Membrane-Electrode Assembly Roll Lamination for Precise Fuel Cell Sealing
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Solution Overview
Problem
The existing methods for producing membrane-electrode assemblies for fuel cell units are discontinuous and time-consuming, with high risks of damaging the assemblies during stacking due to their small layer thickness, and require complex and costly processes for lamination and handling.
Innovation Solution
A continuous method for producing membrane-electrode assemblies involves unwinding proton exchange membranes and subgaskets from storage rolls, forming fluid openings and perforations using embossing rollers, and connecting the layers in a continuous process, allowing for precise alignment and separation of individual assemblies without the need for adhesive coatings between subgaskets at overlap regions, thus reducing material waste and improving handling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If discontinuous manufacture with individual cutting and lamination is used, then manufacturing precision can be maintained, but productivity is reduced and time consumption increases
Solution Approach 1:
The patent implements continuous manufacture by unwinding membrane-electrode assemblies and subgaskets from rolls simultaneously and laminating them in a continuous process, eliminating the discontinuous stop-start nature of traditional individual cutting and assembly methods
Solution Approach 2:
The patent performs preliminary cutting of fluid openings and separation lines in the subgaskets before the lamination process, using embossing rollers to create pre-defined separation lines that guide subsequent cutting and assembly operations
2Ease of operation
If individual membrane-electrode assemblies are handled separately during stacking, then assembly flexibility is improved, but the risk of damage increases due to small layer thickness
Solution Approach 1:
The patent creates perforations and embossed separation lines in advance within the subgaskets, allowing for controlled separation at predetermined locations without requiring manual handling of fragile individual assemblies during the stacking process
Solution Approach 2:
The patent divides the subgasket into multiple connected units with pre-defined separation lines, enabling the membrane-electrode assemblies to be stacked in groups and then separated into individual units after stacking, reducing handling of fragile components
3Strength
If complex lamination processes with adhesive coatings are used, then bonding strength is improved, but device complexity and production cost increase
Solution Approach 1:
The patent removes the adhesive coating step from the lamination process by using mechanical interlocking through embossed features and perforations in the subgasket, eliminating the need for additional adhesive application equipment and processes
Solution Approach 2:
The patent introduces embossed features and perforations as intermediary mechanical structures that facilitate bonding and alignment between layers without requiring chemical adhesives, simplifying the overall lamination process
Data Source
AI summary
A method for producing membrane-electrode assemblies (6) for a fuel cell unit (1) as a fuel cell stack (1), comprising the following steps: providing in each case one proton exchange membrane (5), providing in each case one first subgasket (53) as sealing layer (41), providing in each case one second subgasket (54) as sealing layer (41), arranging the in each case one proton exchange membrane (5) between the in each case first and in each case second subgasket (53, 54), connecting the in each case one proton exchange membrane (5) to the in each case first and/or in each case second subgasket (53, 54), such that in each case one layered inner region (38) of the in each case one proton exchange membrane (5) is enclosed by the in each case one first and second subgasket (53, 54) as sealing layers (41), wherein the proton exchange membranes (5), the first subgaskets (53), and the second subgaskets (54) are provided in that they are removed as proton exchange membrane strip (65), first subgasket strip (63), and second subgasket strip (64) from storage devices (58, 59, 60) and the arrangement of the proton exchange membranes (5) between the first and second subgaskets (53, 54) and the connection of the proton exchange membranes (5) to the first and/or second subgaskets (53, 54) are configured in the state of the first subgaskets (53) as first subgasket strip (63) and of the second subgasket (54) as second subgasket strip (64), such that, during the arrangement and connection, the first subgaskets (53) are arranged connected to one another on the first subgasket strip (63) and the second subgaskets (54) are arranged connected to one another on the second subgasket strip (64).