus 10 (for example, between the loader 13 and the coating unit 14), the suction mechanism 30 is connected to at least one of the first and second suction pipes 21a and 21b of the suction device 12, allowing for continuous suction and suction of the workpiece.

[0025] [Conveyor path and suction mechanism] As shown in Figure 2, the transport path 11 is composed of numerous rollers 11a and 11b arranged in two rows as a planar endless circulation path. The rollers 11a and 11b in front of the loader 13 and unloader 17, and in front of the half-cut peeling section 13a, peeling inspection section 13b, coating section 14, drying oven 15, mask peeling section 15a, and appearance inspection section 16 are driven rollers to which rotational force is transmitted from a drive motor (not shown). When these driven rollers stop, the suction device 12 that has been transported from the upstream of the transport path 11 stops, and when the driven rollers rotate, the suction device 12 is transported to the downstream side of the transport path 11. In addition to the transport by the driven rollers described above, there are no limitations on the transport method as long as it does not affect the suction device 12, such as transporting the suction device 12 by a walking beam system or a conveyor system. Between the two rows of rollers 11a and 11b of the transport path 11, the aforementioned suction mechanism 30 is positioned below the location where the suction device 12 is transported.

[0026] As shown in Figures 4(A) and (a), the suction mechanism 30 includes a first transport suction pipe 31 that extends along the transport path 11 and is connected to the suction pump 8, and a second transport suction pipe 32. An upstream branch suction pipe 31a is formed on the upper part of the first transport suction pipe 31 on the upstream side in the transport direction of the transport path 11 (left side in Figure 4(A)), and a downstream branch suction pipe 31b is formed on the downstream side in the transport direction of the transport path 11. The first transport suction pipe 31 can be raised and lowered by a lifting mechanism (not shown), and when raised, either the upstream branch suction pipe 31a or the downstream branch suction pipe 31b can be connected to the first suction pipe 21a of the suction device 12. A suction pipe 32a is formed at the upper part of the second transport suction pipe 32. The second transport suction pipe 32 is movable up and down by a lifting mechanism (not shown), and is also movable forward and backward along the transport path 11 by a forward and backward movement mechanism (not shown). As a result, when the second transport suction pipe 32 is raised, the suction pipe 32a connects to the second suction pipe 21b of the suction device 12, and the second transport suction pipe 32 can move (forward and backward) together with the suction device 12.

[0027] [Loader] As shown in Figure 2, the loader 13 is a single-sheet type device that receives one of the first coated substrates Ba or the second coated substrate Ca stored in the stock section 35 and holds it adsorbed onto the adsorption surface 20a of the adsorption device 12. The stock section 35 stores multiple sheets of the first coated substrate (sheet for forming a film electrode assembly) Ba or the second coated substrate (sheet for forming a film electrode assembly) Ca, each with a protective film 36 attached by the laminating device 131. An empty suction device 12, with no workpiece attached to the suction surface 20a, is transported to the loader 13. At least the upstream branch suction pipe 31a of the suction mechanism 30 is connected to the second suction pipe 21b, and the suction surface 20a is made capable of holding a workpiece.

[0028] The loader 13 includes, as shown in Figure 5, a coating substrate supply device 37 that adsorbs and holds the first coating substrate Ba or the second coating substrate Ca with a protective film 36 attached and sets it on the adsorption surface 20a of the adsorption device 12, and, as shown in Figure 6, an adhesive peeling roller 38 that winds the protective film 36 while adhesively peeling it off from the first coating substrate Ba or the second coating substrate Ca set on the adsorption surface 20a of the adsorption device 12. Alternatively, the protective film 36 may be adsorbed by an adsorption device (not shown) without using the adhesive peeling roller 38, and the protective film 36 may be peeled off from the electrolyte membrane 2. Alternatively, the protective film 36 may be attached to the electrolyte membrane 2 with an adhesive material such as tape, and the protective film 36 may be peeled off by peeling the adhesive material off the electrolyte membrane 2. Furthermore, if the electrolyte membrane 2 is thin, there is often a support film. In that case, it is preferable to peel off the support film just before coating.

[0029] [Half-cut peeled area] The half-cut peel section 13a peels off the backing material a1 and the half-cut section a5, which will be described later. The half-cut section a5 may be peeled off at the same time as the backing material a1, but if only the half-cut section a5 needs to be peeled off, it can be gripped using an adhesive material or static electricity, and then wound up from the gripped part, diagonally upward, or in a roll shape.

[0030] [Exfoliation Inspection Department] The peel inspection unit 13b detects foreign matter on the electrolyte membrane 2 by irradiating it with ultraviolet light, for example, if a component that may exist as foreign matter on the electrolyte membrane 2, such as the half-cut portion a5, is made of a material that fluoresces under ultraviolet irradiation. For example, the peel inspection unit 13b includes means for irradiating with UV light, such as a UV (ultraviolet) light; means for detecting an abnormality, such as foreign matter remaining on the electrolyte membrane 2 due to UV irradiation; and means for notifying the control unit 50 of information identifying the first coated substrate Ba or the second coated substrate Ca that was inspected when an abnormality is detected. If the component that may exist as foreign matter on the electrolyte membrane 2, such as the half-cut portion a5, is made of a material that does not fluoresce under ultraviolet light, the presence or absence of remaining film from the peeled portion a5 can be confirmed by measuring the thickness of the peeled film.

[0031] [Coating Department] The coating section 14 is equipped with a single-wafer device for coating the exposed electrolyte membrane 2 of the first coating substrate Ba or the second coating substrate Ca, which is adsorbed and held on the adsorption surface 20a of the adsorption device 12, with catalyst layer ink 14b. As shown in Figure 7, the device includes a die head 14a, an ink container 14c for storing the catalyst layer ink 14b, a stirring unit 14d for stirring the catalyst layer ink 14b in the ink container 14c, and a circulation unit 14e for circulating the catalyst layer ink 14b between the die head 14a and the ink container 14c. Furthermore, as shown in Figure 8, the coating section 14 is equipped with a transport plate moving mechanism 39 that raises the adsorption device 12, which has been temporarily stopped in front of the coating section 14 while adsorbing and holding the exposed electrolyte membrane 2 of the first coating substrate Ba or the second coating substrate Ca, and moves the adsorption device 12 horizontally to the coating section 14. Furthermore, the first suction pipe 21a of the adsorption device 12, which has been moved to the coating section 14, is connected to an extendable suction pipe 40 that is connected to the suction pump 8. In addition, the coating section 14 has a mechanism that can accurately measure the gap between the workpiece to be coated, or the surface of the adsorption device 12, and the tip of the die head 14a. By performing a precise measurement before coating and feeding the results back, even more precise coating becomes possible. Note that in Figures 7 and 8, the first coated substrate Ba or the second coated substrate Ca has been simplified for clarity.

