Roll-good fuel cell fabrication processes, equipment, and articles produced from same

• US 20040241525A1
• Filed: 05/28/2003
• Published: 12/02/2004
• Est. Priority Date: 05/28/2003
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Fansler, Duane Douglas, Peterson, Donald George, Mekala, David Robert, Ferguson, Dennis Earl
• Granted Patent: US 7,195,690 B2
• Time in Patent Office: Days
• US Class Current: 429/36
• CPC Class Codes: H01M 4/8828 Coating with slurry or ink
• CPC Class Codes: H01M 8/00 Fuel cells; Manufacture thereof
• CPC Class Codes: H01M 8/0234 Carbonaceous material
• CPC Class Codes: H01M 8/0239 Organic resins; Organic polymers
• CPC Class Codes: H01M 8/0243 in the form of mixtures
• CPC Class Codes: H01M 8/0247 characterised by the form characterised by a channel configuration H01M8/0258
• CPC Class Codes: H01M 8/0258 characterised by the configuration of channels, e.g. by the flow field of the reactant or coolant
• CPC Class Codes: H01M 8/0273 with sealing or supporting means in the form of a frame
• CPC Class Codes: H01M 8/0284 Organic resins; Organic polymers
• 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 8/1023 having only carbon, e.g. polyarylenes, polystyrenes or polybutadiene-styrenes
• CPC Class Codes: H01M 8/1039 halogenated, e.g. sulfonated polyvinylidene fluorides
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y10T 156/1062 Prior to assembly
• CPC Class Codes: Y10T 156/1074 Separate cutting of separate sheets or webs
• CPC Class Codes: Y10T 156/1075 of plural laminae from single stock and assembling to each other or to additional lamina
• CPC Class Codes: Y10T 156/1077 Applying plural cut laminae to single face of additional lamina
• CPC Class Codes: Y10T 156/1084 of continuous or running length bonded web
• CPC Class Codes: Y10T 156/109 Embedding of laminae within face of additional laminae
• CPC Class Codes: Y10T 156/1092 : All laminae planar and face to face
• CPC Class Codes: Y10T 156/1097 : Lamina is running length web
• CPC Class Codes: Y10T 156/1304 : Means making hole or aperture in part to be laminated
• CPC Class Codes: Y10T 156/1322 : Severing before bonding or assembling of parts
• CPC Class Codes: Y10T 29/4911 : including sealing
• CPC Class Codes: Y10T 29/49112 : including laminating of indefinite length material
• CPC Class Codes: Y10T 29/49114 : including adhesively bonding

Abstract

Fabricating roll-good fuel cell material involves laminating first and second bonding material webs having spaced apart windows to first and second surfaces of a fuel cell membrane web. First and second active regions of the membrane web are positioned within the respective bonding material windows. Third and fourth gasket material webs having spaced apart windows are respectively laminated to the bonding material on the first and second membrane web surfaces. The bonding material windows align with the respective gasket material windows so that at least some of the bonding material extends within the respective gasket material windows. Fluid transport layer (FTL) material portions cut from fifth and sixth FTL material webs are laminated to the respective first and second active regions. The FTL material portions are positioned within respective gasket material windows and contact the bonding material extending within the respective gasket material windows.

Claims

1. A method of continuously producing a multiple layer web of fuel cell material, comprising:

laminating first and second webs, each comprising bonding material and having spaced apart windows, to first and second surfaces of a web comprising a fuel cell membrane, first and second active regions of the membrane web positioned within the respective bonding material windows;

laminating third and fourth webs, each comprising a gasket material and having spaced apart windows, respectively to the bonding material disposed on the first and second surfaces the membrane web, the windows of the bonding material aligning with the respective windows of the gasket material so that at least some of the bonding material extends within the respective gasket material windows; and

laminating fluid transport layer (FTL) material portions cut from fifth and sixth webs comprising FTL material to the respective first and second active regions of the membrane web, the FTL material portions positioned within respective gasket material windows and contacting the bonding material extending within the respective gasket material windows.

2. The method according to claim 1, wherein all of the laminating processes comprise rotatable laminating processes.

3. The method according to claim 1, wherein at least some of the laminating processes comprise rotatable laminating processes.

