Planar Array Fuel Cell Manufacturing via Slit Formation
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Solution Overview
Problem
Conventional fuel cell manufacturing methods require precise control of laser output and feed speed to form interconnector portions, making it difficult and costly to produce fuel cells efficiently.
Innovation Solution
A method involving slit formation in electrodes, electrolyte membrane lamination, interconnector formation, and side edge removal processes to create a planar array fuel cell with interconnector portions, allowing for easier assembly and reduced manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional lamination method with multiple unit cells is used, then high voltage output is achieved, but manufacturing time and effort increase significantly
Solution Approach 1:
Multiple unit cells are formed on a single electrolyte membrane in a planar array configuration, merging what would traditionally require multiple separate membranes and assemblies into one integrated structure. This eliminates the need for repeated lamination processes while maintaining the series connection of multiple cells for high voltage output.
Solution Approach 2:
The fuel cell structure transitions from a three-dimensional stacked lamination arrangement to a two-dimensional planar array. By forming multiple unit cells side-by-side on a single membrane plane rather than stacking membranes vertically, the manufacturing process is simplified while achieving the same electrical series connection.
2Manufacturing precision
If precise control of laser output and feed speed is implemented, then appropriate interconnector portions are formed, but manufacturing complexity and cost increase
Solution Approach 1:
Interconnector portions are formed on the electrolyte membrane before the electrode assembly is completed. By pre-forming these critical connection structures on the membrane itself, the subsequent assembly process is simplified and the precision requirements for later steps are reduced.
Solution Approach 2:
The electrode structure is divided into multiple unit cells with distinct interconnector portions that are formed separately on the electrolyte membrane. This segmentation allows each interconnector to be formed independently with standardized processes, reducing the overall complexity compared to forming all connections in a single complex operation.
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 simplifies the manufacturing of fuel cells by eliminating the need for precise lamination of individual unit cells, reducing production time and cost while maintaining high voltage output.
Implementation Method 1
a comparatively low-temperature laser beam is irradiated, then, a comparatively high-temperature laser beam is irradiated
Implementation Method 2
the temperature is gradually raised to form appropriate interconnector portions
Data Source
AI summary
A manufacturing method of fuel cell and a fuel cell are provided. The manufacturing method of fuel cell includes a first slit formation process in which first slits are formed in a first electrode, an electrolyte membrane lamination process in which an electrolyte membrane is laminated on the first electrode, an IC formation process in which interconnector portions are formed on the electrolyte membrane, a second slit formation process in which second slits are formed in a second electrode, a second electrode lamination process in which the second electrode is laminated on the electrolyte membrane, and a side edge portion removal process in which side edge portions of the first electrode and the second electrode are removed to divide the first electrode into a plurality of parts via the first slits and to divide the second electrode into a plurality of parts via the second slits.