Gas Diffusion Sheet Joining via Penetrating Staples
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Solution Overview
Problem
The existing roll-to-roll manufacturing method for gas diffusion sheets in fuel cells faces misalignment issues due to tension acting on the joining parts between films and base materials during the conveyance and heating processes, leading to instability in the coating and drying of the paste material.
Innovation Solution
The method enhances the joining strength of films and base materials by using penetrating staples or continuous fibers through adhesive sheets, ensuring proper alignment and physical joining, even under tension, during the conveyance and heating phases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesive tape is used to join the film to the base material during roll-to-roll conveyance, then the film and base material can be joined together, but the joining strength is insufficient when tension and heating are applied
Solution Approach 1:
The joining process is segmented into two distinct stages: first, adhesive tape is used to temporarily join the film to the base material for initial positioning; second, a penetrating joining material (staples or continuous fibers) is introduced to create permanent, high-strength mechanical bonds that penetrate through both the film and base material. This segmentation allows each joining method to perform its specialized function without interference.
Solution Approach 2:
The joining system uses a composite approach by combining two different joining materials with complementary properties: adhesive tape provides initial bonding and positioning, while penetrating staples or continuous fibers provide structural strength and thermal stability. This composite joining system leverages the advantages of both material types to achieve both ease of application and high reliability under tension and heat.
2Productivity
If the base material is conveyed by roll-to-roll method with heating for drying, then continuous manufacturing is achieved, but misalignment occurs at the joining parts due to tension and heat
Solution Approach 1:
The adhesive tape is applied in advance to temporarily secure the film to the base material before the penetrating joining material is introduced. This preliminary action ensures that the film and base material are properly positioned and held together during the subsequent steps of conveyance, coating, and drying, preventing misalignment before the high-strength joining takes effect.
Solution Approach 2:
The joining system transitions from a low-strength adhesive bond to a high-strength mechanical bond by introducing penetrating staples or continuous fibers. This parameter change in joining strength occurs at the appropriate stage of the process, allowing the material to maintain alignment through the heating and drying phases where thermal expansion and tension could cause misalignment.
3Ease of manufacture
If adhesive tape alone is used to join film and base material, then the joining process is simple, but the joining strength is insufficient under tension during conveyance
Solution Approach 1:
The joining process merges two different joining mechanisms: adhesive bonding from the tape and mechanical penetration from staples or continuous fibers. The adhesive tape provides initial bonding and positioning, while the penetrating material provides structural strength. This merging of mechanisms maintains relative process simplicity while dramatically improving joining strength under tension.
Solution Approach 2:
The adhesive tape serves as an intermediary that facilitates the introduction of the penetrating joining material. By temporarily bonding the film to the base material, the tape holds the components in proper alignment during the subsequent penetration process, ensuring that the staples or fibers are inserted at the correct positions to create effective mechanical bonds.
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 prevents misalignment and enhances the joining strength of films and base materials, allowing for stable coating and drying of the paste material, resulting in improved manufacturing consistency and durability of the gas diffusion sheets.
Implementation Method 1
For joining of the first film, a first joining material is made to penetrate a first overlapping portion where the first film and the base material are superimposed on each other, and the first film and the base material are thus physically joined to each other through the first joining material.
Implementation Method 2
For joining of the second film, a second joining material is made to penetrate a second overlapping portion where the base material and the second film are superimposed on each other, and the second film and the base material are thus physically joined to each other through the second joining material.
Implementation Method 3
manufacturing the gas diffusion sheet as the porous layer is formed as the paste material applied is heated while the base material coated with the paste material is continuously conveyed
Data Source
AI summary
In a manufacturing method for a gas diffusion sheet, when a first film is joined to a front end portion of a base material in a conveyance direction, a first joining material is made to penetrate a first overlapping portion where the first film and the base material are superimposed on each other, and the first film and the base material are thus joined to each other physically through the first joining material. When a second film is joined to a rear end portion of the base material in the conveyance direction, a second joining material is made to penetrate a second overlapping portion where the base material and the second film are superimposed on each other, and the base material and the second film are thus physically joined to each other through the second joining material.