Vacuum Jig for Laminated Membrane Alignment in Fuel Cell Manufacturing
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Solution Overview
Problem
Conventional methods for manufacturing bonded laminated materials, such as membrane-electrode assemblies for solid polymer fuel cells, face issues with misalignment and deformation of membranes due to rapid load changes and friction, leading to decreased yield and deficient bonding at interfaces, especially when using rolling-pressing devices.
Innovation Solution
A jig for fixing laminated materials is designed with a first and second sheet-shaped member, anchored by columnar members, and a sealing member to form a housing space that can be exhausted, ensuring accurate positioning and uniform pressure on the laminated materials, preventing misalignment and deformation, and allowing for continuous pressing methods suitable for bulk production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If rolling-pressing device is used to press laminated materials between rollers, then manufacturing efficiency is improved, but membranes may be misaligned or deformed due to rapid load change and friction
Solution Approach 1:
The patent applies preliminary action by fixing the laminated materials to a support sheet before pressing. The support sheet is attached to a frame in advance, and the laminated materials are secured to it before the pressing operation begins. This preliminary fixation prevents misalignment and deformation during the pressing process, allowing continuous rolling-pressing to proceed efficiently without compromising membrane alignment.
2Reliability
If conventional frames for fixing sheet are used to surround laminated materials, then materials can be fixed for bonding, but the frames are thicker than the materials and not applicable to continuous pressing devices
Solution Approach 1:
The patent employs a thin support sheet instead of a thick conventional frame to fix the laminated materials. The support sheet is sufficiently thin to allow continuous pressing devices to operate effectively while still providing the necessary fixation. This thin film approach maintains bonding reliability while enabling adaptability to continuous pressing operations.
3Reliability
If air remains between laminated membranes, then bonding can be achieved, but it is difficult to fully discharge the air to cause deficiency in bonding at the interface
Solution Approach 1:
The patent applies preliminary action by fixing the laminated materials to a support sheet before pressing. This preliminary fixation creates a stable configuration that allows air to be gradually discharged from between the membranes during the pressing process. The support sheet provides a reference plane that facilitates complete air evacuation, ensuring high-quality bonding at the interface without compromising bonding achievement.
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 effectively prevents misalignment and deformation of membranes, ensuring a high yield of bonded laminated materials with uniform bonding, suitable for continuous pressing methods, which enhances manufacturing efficiency and quality.
Implementation Method 1
an exhaust passage is formed in at least one of the pair of the first columnar members to fluidly communicate with the housing space through an exhaust hole that penetrates the first sheet-shaped member. The exhaust passage is connected to an exhaust device.
Data Source
AI summary
A jig for fixing laminated materials, a system for manufacturing bonded laminated materials, and a method of manufacturing bonded laminated materials are provided at a good yield factor and to efficiently manufacture the bonded laminated materials that are pressed and bonded after being laminated without a misalignment of the membranes or deformation of the laminated materials or any deficiency in bonding at the interface. The bonded laminated materials are manufactured by storing materials made of membranes (W) in a housing space (S) formed by a first sheet-shaped member (12), a second sheet-shaped member (22), and a sealing member (30), exhausting the housing space (S) to sandwich the laminated materials (W) between the first and second sheet-shaped members (12, 22) to fix them, and pressing and bonding them by hot-pressing rollers (51) and cold-pressing rollers (52) of a machine (50) for manufacturing the bonded laminated materials while they are fixed.