[0032] [Drying oven] The drying oven 15 is a device that sequentially heats and dries multiple adsorption devices 12, each adsorbing and holding a first coated substrate Ba or a second coated substrate Ca coated with catalyst layer ink 14b on an adsorption surface 20a. As shown in Figure 9, the drying oven 15 is equipped with multiple shelves 41, and the adsorption devices 12 are placed on each shelf 41. By heating, the ink layer 14f provided on the electrolyte membrane 2 is dried, forming the electrode catalyst layer 3. In addition, the aforementioned conveyor plate moving mechanism 39 is arranged to raise and move the adsorption devices 12 horizontally in order to place the adsorption devices 12 on each shelf 41. Furthermore, as shown in Figure 10, a retractable suction pipe 42 that passes through the wall 151 and is connected to a suction pump 8 outside the drying oven 15 is arranged inside the drying oven 15. By connecting it to the second suction pipe 21b of all the adsorption devices 12 placed on the multiple shelves 41, continuous suction and adsorption of workpieces onto the surface of the adsorption devices 12 is made possible. Note that in Figures 9 and 10, the first coated substrate Ba or the second coated substrate Ca have been simplified for clarity.

[0033] [Mask peeling area] The mask peeling section 15a peels off the first film a2 of the mask section, which will be described later. The mask release section 15a can, for example, grip the first film a2 using an adhesive material or static electricity, and then wind it up from the gripped portion, diagonally upward, or in a roll shape.

[0034] [Visual Inspection Department] The visual inspection unit 16 is a single-wafer type device for inspecting the quality of the electrode catalyst layer 3 formed on the electrolyte membrane 2. As shown in Figure 11, the visual inspection unit 16 is equipped with an inspection camera 43 for inspecting the quality of the electrode catalyst layer 3 formed on the electrolyte membrane 2. The visual inspection unit 16 is also equipped with a transport plate moving mechanism 39 that raises the adsorption device 12, which adsorbs and holds the first coating substrate Ba or the second coating substrate Ca and temporarily stops in front of the visual inspection unit 16, and then moves the adsorption device 12 horizontally to the visual inspection unit 16. Furthermore, the first suction tube 21a of the adsorption device 12 that has moved to the visual inspection unit 16 is connected to an extendable suction tube 44 which is connected to a suction pump 8. Note that in Figure 11, the first coated substrate Ba or the second coated substrate Ca are shown in a simplified form for clarity.

[0035] [Unloader] The unloader 17 is a device that stores the workpiece 4, which has been transported from the visual inspection section 16, into the workpiece stock section 45 or storage area 131c. When the suction device 12 is transported to the unloader 17, the connection between the first suction pipe 21a and the second suction pipe 21b and the suction mechanism 30 is released, as shown in Figure 12. The unloader 17 is equipped with a workpiece suction device 46 that moves between the workpiece stock section 45 and the suction device 12, or between the storage area 131c and the suction device 12. This workpiece suction device 46 picks up the workpiece 4 on the suction device 12 and transports it to the workpiece stock section 45 or the storage area 131c for storage. When the suction device 12 is transported in the first manufacturing process, the unloader 17 transports the workpiece 4 (coated body C) to the storage area 131c, and when the suction device 12 is transported in the second manufacturing process, the unloader 17 transports the workpiece 4 to the workpiece stock section 45. At this time, the unloader 17 is configured to insert interleaving paper between each workpiece 4.

[0036] The interleaving paper is inserted by picking up one sheet at a time from the stocker where the interleaving paper is stacked, using suction or other means. The workpiece 4 is then transported to the workstock section 45 by suction or other means, and while it is in a stationary position, the interleaving paper is transported from the interleaving paper stocker and stacked on top. By repeating this operation, an interleaving sheet is inserted for each workpiece 4 that is stacked in the workstock section 45. Note that in Figure 12, the first coated substrate Ba or the second coated substrate Ca have been simplified for clarity.

[0037] [Control Unit] The control unit 50 is comprised of a CPU that performs various calculations, a ROM that is a read-only memory for storing basic programs, a RAM that is a read-write memory for storing various information, and a magnetic disk for storing control software and data. The CPU of this control unit 50 executes a predetermined processing program, thereby controlling the transport path 11, loader 13, half-cut peeling unit 13a, peeling inspection unit 13b, coating unit 14, drying oven 15, mask peeling unit 15a, appearance inspection unit 16, unloader 17, and suction mechanism 30 provided in the manufacturing apparatus 10 to carry out the manufacturing process of the film electrode assembly 1.

[0038] The control unit 50 controls the rotation and stopping of the drive rollers of the transport path 11, thereby stopping and starting the transport of the suction device 12 on the loader 13 and unloader 17, as well as on the transport path 11 in front of the half-cut peeling section 13a, the peeling inspection section 13b, the coating section 14, the drying oven 15, and the visual inspection section 16. Furthermore, when the control unit 50 receives notification from the mask peeling section 15a that an abnormality has occurred and identifies the first coated substrate Ba or the second coated substrate Ca, it generates an alarm when the unloader 17 stores the transported first coated substrate Ba or second coated substrate Ca in the storage area 131c or the work stock section 45, and performs processing such as storing the corresponding first coated substrate Ba or second coated substrate Ca in a stock area for defective products (not shown).

[0039] [Operation of the suction mechanism] Next, the operation of the suction mechanism 30, which is located along the transport path 11, will be explained with reference to Figures 4(A), (a) to 4(G), (g). The operation of the suction mechanism 30 shown below is also controlled remotely by the control unit 50. The position indicated by the symbol T1 in Figure 4(A) is the position of the suction device 12 that has been transported to the loader 13. First, the upstream branch suction pipe 31a of the first transport suction pipe 31 is connected to the first suction pipe 21a of the suction device 12, making it possible to pick up a workpiece on the suction surface 20a of the suction device 12 (see Figure 4(a)). Next, as shown in Figure 4(B), the second transport suction pipe 32 rises, and the suction pipe 32a is connected to the second suction pipe 21b of the suction device 12, thereby maintaining the state in which the suction surface 20a is capable of picking up a workpiece (see Figure 4(b)). Next, as shown in Figure 4(C), the first transport suction pipe 31 descends, and the upstream branch suction pipe 31a detaches from the first suction pipe 21a of the adsorption device 12. However, the connection between the suction pipe 32a of the second transport suction pipe 32 and the second suction pipe 21b of the adsorption device 12 maintains the state in which the adsorption surface 20a can adsorb a workpiece (see Figure 4(c)).

