Fuel cell subassemblies incorporating subgasketed thrifted membranes

• US 10,446,868 B2
• Filed: 01/25/2016
• Issued: 10/15/2019
• Est. Priority Date: 12/22/2009
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Iverson, Eric J., Pierpont, Daniel M., Yandrasits, Michael A., Hamrock, Steven J., Obradovich, Stephan J., Peterson, Donald G.
• Primary Examiner(s): Douyette, Kenneth J
• Application Number:
  US15/005,571
• Publication Number:
  US 20160141642A1
• Time in Patent Office: 1,359 Days
• CPC Class Codes: H01M 2008/1095 Fuel cells with polymeric electrolytes
• CPC Class Codes: H01M 8/0273 with sealing or supporting means in the form of a frame
• CPC Class Codes: H01M 8/0276 Sealing means characterised by their form H01M8/0273 takes precedence
• CPC Class Codes: H01M 8/0286 Processes for forming seals
• CPC Class Codes: H01M 8/1004 characterised by membrane-electrode assemblies [MEA] H01M8/12 takes precedence
• CPC Class Codes: H01M 8/1016 characterised by the electrolyte material H01M8/12 takes precedence
• CPC Class Codes: H01M 8/2418 Grouping by arranging unit cells in a plane H01M8/2425, H01M8/244 take precedence
• CPC Class Codes: H01M 8/242 comprising framed electrodes or intermediary frame-like gaskets H01M8/2425, H01M8/244 take precedence
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product

Abstract

An automated roll to roll method of making a fuel cell roll good subassembly is described wherein an elongated first subgasket web having a plurality of apertures is moved relative to a plurality of individual electrolyte membranes, each individual electrolyte membrane having a center region. The individual electrolyte membranes are aligned with the first subgasket web so that a center region of each electrolyte membrane is aligned with an aperture of the first subgasket web and the individual electrolyte membranes are attached to the first subgasket web.

Claims

1. An automated roll to roll method of making a fuel cell roll good subassembly, comprising:

providing relative motion between an elongated first subgasket web having a plurality of apertures and a plurality of individual pieces of electrolyte membrane, each individual piece of electrolyte membrane having a center region;

aligning the individual pieces of electrolyte membranes with the first subgasket web so that a center region of each electrolyte membrane is aligned with an aperture of the first subgasket web; and

attaching the individual pieces of electrolyte membrane to the first subgasket web.

2. The method of claim 1, wherein the first subgasket web is disposed on a repositionable adhesive carrier web.

3. The method of claim 1, further comprising:

cutting the first subgasket web having the individual pieces of electrolyte membrane attached thereto into a plurality of individual subgasketed membranes;

providing relative motion between a second subgasket web having a plurality of apertures and the plurality of individual subgasketed membranes;

aligning the individual subgasketed membranes with the second subgasket web so that a center region of each electrolyte membrane is aligned with an aperture of the second subgasket web; and

attaching the individual subgasketed membranes to the second subgasket web.

4. The method of claim 3, wherein the second subgasket web is disposed on repositionable adhesive carrier web.

5. The method of claim 3, wherein:

the first subgasket web includes a first subgasket surface oriented toward the individual pieces of electrolyte membrane and a first adhesive layer is disposed on the first subgasket surface; and

the second subgasket web includes a second subgasket surface oriented toward the individual pieces of electrolyte membrane and at least 25% of the second subgasket surface does not include a second adhesive layer.

6. The method of claim 3, wherein:

the first subgasket web includes a first subgasket surface oriented toward the individual pieces of electrolyte membrane and a first adhesive layer is disposed on the first subgasket surface; and

the second subgasket web includes a second subgasket surface oriented toward the individual pieces of electrolyte membrane the second subgasket surface does not include a second adhesive layer.

7. The method of claim 3, wherein the aperture of the first subgasket web is a different size than the aperture of the second subgasket web.

8. The method of claim 1, further comprising:

providing relative motion between a second subgasket web having a plurality of apertures and the first subgasket web having the individual pieces of electrolyte membrane attached thereto;

aligning the second subgasket web with the first subgasket web having the individual pieces of electrolyte membrane attached thereto so that a center region of each electrolyte membrane is aligned with an aperture of the second subgasket web; and

attaching the first subgasket web having the individual pieces of electrolyte membrane attached thereto to the second subgasket web.

9. The method of claim 8, wherein:

the first subgasket web includes a first subgasket surface oriented toward the individual pieces of electrolyte membrane and a first adhesive layer is disposed on the first subgasket surface; and

the second subgasket web includes a second subgasket surface oriented toward the individual pieces of electrolyte membrane and the second subgasket surface does not include a second adhesive layer.

10. The method of claim 8, wherein one or both of the first subgasket web and the second subgasket web are disposed on a repositionable carrier web.

11. The method of claim 1, further comprising:

moving an electrolyte membrane web into contact with a rotating die; and

cutting the electrolyte membrane web into the individual pieces of electrolyte membrane using the rotating die.

12. The method of claim 11, wherein the rotating die comprises a rotating vacuum die that retains the individual pieces of electrolyte membrane on a surface of the rotating die and moves the individual pieces of electrolyte membrane into contact with the first subgasket web.

13. The method of claim 12, wherein the rotating die comprises:

a cylindrical core;

die blades on the cylindrical core defining die cavities and gaps between the die cavities; and

compliant die cavity inserts disposed within the die cavities.