4. The method according to claim 1, wherein one of the fifth and sixth webs of FTL material comprises an anode catalyst and the other of the fifth and sixth FTL material webs comprises a cathode catalyst.

5. The method according to claim 1, wherein one of the first and second active regions of the membrane web comprises an anode catalyst and the other of the first and second active regions of the membrane web comprises a cathode catalyst.

6. The method according to claim 1, further comprising rotatably cutting the first and second bonding material webs to produce the spaced apart windows.

7. The method according to claim 1, further comprising rotatably cutting the third and fourth gasket material webs to produce the spaced apart windows.

8. The method according to claim 1, wherein the windows of the third and fourth gasket material webs are larger than the windows of the first and second bonding material webs.

9. The method according to claim 1, further comprising rotatably cutting the fifth and sixth FTL material webs to produce the FTL material portions.

10. The method according to claim 1, wherein the FTL material portions are cut to a size substantially equal to that of the active regions of the membrane web.

11. The method according to claim 1, further comprising rotatably moving the FTL material portions under vacuum when laminating the FTL material portions to the respective first and second active regions of the membrane web.

12. The method according to claim 1, further comprising optically sensing positions of the respective bonding material windows relative to the first and second active regions of the membrane web when laminating the first and second bonding material webs to the first and second surfaces of the membrane web.

13. The method according to claim 1, further comprising optically sensing positions of the respective gasket material windows relative to the first and second active regions of the membrane web when laminating the third and fourth gasket material webs to the bonding material disposed on the first and second surfaces of the membrane web.

14. The method according to claim 1, further comprising optically sensing positions of the FTL material portions relative to one or both of the respective gasket material windows and the first and second active regions of the membrane web when laminating the FTL material portions to the respective first and second active regions of the membrane web.

15. The method according to claim 1, wherein a liner of the first and second bonding material webs is removed to expose the bonding material prior to laminating the third and fourth gasket material webs to the bonding material disposed on the first and second surfaces the membrane web.

16. The method according to claim 1, further comprising winding the multiple layer web of fuel cell material and a liner into a roll.

17. The method according to claim 1, further comprising singulating the multiple layer web of fuel cell material to produce a plurality of discrete fuel cell sheets.

18. The method according to claim 1, wherein all of the laminating processes associated with the first and second surfaces of the membrane web are effected substantially concurrently.

19. The method according to claim 1, wherein at least some of the laminating processes associated with the first and second surfaces of the membrane web are effected substantially concurrently.

20. The method according to claim 1, further comprising sealing the produced web of fuel cell material using heat and pressure.

21. The method according to claim 1, further comprising rotatably sealing the produced web of fuel cell material using heat and pressure.

22. A method of continuously producing a multiple layer web of fuel cell material for use with and between a pair of flow field plates or between gasket layers, comprising:

cutting a first web comprising bonding material to produce spaced apart first windows in the first web, the first windows comprising bonding sites provided along a periphery of the first windows;

cutting a second web comprising bonding material to produce spaced apart second windows in the second web, the second windows comprising bonding sites provided along a periphery of the second windows;

providing a web comprising a fuel cell membrane having active regions disposed on respective first and second surfaces of the membrane web;

laminating a first surface of the first bonding material web to the first surface of the membrane web so that the active regions of the first surface of the membrane web are positioned within the first windows;

laminating a first surface of the second bonding material web to the second surface of the membrane web so that the active regions of the second surface of the membrane web are positioned within the second windows; and

laminating fluid transport layer (FTL) material portions cut from fourth and fifth webs comprising FTL material to the active regions of the respective first and second surfaces of the membrane web, each of the FTL material portions contacting the bonding sites of the respective first and second windows.

23. The method according to claim 22, wherein second surfaces of the first and second bonding material webs respectively comprise a release liner.

24. The method according to claim 23, further comprising:

removing the release liner on the respective second surfaces of the first and second bonding material webs; and

adheringly engaging a flow field plate or a gasket layer with each of the second surfaces of the first and second bonding material webs.