[0040] Next, as shown in Figure 4(D), the suction device 12 moves downstream due to the rotation of the drive roller, and the second transport suction pipe 32 moves forward due to the drive of the forward and backward moving means (see Figure 4(d)). The position of the suction device 12 indicated by the symbol T2 in Figure 4(D) is the position of the transport path 11 in front of the coating section 14. Next, as shown in Figure 4(E), the first transport suction pipe 31 rises, and the downstream branch suction pipe 31b connects to the first suction pipe 21a of the suction device 12, maintaining the state in which the suction surface 20a can hold a workpiece (see Figure 4(e)). Next, as shown in Figure 4(F), the second transport suction pipe 32 descends, and the suction pipe 32a detaches from the second suction pipe 21b of the suction device 12, but the state in which the suction surface 20a can hold a workpiece is maintained by the connection between the downstream branch suction pipe 31b of the first transport suction pipe 31 and the first suction pipe 21a of the suction device 12 (see Figure 4(f)). Next, as shown in Figure 4(G), the second transport suction pipe 32 retracts due to the drive of the forward and backward movement mechanism (see Figure 4(g)).

[0041] In this way, while the suction device 12 on the loader 13 (position T1) is being transported to the front of the half-cut peeling section 13a (position T2), at least one of the first transport suction pipe 31 and the second transport suction pipe 32 of the suction mechanism 30 is connected to at least one of the first and second suction pipes 21a and 21b of the suction device 12, thereby maintaining a state where the workpiece can be adsorbed onto the suction surface 20a of the suction device 12.

[0042] Furthermore, while the suction device 12 is being transported along the transport path 11 from in front of the half-cut peeling section 13a to in front of the peeling inspection section 13b, while the suction device 12 is being transported along the transport path 11 from in front of the peeling inspection section 13b to in front of the coating section 14, while the suction device 12 is being transported along the transport path 11 from in front of the coating section 14 to in front of the drying oven 15, and while the suction device 12 is being transported along the transport path 11 from in front of the drying oven 15 to in front of the visual inspection section 16, at least one of the first transport suction pipe 31 and the second transport suction pipe 32 of the suction mechanism 30 is connected to at least one of the first and second suction pipes 21a and 21b of the suction device 12, thereby maintaining a state in which the workpiece can be adsorbed onto the suction surface 20a of the suction device 12.

[0043] In this embodiment, the force with which the workpiece is held by the suction surface 20a of the suction device 12 is 0.05 N / 25 mm 2 More than 100N / 25mm 2 The following is set: The force with which the workpiece is held by the suction surface 20a is 0.05 N / 25 mm 2 If the value is smaller than 100N / 25mm, the adsorption force (gripping force) will be insufficient, resulting in ineffective adsorption and affecting various processes. 2 If the size is larger than this, it may result in a coated surface that is affected during coating and inspection, such as leaving pore marks on the adsorption surface 20a or causing the sheet-like material to warp.

[0044] [Lamination device] The bonding apparatus 131 includes, for example, a bonding plate for holding one sheet-like member (e.g., laminated substrate A) and a bonding plate for holding the other sheet-like member (e.g., electrolyte-side substrate B). Each bonding plate holds the objects to be bonded, and the bonding apparatus 131 aligns the objects to be bonded using alignment marks or the like pre-provided on the bonding plates, and bonds the objects to be bonded together by applying pressure with rollers. The bonding apparatus 131 detects the alignment marks pre-provided on each bonding plate, marks provided on at least one of the four sides and four corners of the rectangular half-cut section a5 described later, or the four corners of the half-cut section a5 itself using a camera or sensor to perform positioning. If the four corners of the half-cut section a5 are used as alignment marks, for example, a light source may be provided to illuminate the corners of the half-cut section a5, and the positions of the light source, camera, and sensor may be adjusted to create shadows in the area corresponding to the cut a6, thereby detecting the position of the corners of the half-cut section a5 using the position of the cut a6.

[0045] Furthermore, in the first manufacturing process, the laminating device 131 laminates the laminated substrate A stored in storage area 131a and the electrolyte-side substrate B stored in storage area 131b to form the first coated substrate 2a, and in the second manufacturing process, laminates the laminated substrate A stored in storage area 131a and the coated body C stored in storage area 131c to form the second coated substrate 2b, and transfers them to the stock section 35 of the loader 13. In addition, when the laminating device 131 transfers the first coated substrate 2a and the second coated substrate 2b to the stock section 35, it laminates a protective film 36 onto the side of the first coated substrate 2a and the second coated substrate 2b where the electrolyte membrane 2 is exposed before transfer.

[0046] Furthermore, the bonding apparatus 131 includes a peeling device for peeling off the separator a4 of the laminated substrate A. The peeling device has at least one of the following: a mechanism with suction properties, a mechanism with adhesive properties, a mechanism with a peeling jig that utilizes static electricity, a mechanism that performs mechanical sliding to peel off the separator a4, and a peeling jig that utilizes differences in surface roughness. When the peeling device has multiple of the above mechanisms, it is preferable to appropriately select the mechanism to be applied as the peeling device depending on the adhesion, weight, area, etc. of the material to be peeled off. In particular, for materials with strong adhesion, it is preferable to use a jig with suction or adhesive properties to mechanically slide the material, and to appropriately select the peeling speed, peeling angle, etc. for peeling.

[0047] [Laminated base material] The laminated substrate A has the configuration shown, for example, in the upper part of Figures 13(a) and 14(a). Specifically, the laminated substrate A is formed in a rectangular sheet shape in plan view, and consists of a backing material (process paper) a1 having a three-layer structure, a first film a2 which will become part of the mask portion a7 described later, a second film a3 which will become a sub-gasket, and a separator a4 which are laminated in this order. Adhesive material is provided on the first film a2 side of the backing material a1, on the second film a3 side of the first film a2, and on the separator a4 side of the second film a3, and is formed to be detachable. The separator a4 is provided to prevent the adhesive material of the second film a3 from adhering to other components.

[0048] Furthermore, the separator a4, the second film a3, and the first film a2 are provided with notches a6 that divide only these separator a4, the second film a3, and the first film a2 into a rectangular central portion, which is a half-cut portion a5, and its surrounding portion. In Figure 14(a), the notches a6 are provided with a margin to ensure that the half-cut portion a5 is reliably divided, so that they extend to a part of the backing material a1 on the first film a2 side. For the half-cut section a5, the displacement of each side between the electrolyte membrane 2 and the half-cut section a5 is between 0.1 mm and 50 mm, and the bonding accuracy is ±0.1.

