Membrane Electrode Assembly Web Sealing With Reduced Overlap Waste
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Solution Overview
Problem
Existing methods for producing membrane electrode assemblies result in low membrane utilization due to large overlapping regions with rim materials, leading to high costs and inefficiencies.
Innovation Solution
A method involving the generation of frame-shaped seals from roll goods, which surround the outer rims of membrane electrode assemblies, allowing an inner region to be exposed, and the use of adhesive or radiation-curable materials to create a continuous web of membrane electrode assemblies with improved sealing and reduced waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a continuous web of catalyst coated membrane is used with circumferential rim material for sealing, then sealing function is achieved, but membrane utilization becomes very low due to large overlapping regions
Solution Approach 1:
The seal is segmented into a frame-shaped structure with separate first and second seals positioned at opposite sides of the membrane, rather than using a continuous circumferential rim. This segmentation allows the membrane to extend beyond the seal regions, increasing the active area while maintaining sealing functionality through the distributed frame-shaped seals.
Solution Approach 2:
The seal structure transitions from a two-dimensional circumferential rim covering the membrane edge to a three-dimensional frame-shaped structure positioned at opposite sides. This dimensional change allows the membrane to be utilized more effectively in the active region while the frame seals provide the necessary containment from multiple perspectives.
2Reliability
If a large circumferential rim material is used to seal the membrane, then sealing reliability is improved, but the active region of the membrane is reduced leading to high costs
Solution Approach 1:
The seal is divided into discrete frame-shaped segments (first and second seals) rather than using a continuous large-area rim material. This segmentation reduces the total amount of seal material required while maintaining sealing effectiveness, thereby reducing material loss and costs.
Solution Approach 2:
Sealing functionality is concentrated at specific local regions (frame-shaped seals at opposite sides) rather than distributed across a large circumferential area. This local quality approach maintains sealing reliability where needed while minimizing material usage in non-critical regions.
3Extent of automation
If frame-shaped seals are generated from roll goods with protective foils, then automated continuous production is enabled, but process complexity increases due to multiple steps including foil removal and adhesive application
Solution Approach 1:
Protective foils are pre-applied to the seal materials before they are fed into the production line. This preliminary action protects the seal materials during handling and storage, and the foils are removed at predetermined locations during the automated process, simplifying the overall workflow despite the additional step.
Solution Approach 2:
Adhesive materials are introduced as intermediaries between the first and second seals to bond them to the membrane and to each other. This intermediary substance enables automated continuous production by providing a reliable bonding mechanism that can be applied and cured in a continuous manufacturing process.
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 enables efficient, automated, and cost-effective production of membrane electrode assemblies with enhanced membrane utilization, suitable for use in fuel cells, water electrolysis cells, and electrochemical sensors, by minimizing the overlap of seal materials and maximizing the active membrane area.
Implementation Method 1
on the first seal material and/or on the second seal material an adhesive material is arranged such or a radiation-curable material is arranged such that after arranging the first partial seals, the layer assemblies and the second partial seals one upon the other the adhesive material or the radiation-curable material is arranged between the first and second partial seals being arranged one upon the other
Implementation Method 2
a radiation-curable material is arranged such that after arranging the first partial seals, the layer assemblies and the second partial seals one upon the other the adhesive material or the radiation-curable material is arranged between the first and second partial seals being arranged one upon the other
Implementation Method 3
thermally activating of the adhesive material or radiation-curing of the radiation-curable material
Data Source
AI summary
The invention relates to a first and a second method for the efficient, automated, exact and cost-efficient production of multi-layer continuous webs of membrane electrode assemblies which are suitable for the use in fuel cells, water electrolysis cells, electrochemical compressors and electrochemical sensors.