Fuel Cell Electrode Bonding With Spray-Applied Ionomer Particles
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Solution Overview
Problem
Conventional fuel cells face issues with unstable electricity generation due to liquid water accumulation between electrode layers and gas diffusion layers, leading to deformation and breakage during thermo-compression bonding, and require the use of adhesives and additional film members, increasing facility costs and person hours.
Innovation Solution
The fuel cell employs ionomer particles on the surface of the gas diffusion layer to bond with the electrode layer through thermo-compression, utilizing an anchor effect for a strong bond without adhesives, allowing gas passage and reducing ionomer infiltration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive layers are used to bond electrode layers and gas diffusion layers, then bonding performance is improved, but thermal expansion causes membrane electrode assembly to deform and break
Solution Approach 1:
The patent removes the adhesive layer from the structure, replacing it with direct bonding between the gas diffusion layer and electrode layer through ionomer particles. This extraction eliminates the source of thermal expansion problems while maintaining bonding function through alternative mechanisms.
Solution Approach 2:
The patent changes the bonding mechanism from adhesive-based to ionomer particle-based bonding. By utilizing the ionomer's thermal properties and electrostatic adhesion characteristics, the system achieves bonding without the thermal expansion issues inherent in conventional adhesives.
2Reliability
If film members are used to mitigate stress transmission, then membrane electrode assembly protection is improved, but facility cost and person hours increase
Solution Approach 1:
The patent merges the protective function previously requiring a separate film member into the gas diffusion layer itself. The ionomer particles embedded in the gas diffusion layer provide both bonding and protection functions, eliminating the need for additional components.
Solution Approach 2:
The gas diffusion layer is given multiple functions: it serves as both the gas transport medium and the bonding interface with the electrode layer. The ionomer particles within it provide stress mitigation, bonding, and protection functions simultaneously, reducing overall system complexity.
3Strength
If ionomer particles are included in gas diffusion layer surface, then bonding strength is improved, but gas passage may be blocked
Solution Approach 1:
The patent applies ionomer particles locally at the bonding interface between the gas diffusion layer and electrode layer, rather than uniformly throughout the entire gas diffusion layer. This localized application provides bonding strength where needed while preserving gas permeability in the bulk of the gas diffusion layer.
Solution Approach 2:
The patent utilizes the porous structure of the gas diffusion layer to maintain gas passage. The ionomer particles are positioned in a way that does not fill the pores, allowing gas to flow through while still providing bonding at the interface.
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 achieves a stronger bond between electrode and gas diffusion layers, reducing costs and preventing liquid water accumulation, thereby improving electricity generation performance and simplifying the manufacturing process.
Implementation Method 1
Since the ionomer is a synthetic resin in which a cohesive force of metal ions is utilized to form an aggregate of high polymers, it is possible to use thermo-compression bonding to soften and bond pieces of the ionomer to each other.
Implementation Method 2
it is possible to use thermo-compression bonding to soften and bond pieces of the ionomer to each other
Implementation Method 3
as the ionomer particles are included in at least the part of the surface of the gas diffusion layer, such an effect is presented that gas from the gas diffusion layer is not blocked, but is allowed to pass through the electrode layer
Data Source
AI summary
To provide a fuel cell where no adhesive is used to bond an electrode layer and a gas diffusion layer to each other and a method for manufacturing the fuel cell. A fuel cell includes an electrode layer and a gas diffusion layer bonded to the electrode layer, in which the electrode layer includes an ionomer, the gas diffusion layer includes ionomer particles in at least a part of a surface facing the electrode layer, the ionomer particles are identical to the ionomer included in the electrode layer, and the ionomer particles are spray-applied.