[0049] The laminated substrate A is formed, for example, by the following procedure. That is, as shown in Figure 13(a), a backing material a1, a first film a2, a second film a3, and a separator a4 are laminated in this order. Then, a rectangular frame member corresponding to the rectangle of the half-cut portion a5 is used, and this frame member is pressed from the separator a4 side, and a cut a6 is made by the frame member from the separator a4 to the first film a2, and further to a part of the backing material a1 as a margin, thereby forming a cut a6 in the laminated substrate A that goes from the separator a4 to the first film a2, and further to a part of the backing material a1, as shown in Figure 13(b).

[0050] [Electrolyte-side base material] The electrolyte-side substrate B has, for example, the structure shown in the lower part of Figure 14(a). The electrolyte-side substrate B has a rectangular sheet shape in plan view, formed by laminating a base film b1 and an electrolyte membrane b2.

[0051] [Manufacturing procedure for membrane electrode assemblies] Next, the procedure for manufacturing workpiece 4 using the manufacturing apparatus 10 with the above configuration will be explained with the help of cross-sectional process diagrams shown in Figures 14 to 17. Note that in Figures 14 to 17, gaps are shown between each layer and between the base materials for easier understanding. As described above, the manufacturing apparatus 10 produces a workpiece 4 in the first manufacturing step by applying one of the electrode catalyst layers 3 for the anode or cathode to one side of the electrolyte membrane 2, and in the second manufacturing step, it forms the workpiece 4 by applying the other electrode catalyst layer 3 for the anode or cathode to the other side of the electrolyte membrane 2, which already has one side with the electrode catalyst layer 3 for the anode or cathode. Therefore, the manufacturing apparatus 10 produces the membrane electrode assembly 1 by performing two manufacturing steps to form the workpiece 4 on one side and the other side of the electrolyte membrane 2. Of course, depending on the specifications, it may be sufficient to coat only one side of the electrolyte membrane 2, in which case the membrane electrode assembly 1 can be produced in a single manufacturing step.

[0052] In the manufacturing apparatus 10 shown in Figure 2, multiple laminated substrates A in sheet form as shown in Figure 14(a) are stored in storage area 131a, with interleaving paper between them. Multiple electrolyte-side substrates B in sheet form as shown in Figure 14(a) are stored in storage area 131b, with protective film 36 provided on the side where the electrolyte membrane 2 is exposed. Multiple second coated substrates Ca are stored in storage area 131c, with interleaving paper provided on the side where the electrolyte membrane 2 is exposed.

[0053] The lamination device 131 uses a laminated substrate A (a sheet of laminated substrate) and an electrolyte-side substrate B (a sheet of electrolyte-side substrate) as a set to produce a membrane electrode assembly. Specifically, the lamination device 131 first takes one of the laminated substrates A stored in storage area 131a (Figure 14(a)), removes the interleaving paper, peels off the separator a4 (Figure 14(b)), and holds it with the second film a3 side facing outwards on one lamination plate (not shown) of the lamination device 131. The lamination device 131 also takes one of the electrolyte-side substrates B stored in storage area 131b (Figure 14(a)), removes the protective film 36, and laminates it with the side of the base film b1 opposite to the electrolyte membrane b2 facing down onto the adhesive-deadened backing material b3 (Figure 14(b)), and holds it with the electrolyte membrane b2 side facing outwards on the other lamination plate of the lamination device 131.

[0054] The lamination device 131 uses alignment marks on the lamination plate and cameras or sensors to detect at least one of the sides and corners of the electrolyte membrane b2 and half-cut portion a5, and uses these to position the devices so that the misalignment of each side between the half-cut portion a5 of the laminated substrate A and the electrolyte membrane b2 of the electrolyte-side substrate B is maintained at a set value of ±0.1 mm within a range of 0.1 mm to 50 mm. Then, the adhesive material of the second film a3 is used to bond the second film a3 to the half-cut portion a5 (Figure 14(c)). This forms the first coated substrate Ba, in which the laminated substrate A side and the electrolyte-side substrate B side are bonded together. The lamination device 131 then places a protective film 36 on the backing material a1 side of the formed first coated substrate Ba and transfers it to the stock section 35 of the loader 13.

[0055] When the loader 13 receives an empty adsorption device 12 with no workpiece 4 adsorbed onto its adsorption surface 20a, the coating substrate supply device 37 adsorbs and holds the first coating substrate Ba from the stock section 35 onto the adsorption surface 20a of the adsorption device 12, as shown in Figure 5 (Figure 15(a)). Next, as shown in Figure 6, the adhesive peeling roller 38 is moved toward the first coating substrate Ba that is adsorbed and held on the adsorption surface 20a of the adsorption device 12, and rotates in contact with the protective film 36, thereby peeling the protective film 36 from the first coating substrate Ba and winding it up. In some cases, the loader 13 may also continuously transport workpieces that have been bonded with the electrolyte membrane 2 in the previous process from the bonding device.

[0056] Next, when the adsorption device 12 is transported from the loader 13 to the half-cut peeling section 13a with the first coated substrate Ba adsorbed and held on the adsorption surface 20a, as shown in Figure 8, the retractable suction pipe 40 connected to the suction pump 8 is connected to the first suction pipe 21a of the adsorption device 12, and the transport plate moving mechanism 39 moves the adsorption device 12 from the transport path 11 to the half-cut peeling section 13a. Then, in the half-cut peeling section 13a, the backing material a1 is peeled off (Figure 15(b)), and then the half-cut section a5 is peeled off (Figure 15(c)). As a result, the electrolyte membrane 2 is exposed, and the electrolyte membrane 2 is surrounded by the portion of the laminate of the first film a2 and the second film a3 from which the half-cut section a5 has been removed. This portion of the laminate of the first film a2 and the second film a3 from which the half-cut section a5 has been removed becomes the mask section a7. Then, the conveyor plate moving mechanism 39 returns the suction device 12, which has undergone the peeling process of the half-cut section a5, from the half-cut peeling section 13a to the conveyor path 11.

[0057] Next, as the adsorption device 12 is transported from the half-cut peeling section 13a to the peeling inspection section 13b, with the first coated substrate Ba adsorbed and held on the adsorption surface 20a, the retractable suction tube 40 connected to the suction pump 8 is connected to the first suction tube 21a of the adsorption device 12, and the transport plate moving mechanism 39 moves the adsorption device 12 from the transport path 11 to the peeling inspection section 13b. Then, in the peeling inspection section 13b, the surface of the electrolyte membrane b2 exposed by peeling off the half-cut section a5 is irradiated with a UV light to confirm that no half-cut section a5 or other foreign matter remains on the electrolyte membrane b2. If any foreign matter, such as a part of the half-cut section a5, remains on the surface of the electrolyte membrane b2, for example, the control unit 50 is notified that there is an abnormality, along with identification information that identifies the first coated substrate Ba to be inspected. Then, the conveyor tray moving mechanism 39 returns the suction device 12, which has been inspected in the peeling inspection section 13b, from the peeling inspection section 13b back to the conveyor path 11.

