Fuel Cell Adhesive Application via Screen Printing Inversion

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Solution Overview

Problem

The existing manufacturing methods for fuel-cell single cells face challenges with high-viscosity adhesives, as they tend to stick to screen printing plates due to the adhesive's viscosity, and solvent evaporation degrades catalyst performance, reducing fuel cell efficiency.

Innovation Solution

A manufacturing method where the adhesive is applied to a resin frame by screen printing while fixing it with suction, allowing for firm fixation and reducing solvent content, enabling easy assembly and minimizing catalyst poisoning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If the solvent content in the adhesive is reduced to prevent catalyst poisoning, then the harmful effect is reduced, but the viscosity of the adhesive increases making it difficult to apply by screen printing

Engineering Contradiction:

Improvecatalyst poisoning by solventVSAvoidadhesive application by screen printing

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

Instead of applying adhesive to the MEA (conventional method), the patent inverts the approach by applying adhesive to the resin frame. This inversion allows the use of high-viscosity, low-solvent adhesive while avoiding the sticking problem that occurs when such adhesive is applied to the porous gas diffusion layer during conventional screen printing

Inventive Principle:

Principle #13The other way round (Inversion)

2Object-affected harmful factors

If the adhesive viscosity is increased by reducing solvent content, then the harmful effect on catalyst is reduced, but the adhesive sticks to the screen printing plate during application

Engineering Contradiction:

Improvecatalyst degradationVSAvoidadhesive sticking to screen printing plate

Core Design Contradiction:

Object-affected harmful factorsVSObject-generated harmful factors

Solution Approach 1:

The patent applies adhesive to the resin frame instead of the MEA, inverting the conventional application target. This inversion prevents the high-viscosity adhesive from sticking to the screen printing plate while still achieving proper bonding, as the resin frame provides a stable, non-porous surface for adhesive application

Inventive Principle:

Principle #13The other way round (Inversion)

3Ease of operation

If the gas diffusion layer is fixed by suction during screen printing, then the MEA can be positioned, but the porous structure makes it difficult to firmly fix the gas diffusion layer

Engineering Contradiction:

ImproveMEA positioning during screen printingVSAvoidfixation stability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

Instead of suction-fixing the porous gas diffusion layer (conventional method), the patent inverts the approach by suction-fixing the resin frame. The resin frame's non-porous structure provides reliable fixation, eliminating the instability associated with suction-fixing porous materials

Inventive Principle:

Principle #13The other way round (Inversion)

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 method allows for the effective use of high-viscosity adhesives without sticking issues and reduces solvent-induced catalyst degradation, enhancing fuel cell performance and manufacturing efficiency.

Implementation Method 1

a first step of applying an adhesive by screen printing to a predetermined area of the resin frame while fixing the resin frame by suction

Methodology Applied

Scientific EffectSuction: Suction

Data Source

PatentUS11482715B2Manufacturing method of fuel-cell single cell

Publication Date: 2022.10.25 TOYOTA JIDOSHA KK

AI summary

Provided is a manufacturing method of a fuel-cell single cell including a membrane-electrode assembly, an anode gas diffusion layer, a cathode gas diffusion layer, and a frame-shaped resin frame to which a peripheral edge portion of the membrane-electrode assembly is fixed. The method includes an adhesive application step of applying an adhesive by screen printing to a predetermined area of the resin frame while fixing the resin frame by suction, and a stacking step and a UV irradiation step of bonding together the resin frame to which the adhesive has been applied and the membrane-electrode assembly by the adhesive.