25. The method according to claim 22, wherein all of the laminating processes comprise rotatable laminating processes.

26. The method according to claim 22, wherein at least some of the laminating processes comprise rotatable laminating processes.

27. The method according to claim 22, wherein all of the cutting processes comprise rotatable laminating processes.

28. The method according to claim 22, wherein at least some of the cutting processes comprise rotatable laminating processes.

29. The method according to claim 22, wherein one of the fourth and fifth webs of FTL material comprises an anode catalyst and the other of the fourth and fifth FTL material webs comprises a cathode catalyst.

30. The method according to claim 22, wherein the active regions of one of the first and second membrane web surfaces comprises an anode catalyst, and the active regions of the other of the first and second membrane web surfaces comprises a cathode catalyst.

31. The method according to claim 22, further comprising rotatably cutting the fourth and fifth FTL material webs to produce the FTL material portions.

32. The method according to claim 22, further comprising rotatably moving the FTL material portions under vacuum when laminating the FTL material portions to the active regions of the first and second membrane web surfaces.

33. The method according to claim 22, further comprising optically sensing positions of the first and second bonding material windows relative to the active regions of the first and second membrane web surfaces when laminating the first and second bonding material webs to the first and second membrane web surfaces.

34. The method according to claim 22, further comprising optically sensing positions of the FTL material portions relative to active regions of the first and second membrane web surfaces when laminating the FTL material portions to the active regions of the first and second membrane web surfaces.

35. The method according to claim 22, further comprising winding the multiple layer web of fuel cell material and a liner into a roll.

36. The method according to claim 22, further comprising singulating the multiple layer web of fuel cell material to produce a plurality of discrete fuel cell material sheets.

37. The method according to claim 22, wherein all of the laminating processes associated with the first and second surfaces of the membrane web are effected substantially concurrently.

38. The method according to claim 22, wherein at least some of the laminating processes associated with the first and second surfaces of the membrane web are effected substantially concurrently.

39. The method according to claim 22, further comprising sealing the produced web of fuel cell material using heat and pressure.

40. The method according to claim 22, further comprising rotatably sealing the produced web of fuel cell material using heat and pressure.

41. A method of continuously producing multiple layer fuel cell assemblies, comprising:

processing a web of membrane material, a first bonding web, and a first web comprising fluid transport layer (FTL) material to form a first surface of a membrane electrode assembly (MEA) web;

processing the web of membrane material, a second bonding web, and a second web comprising FTL material to form a second surface of the MEA web;

providing first flow field plates;

providing second flow field plates; and

encasing each MEA of the MEA web between a respective pair of the first and second flow field plates.

42. The method according to claim 41, wherein:

providing the first and second flow field plates comprises providing a first web comprising the first flow field plates and a second web comprising the second flow field plates; and

the method further comprises registering the first and second webs with the MEA web.

43. The method according to claim 41, wherein providing the first and second flow field plates further comprises:

providing a first web comprising the first flow field plates; and

providing a second web comprising the second flow field plates.

44. The method according to claim 41, wherein providing the first and second flow field plates further comprises:

molding a polymeric material to produce the first flow field plates; and

molding the polymeric material to produce the second flow field plates.

45. The method according to claim 41, wherein providing the first and second flow field plates further comprises:

molding a polymeric material to produce a first web of the first flow field plates; and

molding the polymeric material to produce a second web of the second flow field plates.

46. A method of continuously producing multiple layer fuel cell assemblies, comprising:

producing a continuous membrane electrode assembly (MEA) web, comprising;

providing a first web comprising bonding material having spaced apart first windows, the first windows comprising bonding sites provided along a periphery of the first windows;

providing a second web comprising bonding material having spaced apart second windows, the second windows comprising bonding sites provided along a periphery of the second windows;

providing a web comprising a fuel cell membrane having active regions disposed on respective first and second surfaces of the membrane web;

laminating a first surface of the first bonding material web to the first surface of the membrane web so that the active regions of the first surface of the membrane web are positioned within the first windows;

laminating a first surface of the second bonding material web to the second surface of the membrane web so that the active regions of the second surface of the membrane web are positioned within the second windows;

laminating fluid transport layer (FTL) material portions cut from fourth and fifth webs comprising FTL material to the active regions of the respective first and second surfaces of the membrane web, each of the FTL material portions contacting the bonding sites of the respective first and second windows;

providing a continuous web of first flow field plates;

providing a continuous web of second flow field plates; and

encasing each of the MEAs between a respective pair of the first and second flow field plates.