[0058] Next, the adsorption device 12, with the first coating substrate Ba adsorbed and held on the adsorption surface 20a, is transported from the peel inspection section 13b to the front of the coating section 14. As shown in Figure 8, the retractable suction tube 40 connected to the suction pump 8 is connected to the first suction tube 21a of the adsorption device 12, and the transport plate moving mechanism 39 moves the adsorption device 12 from the transport path 11 to the coating section 14, positioning it so that the electrolyte membrane b2 is located below the die head 14a, as shown in Figure 7. Then, the die head 14a is moved in the coating direction indicated by the arrow to provide the ink layer 14f on the electrolyte membrane b2 (Figure 15(d)). The transport plate moving mechanism 39 then returns the adsorption device 12, with the ink layer 14f on the electrolyte membrane b2, from the coating section 14 to the transport path 11. At this time, since the electrolyte membrane b2 is surrounded by the mask section a7, the mask section a7 acts as a mask, and the ink layer 14f is provided on the electrolyte membrane b2.

[0059] Next, as the adsorption devices 12, each with an ink layer 14f on an electrolyte membrane b2, are transported from the front of the coating section 14 to the transport path 11 in front of the drying oven 15, the transport panel moving mechanism 39 places the adsorption devices 12 on any available shelves 41 of the multiple shelves 41 of the drying oven 15, as shown in Figure 9. Then, as shown in Figure 10, the suction pipes 42 are connected to the second suction pipes 21b of all the adsorption devices 12 placed on the shelves 41 of the drying oven 15. When the adsorption devices 12 placed on the shelves 41 of the drying oven 15 are heated and dried for a certain period of time, the solvent components volatilize and solidify from the ink layer 14f, forming a workpiece 4 with an electrode catalyst layer 3 on an electrolyte membrane b2. Then, the conveyor tray moving mechanism 39 returns the suction device 12, on which the dried workpiece 4 is being held, from the designated shelf section 41 back to the conveyor path 11.

[0060] Next, the adsorption device 12, which has adsorbed the workpiece 4, is transported from in front of the drying oven 15 to the transport path 11 in front of the mask peeling section 15a, and the mask peeling section 15a peels off the first film a2 (Figure 15(e)). Then, the transport plate moving mechanism 39 returns the adsorption device 12, which has peeled off the first film a2, from the coating section 14 to the transport path 11. The remaining second film a3 becomes a sub-gasket on one side of the electrolyte membrane b2. Next, when the suction device 12, which has adsorbed the workpiece 4, is transported from in front of the mask peeling section 15a to the transport path 11 in front of the visual inspection section 16, as shown in Figure 11, the retractable suction tube 44 connected to the suction pump 8 is connected to the first suction tube 21a of the suction device 12, and the transport plate moving mechanism 39 moves the suction device 12 from the transport path 11 to below the inspection camera 43. The inspection camera 43 then inspects the appearance of the electrode catalyst layer 3 (Figure 15(f)). Then, the transport panel moving mechanism 39 returns the suction device 12, which has picked up the workpiece 4 after the inspection by the inspection camera 43 has finished, from the visual inspection unit 16 back to the transport path 11.

[0061] Next, when the suction device 12, which has picked up the workpiece 4, is transported from the front of the visual inspection section 16 to the unloader 17, the connection between the first suction pipe 21a and the second suction pipe 21b and the suction mechanism 30 is released. As shown in Figure 12, the unloader 17 is equipped with a workpiece suction device 46 that moves between the storage area 131c and the workpiece stock section 45 and the suction device 12. This workpiece suction device 46 picks up the workpiece 4 on the suction device 12 and transports it to the storage area 131c as a coated body C for storage. In the unloader 17, the coated body C is stored in the storage area 131c with interleaving paper in place (Figure 15(g)). This completes the first manufacturing process.

[0062] Next, when performing the second manufacturing process, the laminating device 131 takes one of the laminated substrates A stored in storage area 131a (Figure 16(a)), removes the interleaving paper, peels off the separator a4 (Figure 16(b)), and holds it with the second film a3 side facing outwards on one laminating plate of the laminating device 131. The laminating device 131 also takes one of the coated bodies C stored in storage area 131c, removes the interleaving paper, turns the backing material b3 side facing outwards (Figure 16(a)), peels off the backing material b3 (Figure 16(b)), and peels off the base film b1 (Figure 16(b)). Then, with the exposed electrolyte membrane b2 side facing outwards, it holds it with the other laminating plate of the laminating device 131. In other words, the lamination apparatus 131 peels off the base film b1, considers the laminate consisting of the second film a3 and the electrode catalyst layer 3 as a component equivalent to the base film, considers this component equivalent to the base film and the electrode catalyst layer 3 laminated on it as a sheet of electrolyte-side substrate, sets this sheet of electrolyte-side substrate and laminated substrate A (sheet of laminated substrate) together, and uses these to produce a membrane electrode assembly in the same manner as in the first manufacturing process.

[0063] In other words, the lamination device 131 positions and laminates the laminated substrate A and the electrolyte membrane b2 of the coated body C based on alignment marks provided on the lamination plate so that the amount of misalignment of each side is maintained within a set range of 0.1 mm to 50 mm (Figure 16(c)). As a result, a second coated substrate Ca is formed in which the laminated substrate A side and the coated body C side are laminated by the adhesive of the second film a3. The lamination device 131 then laminates the protective film 36 onto the formed second coated substrate Ca and transfers it to the stock section 35 of the loader 13.

[0064] Similar to the first manufacturing process, when an empty suction device 12 with no workpiece 4 attached to the suction surface 20a is transported by the loader 13, the loader 13 adsorbs and holds the second coating substrate Ca from the stock section 35 onto the suction surface 20a of the suction device 12 (Figure 17(a)), and peels the protective film 36 from the second coating substrate Ca and winds it up. At this time, the second film layer a3, which is included in the first coating substrate Ba in the first manufacturing process and is contained in the second coating substrate Ca, is held so as to face the suction surface 20a of the suction device 12.

[0065] Next, when the adsorption device 12 is transported from the loader 13 to the half-cut peeling section 13a with the second coating substrate Ca adsorbed and held on the adsorption surface 20a, the half-cut peeling section 13a peels off the backing material a1 (Figure 17(b)), and then peels off the half-cut section a5 to form the mask section a7 (Figure 17(c)). Then, when the adsorption device 12 is transported from the half-cut peeling section 13a to the peeling inspection section 13b with the second coating substrate Ca adsorbed and held on the adsorption surface 20a, UV irradiation is performed in the peeling inspection section 13b to check whether any part of the half-cut section a5 remains on the surface of the electrolyte membrane b2. In the peel inspection section 13b, it is confirmed that no part of the half-cut section a5 remains on the surface of the electrolyte membrane b2. When the adsorption device 12, which has the second coating substrate Ca adsorbed and held on the adsorption surface 20a, is transported from the peel inspection section 13b to the coating section 14, the coating section 14 applies an ink layer 14f on the electrolyte membrane b2 using the mask section a7 as a mask (Figure 17(d)).

