Asymmetric Thermal Compression for Reinforced Electrolyte Membranes

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Solution Overview

Problem

The existing reinforced electrolyte membranes lack consideration for the elastic modulus on the cathode and anode sides, which affects the power generation performance and manufacturing efficiency, necessitating a method to enhance strength and bonding of the catalyst layers while reducing manufacturing costs.

Innovation Solution

A method involving thermal compression of reinforcing films on both surfaces of the electrolyte membrane, where the first reinforcing film is compressed multiple times to enhance strength and the second reinforcing film is compressed fewer times to achieve a lower surface elastic modulus, facilitating better bonding of the cathode catalyst layer and improving power generation performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the number of times of thermally compressing the second reinforcing film is increased to enhance strength, then the strength of the reinforced electrolyte membrane is improved, but the surface elastic modulus of the second reinforcing film side becomes too high, which deteriorates the bonding performance of the cathode catalyst layer

Engineering Contradiction:

Improvestrength of reinforced electrolyte membraneVSAvoidbonding performance of cathode catalyst layer

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent applies different numbers of thermal compression cycles to different sides of the electrolyte membrane: the first reinforcing film (anode side) is thermally compressed two or more times to achieve high strength, while the second reinforcing film (cathode side) is thermally compressed only once to maintain lower surface elastic modulus. This local differentiation of compression cycles allows each side to have optimized properties for its specific function.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent creates an asymmetric compression process where the number of thermal compression cycles applied to each reinforcing film is deliberately made different. The anode side receives more compression cycles than the cathode side, creating asymmetric surface elastic moduli that match the different requirements of anode and cathode catalyst layers.

Inventive Principle:

Principle #4Asymmetry

2Strength

If the number of times of thermally compressing the first reinforcing film is increased to enhance strength, then the strength of the reinforced electrolyte membrane is improved, but the manufacturing process becomes more complex and time-consuming

Engineering Contradiction:

Improvestrength of reinforced electrolyte membraneVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent performs preliminary thermal compression of the first reinforcing film two or more times before final assembly, ensuring the anode side achieves the required strength and surface elastic modulus in advance. This preliminary action allows the subsequent cathode side compression to be simplified to just one cycle.

Inventive Principle:

Principle #10Preliminary action

3Strength

If the cathode catalyst layer is placed on the first reinforcing film side with higher surface elastic modulus, then the strength of the membrane electrode assembly is improved, but the bonding performance deteriorates and power generation performance decreases

Engineering Contradiction:

Improvestrength of membrane electrode assemblyVSAvoidpower generation performance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent creates local quality differences in surface elastic modulus on each side of the electrolyte membrane by applying different numbers of thermal compression cycles. The cathode side is specifically optimized with lower surface elastic modulus to match the requirements of the cathode catalyst layer, ensuring optimal bonding and power generation performance.

Inventive Principle:

Principle #3Local quality

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This approach results in a reinforced electrolyte membrane with improved power generation performance and manufacturing efficiency, ensuring sufficient strength and enhanced adhesiveness of the cathode catalyst layer, leading to better overall performance of the membrane electrode assembly.

Implementation Method 1

process of thermally compressing the first reinforcing film and the second reinforcing film to the electrolyte membrane

Methodology Applied

Scientific EffectThermal compression: Heating

Data Source

PatentUS9793565B2Method of manufacturing reinforced electrolyte membrane, method of manufacturing membrane electrode assembly, and membrane electrode assembly

Publication Date: 2017.10.17 TOYOTA JIDOSHA KK

AI summary

An object is to provide a technique that improves the power generation performance, while enhancing the strength of a reinforced electrolyte membrane. There is provided a method of manufacturing a reinforced electrolyte membrane that comprises a first reinforcing film on one surface of an electrolyte membrane and a second reinforcing film on the other surface of the electrolyte membrane. The method of manufacturing the reinforced electrolyte membrane comprises (a) process of thermally compressing the first reinforcing film and the second reinforcing film to the electrolyte membrane. In the process (a), a number of times of thermally compressing the second reinforcing film to the electrolyte membrane is less than a number of times of thermally compressing the first reinforcing film to the electrolyte membrane.