47. The method according to claim 46, further comprising registering each of the webs of first and second flow field plates with the MEA web.

48. The method according to claim 46, wherein providing the continuous webs of first and second flow field plates comprises molding a material to form the continuous webs of first and second flow field plates substantially concurrently with respect to producing the MEAs.

49. The method according to claim 48, wherein the material comprises a carbon/polymer composite material.

50. The method according to claim 46, wherein providing the continuous webs of first and second flow field plates comprises molding a material to form an interlocking arrangement between adjacent ones of the first flow field plates and between adjacent ones of the second flow field plates.

51. The method according to claim 46, wherein providing the continuous webs of first and second flow field plates comprises molding a material to form a living hinge between adjacent ones of the first flow field plates and between adjacent ones of the second flow field plates.

52. The method according to claim 46, wherein providing the continuous webs of first and second flow field plates comprises molding a material to form carrier strips along opposing sides of the first flow field plates and along opposing sides of the second flow field plates.

53. The method according to claim 46, wherein providing the continuous webs of first and second flow field plates comprises molding a material to form a plug and hole interlocking arrangement at corners of adjacent ones of the first flow field plates and at corners of adjacent ones of the second flow field plates.

54. The method according to claim 46, further comprising winding the multiple layer fuel cell assemblies into a roll.

55. The method according to claim 46, further comprising subjecting the multiple layer fuel cell assemblies to heat and pressure to seal the MEAs within the respective pair of first and second flow field plates.

56. The method according to claim 46, wherein one of the fourth and fifth webs of FTL material comprises an anode catalyst and the other of the fourth and fifth FTL material webs comprises a cathode catalyst.

57. The method according to claim 46, wherein one of the first and second membrane surfaces comprises an anode catalyst and the other of the first and second membrane surfaces comprises a cathode catalyst.

58. An apparatus for continuously producing a multiple layer web of fuel cell material, comprising:

a first cutting station configured for cutting a first web comprising bonding material, the first cutting station comprising a first cutting mechanism configured to produce spaced apart first windows in the first web, the first windows comprising bonding sites provided along a periphery of the first windows;

a second cutting station configured for cutting a second web comprising bonding material, the second cutting station comprising a second cutting mechanism configured to produce spaced apart second windows in the second web, the second windows comprising bonding sites provided along a periphery of the second windows;

a membrane web transport mechanism configured to transport a membrane web, the membrane web comprising a fuel cell membrane having active regions disposed on respective first and second surfaces of the membrane web;

a first laminating station configured to laminate a first surface of the first bonding material web to the first surface of the membrane web so that the active regions of the first surface of the membrane web are positioned within the first windows;

a second laminating station configured to laminate a first surface of the second bonding material web to the second surface of the membrane web so that the active regions of the second surface of the membrane web are positioned within the second windows;

a third laminating station configured to laminate first fluid transport layer (FTL) patches to the active regions of the first surface of the membrane web, each of the first FTL patches contacting the bonding sites of the first windows; and

a fourth laminating station configured to laminate second FTL patches to the active regions of the second surface of the membrane web, each of the second FTL patches contacting the bonding sites of the second windows.

59. The apparatus according to claim 58, wherein the first and second cutting mechanisms respectively comprise a rotary cutting die and a rotary anvil.

60. The apparatus according to claim 58, wherein the first and second laminating stations respectively comprise nip rolls.

61. The apparatus according to claim 60, wherein the first and second cutting mechanisms respectively comprise a rotary cutting die and a rotary anvil, the respective rotary anvils serving as one of the nip rolls for the respective first and second laminating stations.