[0066] Next, the adsorption device 12, which has an ink layer 14f on the electrolyte membrane b2, is transported from the front of the coating section 14 to the transport path 11 in front of the drying oven 15. The adsorption device 12 is then placed on an empty shelf 41 of the multiple shelves 41 of the drying oven 15. The adsorption device 12 placed on the shelf 41 is then heated and dried for a certain period of time, forming a workpiece 4 with an electrode catalyst layer 3 on the electrolyte membrane b2. As a result, electrode catalyst layers 3 are formed on both sides of the electrolyte membrane b2. Next, the adsorption device 12, which has adsorbed the workpiece 4, is transported from the front of the drying oven 15 to the transport path 11 in front of the mask peeling section 15a. At the mask peeling section 15a, the first film a2 is peeled off (Figure 17(e)). The remaining second film a3 becomes a sub-gasket on the other side of the electrolyte membrane b2.

[0067] Next, when the adsorption device 12, which has adsorbed the workpiece 4, is transported from in front of the mask peeling section 15a to the transport path 11 in front of the visual inspection section 16, the visual inspection section 16 inspects the appearance of the electrode catalyst layer 3 using the inspection camera 43 (Figure 17(f)). Next, when the adsorption device 12, which has adsorbed the workpiece 4, is transported from the front of the visual inspection section 16 to the unloader 17, the unloader 17 transports the workpiece 4, which has completed the second manufacturing process, that is, the membrane electrode assembly 1a shown in Figure 1, in which electrode catalyst layers 3 have been formed on both sides of the electrolyte membrane b2 and a second film a3 as a sub-gasket is provided on both sides of the electrolyte membrane 2, that is, the membrane electrode assembly 1 protected by the sub-gasket (second film a3), to the workstock section 45 for storage.

[0068] [Effects of the manufacturing apparatus and manufacturing method according to the present invention] Next, the effects of the manufacturing apparatus 10 for the membrane electrode assembly 1 according to the present invention will be described. In the manufacturing method of the membrane electrode assembly 1 described above, the entire surface of the first coating substrate Ba and the second coating substrate Ca are uniformly adsorbed and held on the flat adsorption surface 20a of the adsorption device 12 in the loader 13. In the coating section 14, the ink layer 14f is applied while maintaining the adsorption hold of the first coating substrate Ba and the second coating substrate Ca. In the drying oven 15, the ink layer 14f is dried while maintaining the adsorption hold of the first coating substrate Ba and the second coating substrate Ca. As a result, no swelling or shrinkage occurs in the electrolyte membrane b2 after drying, and a high-quality membrane electrode assembly 1 can be manufactured.

[0069] Furthermore, the loader 13 is a single-wafer type in which the first coated substrate Ba and the second coated substrate Ca are adsorbed and held by each individual adsorption device 12, and the coating section 14 is also a single-wafer type in which the ink layer 14f is coated onto the first coated substrate Ba and the second coated substrate Ca of each individual adsorption device 12. In the drying oven 15, multiple adsorption devices 12, each adsorbing and holding the first coated substrate Ba and the second coated substrate Ca coated with the ink layer 14f, are sequentially heated and dried on multiple shelves 41, and the adsorption devices 12 that have completed drying are carried out of the drying oven 15. Therefore, compared to conventional manufacturing methods that use adsorption rollers, which require slowing down the rotation speed to extend the drying time, the production efficiency of the film electrode assembly 1 can be significantly improved.

[0070] Furthermore, the suction device 12 holds the workpiece by adsorption to the suction surface 20a of the suction part 20, but with a force of 0.2N / 25mm 2 More than 100N / 25mm 2 As it is set as follows, there is no risk of insufficient suction force or of leaving holes in the workpiece from the suction surface 20a. Furthermore, the adsorption part 20 is a porous material with an average pore diameter of 0.5 μm to 1200 μm on its adsorption surface 20a, a surface opening ratio of 10% to 85%, and a thickness of 0.5 mm to 100 mm, so it can generate a stable suction force from the entire adsorption surface 20a.

[0071] Furthermore, the adsorption device 12 that moves along the transport path 11 from the loader 13 to the visual inspection section 16 is connected to the suction mechanism 30, thereby maintaining the adsorption and retention of the first coated substrate Ba and the second coated substrate Ca. In addition, the adsorption devices 12 housed in the coating section 14 and the drying oven 15 are also connected to the suction pump 8 via suction pipes 40 and 42, thereby maintaining the adsorption and retention of the first coated substrate Ba and the second coated substrate Ca, so that the first coated substrate Ba and the second coated substrate Ca can be transported reliably and stably.

[0072] Furthermore, the adsorption device 12 is formed of an adsorption section 20 made of a porous material, a base section 19 made of a heat-resistant material such as granite or heat-resistant glass, and a transport case 18 made of a heat-resistant and impact-resistant synthetic resin or the like that houses the adsorption section 20 and the base section 19, and is structured to fully accommodate heat-resistant use in the drying oven 15. Furthermore, MEAs are generally produced by directly coating an electrolyte membrane with a catalyst ink, which consists of catalyst particles containing platinum (Pt) dispersed in a solvent such as water or alcohol, and then drying the coating, or by transferring a coated film made on a separate sheet onto the electrolyte membrane. In either method, it is necessary to have the catalyst ink coated in a fixed shape. In that case, intermittent coating or masking is used to form a fixed coated film.

[0073] Masking requires a mask material with a fixed shape, which needs to be laminated with the electrolyte membrane or other materials. In particular, to form a MEA by directly coating a catalyst layer onto the electrolyte membrane, a substrate equipped with mask material on one or both sides of the electrolyte membrane is required. For example, a coated substrate can be obtained by laminating a substrate with openings to the electrolyte membrane in a roll-shaped sheet, but in this case, the electrolyte membrane will be present even in areas that do not contribute to the battery reaction. Because electrolyte membranes are very expensive, even if the lamination process is easy, it is cost-ineffective to include them in unnecessary areas. Therefore, it is desirable to use electrolyte membranes only in the minimum necessary areas.

