Photocurable Fuel Cell Sealing Agent for Rapid Curing and Adhesion
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Solution Overview
Problem
Photocurable resin compositions for fuel cells have been insufficient in photocurability and adhesiveness to electrolyte membranes and materials like polypropylene (PP) and polyethylene naphthalate (PEN), which are difficult to bond, due to low polarity and poor bonding properties.
Innovation Solution
A photocurable sealing agent containing a polymer with a polyisobutylene backbone, a photo-radical polymerization initiator, and a methacrylate monomer with an alkyl or alicyclic group, which can be quickly cured by irradiation with active energy rays, achieving excellent adhesion to electrolyte membranes and PP/PEN.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermosetting resin compositions are used for sealing, then gas barrier properties and heat resistance are improved, but curing process time increases and electrolyte membrane deterioration occurs
Solution Approach 1:
The patent replaces thermal curing (heat-based) with photocuring (light-based) by using a photopolymerizable resin composition containing photoinitiators. This substitution eliminates the need for heating processes, dramatically reducing curing time from hours to minutes while preventing electrolyte membrane deterioration caused by heat exposure, yet maintains excellent gas barrier properties through the crosslinked network structure formed by photocuring.
Solution Approach 2:
The patent changes the curing mechanism from thermal to photonic by introducing photoinitiators that activate upon UV irradiation. This parameter change in the curing process enables rapid curing without heat generation, solving both the time consumption and membrane deterioration issues while preserving the functional properties of the cured sealant.
2Loss of time
If photocurable resin compositions with polyisobutylene diacrylate are used, then curing process time is reduced, but adhesiveness to electrolyte membrane and frame materials deteriorates
Solution Approach 1:
The patent creates a composite resin composition by combining polyisobutylene diacrylate (for rapid photocuring) with silane-modified polyisobutylene diacrylate (for enhanced adhesion). The silane groups form strong chemical bonds with the electrolyte membrane and frame materials, while the acrylate groups enable rapid photocuring. This composite approach synergistically achieves both fast curing and strong adhesion that neither component could achieve alone.
Solution Approach 2:
The patent introduces silane modification at specific molecular locations within the polyisobutylene diacrylate structure. The silane groups are positioned to interact with frame materials and electrolyte membranes, providing localized adhesion enhancement, while the bulk polyisobutylene diacrylate structure maintains rapid photocuring capability. This local quality modification resolves the adhesion-deficiency problem without sacrificing curing speed.
3Ease of manufacture
If conventional sealing agents are used, then ease of manufacture is maintained, but adhesion to difficult-to-bond materials like PP and PEN deteriorates
Solution Approach 1:
The patent modifies the chemical structure of the polyisobutylene diacrylate by introducing silane groups, which fundamentally changes the adhesion mechanism. The silane groups can form strong chemical bonds with frame materials like PP and PEN, transforming the sealing agent from one with poor adhesion to one with excellent adhesion to these difficult-to-bond materials, while maintaining the simplicity of the application 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
The solution enables rapid curing and strong adhesion to electrolyte membranes and PP/PEN, enhancing sealability and durability while maintaining low moisture permeability and heat resistance.
Implementation Method 1
a photo-radical polymerization initiator; wherein the photocurable sealing agent for a fuel cell can be quickly cured by irradiation with active energy rays
Implementation Method 2
achieves excellent adhesion to an electrolyte membrane, PP, and PEN having properties difficult to bond
Data Source
Figure 1~2
AI summary
The present invention has an object to provide a photocurable sealing agent for a fuel cell which can be quickly cured by irradiation with active energy rays such as ultraviolet rays and achieves excellent adhesion to an electrolyte membrane, PP, and PEN having properties difficult to bond. Specifically, provided is a photocurable sealing agent includes the following (A) to (C) ingredients: (A) ingredient: a polymer having a polyisobutylene backbone containing a -[CH2C(CH3)2]- unit, the polymer having one or more (meth) acryloyl groups per molecule; (B) ingredient: a photo-radical polymerization initiator; and (C) ingredient: a methacrylate monomer.