62. The apparatus of claim 58, further comprising:

a third cutting station configured to receive a first web of FTL material, the third cutting station comprising a third cutting mechanism configured to cut the first FTL patches from the first FTL material web; and

a fourth cutting station configured to receive a second web of FTL material, the fourth cutting station comprising a fourth cutting mechanism configured to cut the second FTL patches from the second FTL material web.

63. The apparatus according to claim 62, wherein the third and fourth cutting mechanisms respectively comprise a rotary cutting die and a rotary anvil.

64. The apparatus according to claim 62, wherein the third and fourth laminating stations respectively comprise nip rolls.

65. The apparatus according to claim 64, wherein the third and fourth cutting mechanisms respectively comprise a rotary cutting die and a rotary anvil, the respective rotary anvils serving as one of the nip rolls for the respective third and fourth laminating stations.

66. The apparatus according to claim 58, further comprising:

a fifth laminating station configured to laminate a first gasket material web to the first bonding material web on the first membrane web surface; and

a sixth laminating station configured to laminate a second gasket material web to the second bonding material web on the second membrane web surface.

67. The apparatus according to claim 66, further comprising:

a fifth cutting station comprising a fifth cutting mechanism configured to cut spaced apart windows in the first gasket material web; and

a sixth cutting station comprising a sixth cutting mechanism configured to cut spaced apart windows in the second gasket material web.

68. The apparatus according to claim 67, wherein the fifth and sixth cutting mechanisms respectively comprise a rotary cutting die and a rotary anvil.

69. The apparatus according to claim 67, wherein the fifth and sixth laminating stations respectively comprise nip rolls.

70. The apparatus according to claim 69, wherein the fifth and sixth cutting mechanisms respectively comprise a rotary cutting die and a rotary anvil, the respective rotary anvils serving as one of the nip rolls for the respective fifth and sixth laminating stations.

71. The apparatus according to claim 58, further comprising a sealing station configured to receive the produced web of fuel cell material, the sealing station subjecting the fuel cell material web to heat and pressure.

72. The apparatus according to claim 71, wherein the sealing station comprises a sealing drum and a tension roll, the produced web of fuel cell material contacting an outer periphery of the sealing drum under pressure via cooperation between the sealing drum and the tension roll.

73. The apparatus according to claim 58, further comprising a molding system, the molding system comprising:

first and second molding stations, the first molding station configured to mold a polymeric material to produce first flow field plates, the second molding station configured to mold a polymeric material to produce second flow field plates; and

an assembly station configured to encase each MEA of the produced web of fuel cell material between a respective pair of the first and second flow field plates.

74. The apparatus according to claim 73, wherein the first and second molding stations are configured to produce continuous webs of the first and second flow field plates.

75. The apparatus according to claim 74, wherein the first and second molding stations are configured to form a living hinge between adjacent ones of the first flow field plates and between adjacent ones of the second flow field plates.

76. The apparatus according to claim 74, wherein the first and second molding stations are configured to form carrier strips along opposing sides of the first flow field plates and along opposing sides of the second flow field plates.

77. The apparatus according to claim 74, wherein the first and second molding stations are configured to form a plug and hole interlocking arrangement at corners of adjacent ones of the first flow field plates and at corners of adjacent ones of the second flow field plates.

78. The method according to claim 58, further comprising a winding station configured to wind the produced web of fuel cell material into a roll.

79. The method according to claim 58, further comprising a singulation station configured to singulate the produced web of fuel cell material into discrete fuel cell material sheets.

80. A fuel cell assembly, comprising:

a membrane comprising a first surface and a second surface, the first and second surfaces comprising first and second active regions, respectively;

a first bonding layer having a first surface in contact with the first surface of the membrane and comprising a first window in alignment with the first active region of the membrane, the first window comprising protrusions of bonding material in contact with the first active region;

a second bonding layer having a first surface in contact with the second surface of the membrane and comprising a second window in alignment with the second active region of the membrane, the second window comprising protrusions of bonding material in contact with the second active region;

a first gasket layer disposed on a second surface of the first bonding layer and comprising a third window in alignment with the first window of the first bonding layer;

a second gasket layer disposed on a second surface of the second bonding layer and comprising a fourth window in alignment with the second window of the second bonding layer;

a first fluid transport layer (FTL) in contact with the first surface of the membrane, a peripheral edge of the first FTL contacting at least the bonding material protrusions of the first window;

a second FTL in contact with the second surface of the membrane, a peripheral edge of the second FTL contacting at least the bonding material protrusions of the second window;

an anode catalyst disposed at one of the first and second active regions; and

a cathode catalyst disposed at the other of the first and second active regions.