[0074] In this embodiment, an electrolyte membrane is prepared by cutting a single sheet several millimeters larger than the opening and precisely bonding it to the opening. This allows the electrolyte membrane to be positioned only where necessary in relation to the catalyst layer. Therefore, it is cost-effective without affecting battery performance. In the above embodiment, the case where the laminating device 131 is a sheet-type device was described, but it can also be applied to a roll-type device. Furthermore, while Figure 3(c) illustrates an adsorption device 12 that adsorbs one electrolyte membrane 2 by providing a rectangular frame-shaped closure plate 25 on the outer periphery of the upper surface of the adsorption unit 20, the gist of the present invention is not limited to this. For example, an adsorption device 12 that adsorbs multiple electrolyte membranes 2 may be provided by providing a closure plate with multiple rectangular openings on the upper surface of the adsorption unit 20.

[0075] Furthermore, in the operation of the suction mechanism 30, which is arranged along the transport path shown in Figures 4(A), (a) to (G), and (g), it was explained that the first and second suction pipes 21a and 21b of the adsorption device 12 are connected to either the first transport suction pipe 31 or the second transport suction pipe 32 of the suction mechanism 30. However, if a third suction pipe (not shown) is provided in the adsorption device 12 and can be connected to the first transport suction pipe 31 and the second transport suction pipe 32, the handling of the first transport suction pipe 31 and the second transport suction pipe 32 can be made easier when the suction mechanism 30 is in operation.

[0076] Furthermore, although the adsorption device 12 is a device in which an adsorption section 20 formed of a porous material and a base section 19 with suction passages (main suction passage 23, branch suction passage 24) formed inside are stacked, the gist of the present invention is not limited to this. That is, as another example of the first example of an adsorption device, an adsorption device can be considered in which suction holes are formed on the side of the adsorption section 20, without suction passages in the base section 19, and a suction pipe with a check valve 22 is connected to these suction holes so that it can be freely connected to the suction mechanism 30. Also, as another example of the second example of an adsorption device, a spacer made of synthetic resin or the like, which also has suction passages, is interposed between the lower part of the adsorption section 20 and the upper surface of the base section 19, and a suction pipe with a check valve 22 is connected to a suction hole communicating with the suction passage of this spacer so that it can be freely connected to the suction mechanism 30. Even if other examples of the first and second examples of adsorption devices are used, the production efficiency of the membrane electrode assembly 1 can be improved.

[0077] Furthermore, if the workpiece 4 is held by adsorption on the adsorption surface 20a of the adsorption unit 20, and a frame-shaped support is positioned on top of the workpiece 4 from above, the holding of the workpiece 4 becomes even more secure, enabling stable transport operation. The embodiments described above are merely examples of the present invention, and the present invention is not limited to the embodiments described above. Various modifications can be made to forms other than those described above, as long as they do not depart from the technical spirit of the present invention, depending on the design and other factors. [Explanation of symbols]

[0078] 1 Membrane electrode assembly for fuel cells 2 Electrolyte membrane 3 Electrode catalyst layer 4 Work 8. Suction pump (external suction means) 10 Manufacturing equipment 11 Conveyor path 11a,11b Koro 12 Adsorption device 13 Loaders 13a Half-cut peeled section 13b Peeling Inspection Section 14. Coating Section 14a Die head 14b Ink for catalyst layer 14c Ink Container 14d Stirring section 14e Circulation section 14f ink layer 15 Drying oven 15a Mask peeling area 16. Visual Inspection Department 17 Unloader 18 Transport Cases 18a opening 18b bottom 19. Base 19a Top side 20 Adsorption part 20a Adsorption surface 21a 1st suction tube 21b 2nd suction tube 22 Check valve 23 Main suction path 24 Branch suction path 25 Occlusion plate 25a opening 30 Suction mechanism 31. First transport suction tube 31a Upstream branch suction pipe 31b Downstream branch suction pipe 32. Second transport suction tube 32a Suction tube 35 Stock section 36 protective films 37 Coating substrate supply device 38 Adhesive release roller 39. Transport panel moving mechanism 40,42,44 Suction tube (external suction means) 41 Shelf 43 Inspection camera 45 Workstock area (storage area) 46 Workpiece suction device 50 Control Unit 131 Laminating device 131a Storage location 131b Storage location 131c Storage location A Laminated substrate a1 Backing material a2 First film a3 2nd film A4 Separator a5 Half-cut section a6 cut a7 Mask section B Electrolyte side base material b1 Base film b2 Electrolyte membrane b3 Backing material C Coated body Ba First coated substrate Ca Second Coating Substrate

Claims

1. The process involves preparing a laminated substrate having a rectangular shape in plan view, wherein a backing material, a first film, and a second film are laminated in this order, and the first and second films are provided with cuts that divide only the first and second films into a rectangular central portion called a half-cut portion and a surrounding portion, and an electrolyte-side substrate having a rectangle larger than the half-cut portion in plan view, wherein an electrolyte membrane and a base film are laminated together, A step of obtaining a first coated substrate by bonding the laminated substrate and the electrolyte-side substrate such that the second film and the electrolyte membrane face each other and the electrolyte membrane covers the entire surface of the half-cut portion, A step of adsorbing the base film of the first coated substrate onto an adsorption device to hold the first coated substrate on the adsorption device, The process involves transporting the material while maintaining the adsorbed and held state, peeling off the backing material and the half-cut portion of the laminated substrate contained in the first coated substrate, and forming a mask portion surrounding the exposed electrolyte membrane. The process involves transporting the material while maintaining the adsorbed and held state, applying catalyst layer ink onto the electrolyte membrane using the mask portion as a mask, and then drying it. The process involves transporting the material while maintaining the adsorption-held state, peeling off only the first film from the mask portion to obtain a coated body in which an electrode catalyst layer is formed on one side of the electrolyte membrane, and then releasing the adsorption-held state. A method for manufacturing a sheet for forming a membrane electrode assembly, characterized by having the following features.