81. The assembly according to claim 80, wherein the protrusions of bonding material of the first and second windows define a plurality of edge portions of the first and second windows, respectively.

82. The assembly according to claim 80, wherein the plurality of edge portions define a continuous peripheral edge of the first and second windows, respectively.

83. The assembly according to claim 80, wherein the protrusions of bonding material of the first and second windows define a plurality of inwardly projecting fingers disposed along a peripheral edge of the first and second windows, respectively.

84. The assembly according to claim 80, wherein the first and second bonding layers comprise a heat-activated bonding.

85. The assembly according to claim 80, wherein the first and second bonding layers comprise a thermobonding material.

86. The assembly according to claim 80, wherein the first and second bonding layers comprise a pressure sensitive bonding.

87. The assembly according to claim 80, wherein the first and second bonding layers comprise a bonding agent.

88. The assembly according to claim 80, wherein the first and second bonding layers comprise a light-curable bonding agent.

89. The assembly according to claim 80, wherein the third and fourth windows of the first and second gaskets are larger than first and second windows of the first and second bonding layers, respectively.

90. The assembly according to claim 80, wherein a plurality of the fuel cell assemblies are arranged to define a web of fuel cell assemblies.

91. The assembly according to claim 80, wherein the fuel cell assembly defines a proton exchange membrane fuel cell assembly.

92. A fuel cell sub-assembly for use with and between a pair of flow field plates or between gasket layers, comprising:

a membrane comprising a first surface and a second surface, the first and second surfaces comprising first and second active regions, respectively;

a first bonding layer having a first surface in contact with the first surface of the membrane and comprising a first window in alignment with the first active region of the membrane, the first window comprising protrusions of bonding material in contact with the first active region;

a second bonding layer having a first surface in contact with the second surface of the membrane and comprising a second window in alignment with the second active region of the membrane, the second window comprising protrusions of bonding material in contact with the second active region;

a first fluid transport layer (FTL) in contact with the first surface of the membrane, a peripheral edge of the first FTL contacting at least the bonding material protrusions of the first window;

a second FTL in contact with the second surface of the membrane, a peripheral edge of the second FTL contacting at least the bonding material protrusions of the second window;

an anode catalyst disposed at one of the first and second active regions; and

a cathode catalyst disposed at the other of the first and second active regions.

93. The sub-assembly according to claim 92, further comprising:

a first flow field plate in contact with the first FTL and a second surface of the first bonding layer; and

a second flow field plate in contact with the second FTL and a second surface of the second bonding layer.

94. The assembly according to claim 92, wherein the protrusions of bonding material of the first and second windows define a plurality of edge portions of the first and second windows, respectively.

95. The assembly according to claim 94, wherein the plurality of edge portions define a continuous peripheral edge of the first and second windows, respectively.

96. The assembly according to claim 92, wherein the protrusions of bonding material of the first and second windows define a plurality of inwardly projecting fingers disposed along a peripheral edge of the first and second windows, respectively.

97. The assembly according to claim 92, wherein the first and second bonding layers comprise a heat-activated bonding.

98. The assembly according to claim 92, wherein the first and second bonding layers comprise a thermobonding material.

99. The assembly according to claim 92, wherein the first and second bonding layers comprise a pressure sensitive bonding.

100. The assembly according to claim 92, wherein the first and second bonding layers comprise a bonding agent.

101. The assembly according to claim 92, wherein the first and second bonding layers comprise a light-curable bonding agent.

102. The assembly according to claim 92, wherein a plurality of the fuel cell sub-assemblies are arranged to define a web of fuel cell sub-assemblies.

103. The assembly according to claim 92, wherein the fuel cell sub-assembly defines a proton exchange membrane fuel cell sub-assembly.