2. A method for manufacturing a membrane electrode assembly, The process involves preparing a laminated substrate having a rectangular shape in plan view, wherein a backing material, a first film, and a second film are laminated in this order, and the first and second films are provided with cuts that divide only the first and second films into a rectangular central portion called a half-cut portion and a surrounding portion, and an electrolyte-side substrate having a rectangle larger than the half-cut portion in plan view, wherein an electrolyte membrane and a base film are laminated together, A step of obtaining a first coated substrate by bonding the laminated substrate and the electrolyte-side substrate such that the second film and the electrolyte membrane face each other and the electrolyte membrane covers the entire surface of the half-cut portion, A step of adsorbing the base film of the first coated substrate onto an adsorption device to hold the first coated substrate on the adsorption device, The process involves transporting the material while maintaining the adsorbed and held state, peeling off the backing material and the half-cut portion of the laminated substrate contained in the first coated substrate, and forming a mask portion surrounding the exposed electrolyte membrane. The process involves transporting the material while maintaining the adsorbed and held state, applying catalyst layer ink onto the electrolyte membrane using the mask portion as a mask, and then drying it. The process involves transporting the material while maintaining the adsorbed and held state, peeling off only the first film from the mask portion to obtain the coated body, and then releasing the adsorbed and held state. A step of preparing a new laminated substrate, A step of peeling off the base film of the coated body, A step of obtaining a second coated substrate by laminating the new laminated substrate and the coated body such that the second film of the new laminated substrate and the electrolyte membrane of the coated body face each other and the electrolyte membrane covers the entire half-cut portion of the new laminated substrate, A step of adsorbing the second film of the second coated substrate onto an adsorption device to hold the second coated substrate on the adsorption device, The process involves transporting the second coated substrate while maintaining the adsorbed and held state, peeling off the backing material and the half-cut portion of the laminated substrate contained in the second coated substrate, and forming a mask portion surrounding the exposed electrolyte membrane. The process involves transporting the material while maintaining the adsorbed and held state, applying catalyst layer ink onto the electrolyte membrane using the mask portion as a mask, and then drying it. The process involves transporting the material while maintaining the adsorbed and held state, peeling off the first film from the mask portion to obtain the film electrode assembly, and then releasing the adsorbed and held state. A method for manufacturing a membrane electrode assembly, characterized by comprising the following:

3. The method for manufacturing a membrane electrode assembly according to claim 2, characterized in that, in a plan view, the displacement of each side between the electrolyte membrane and the half-cut portion is 0.1 mm or more and 50 mm or less.

4. The step of obtaining the first coated substrate includes the step of providing a backing material on the side of the base film opposite to the electrolyte membrane before bonding the laminated substrate and the electrolyte-side substrate, The method for manufacturing a film electrode assembly according to claim 2 or 3, characterized in that, in the step of adsorbing the first coated substrate onto the adsorption device, the base film is adsorbed via the backing material.

5. A method for manufacturing a membrane electrode assembly according to any one of claims 2 to 4, characterized by comprising a step of inspecting for any remaining peeling after peeling off the half-cut portion.

6. A method for manufacturing a film electrode assembly according to any one of claims 2 to 5, characterized in that, after obtaining the coated body and after obtaining the film electrode assembly, a step is taken to perform an appearance inspection of the catalyst layer formed by drying the catalyst layer ink.

7. A set of sheets for generating a membrane electrode assembly used in a method for manufacturing a membrane electrode assembly according to any one of claims 2 to 6, A set of sheets for forming a membrane electrode assembly, comprising: a sheet of laminated substrate having a rectangular shape in plan view, in which a backing material, a first film, and a second film are laminated in that order, and the first film and the second film are provided with cuts that divide only the first film and the second film into a rectangular central half-cut portion and a surrounding portion; and a sheet of electrolyte-side substrate having a rectangle larger than the half-cut portion in plan view, in which an electrolyte membrane and a base film are laminated.

8. The process involves preparing a laminated substrate having a rectangular shape in plan view, wherein a backing material, a first film, and a second film are laminated in this order, and the first and second films are provided with cuts that divide only the first and second films into a rectangular central portion called a half-cut portion and a surrounding portion, and an electrolyte-side substrate having a rectangle larger than the half-cut portion in plan view, wherein an electrolyte membrane and a base film are laminated together, A step of obtaining a first coated substrate by bonding the laminated substrate and the electrolyte-side substrate such that the second film and the electrolyte membrane face each other and the electrolyte membrane covers the entire surface of the half-cut portion, A step of adsorbing the base film of the first coated substrate onto an adsorption device to hold the first coated substrate on the adsorption device, The process involves transporting the material while maintaining the adsorbed and held state, peeling off the backing material and the half-cut portion of the laminated substrate contained in the first coated substrate, and forming a mask portion surrounding the exposed electrolyte membrane. The process involves transporting the material while maintaining the adsorbed and held state, applying catalyst layer ink onto the electrolyte membrane using the mask portion as a mask, and then drying it. The process involves transporting the material while maintaining the adsorption-held state, peeling off only the first film from the mask portion to obtain a coated body in which an electrode catalyst layer is formed on one side of the electrolyte membrane, and then releasing the adsorption-held state. A manufacturing apparatus for membrane electrode assemblies, characterized by being configured to perform the following actions.

9. A manufacturing apparatus for membrane electrode assemblies, The process involves preparing a laminated substrate having a rectangular shape in plan view, wherein a backing material, a first film, and a second film are laminated in this order, and the first and second films are provided with cuts that divide only the first and second films into a rectangular central portion called a half-cut portion and a surrounding portion, and an electrolyte-side substrate having a rectangle larger than the half-cut portion in plan view, wherein an electrolyte membrane and a base film are laminated together, A step of obtaining a first coated substrate by bonding the laminated substrate and the electrolyte-side substrate such that the second film and the electrolyte membrane face each other and the electrolyte membrane covers the entire surface of the half-cut portion, A step of adsorbing the base film of the first coated substrate onto an adsorption device to hold the first coated substrate on the adsorption device, The process involves transporting the material while maintaining the adsorbed and held state, peeling off the backing material and the half-cut portion of the laminated substrate contained in the first coated substrate, and forming a mask portion surrounding the exposed electrolyte membrane. The process involves transporting the material while maintaining the adsorbed and held state, applying catalyst layer ink onto the electrolyte membrane using the mask portion as a mask, and then drying it. The process involves transporting the material while maintaining the adsorbed and held state, peeling off only the first film from the mask portion to obtain the coated body, and then releasing the adsorbed and held state. A step of preparing a new laminated substrate, A step of peeling off the base film of the coated body, A step of obtaining a second coated substrate by laminating the new laminated substrate and the coated body such that the second film of the new laminated substrate and the electrolyte membrane of the coated body face each other and the electrolyte membrane covers the entire half-cut portion of the new laminated substrate, A step of adsorbing the second film of the second coated substrate onto an adsorption device to hold the second coated substrate on the adsorption device, The process involves transporting the second coated substrate while maintaining the adsorbed and held state, peeling off the backing material and the half-cut portion of the laminated substrate contained in the second coated substrate, and forming a mask portion surrounding the exposed electrolyte membrane. The process involves transporting the material while maintaining the adsorbed and held state, applying catalyst layer ink onto the electrolyte membrane using the mask portion as a mask, and then drying it. The process involves transporting the material while maintaining the adsorbed and held state, peeling off the first film from the mask portion to obtain the film electrode assembly, and then releasing the adsorbed and held state. A manufacturing apparatus for a membrane electrode assembly, characterized by being configured to perform the following actions.

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