METHOD AND APPARATUS FOR FABRICATING ROLL GOOD FUEL CELL SUBASSEMBLIES

• US 20080142152A1
• Filed: 12/15/2006
• Published: 06/19/2008
• Est. Priority Date: 12/15/2006
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Debe, Mark K., Obradovich, Stephan J., Steinbach, Andrew J. L., Iverson, Eric J., Le, Jimmy M.
• Granted Patent: US 8,012,284 B2
• Time in Patent Office: Days
• US Class Current: 156/182
• CPC Class Codes: H01M 8/0202 Collectors; Separators, e.g. bipolar separators; Interconnectors
• 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 8/1004 characterised by membrane-electrode assemblies [MEA] H01M8/12 takes precedence
• CPC Class Codes: H01M 8/241 with solid or matrix-supported electrolytes
• CPC Class Codes: H01M 8/242 comprising framed electrodes or intermediary frame-like gaskets H01M8/2425, H01M8/244 take precedence
• CPC Class Codes: H01M 8/2457 with both reactants being gaseous or vaporised
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y10T 156/10 Methods of surface bonding and/or assembly therefor
• CPC Class Codes: Y10T 156/1705 Lamina transferred to base from adhered flexible web or sheet type carrier
• CPC Class Codes: Y10T 156/1712 Indefinite or running length work

Abstract

Fabrication methods for making a gas diffusion layer incorporating a gasket (GIG) fuel cell subassemblies via roll-to-roll processes are described. A material processable by one or both of heat and pressure having spaced apart apertures is transported to a bonding station. A first gasket layer having gas diffusion layers arranged in relation to spaced apart apertures of a first gasket layer is transported to the bonding station. The heat/pressure processable material is aligned with the first gasket layer and the gas diffusion layers. At the bonding station, the heat/pressure processable material is bonded to the first gasket layer and the gas diffusion layers. After bonding, the heat/pressure processable material forms a second gasket layer that attaches the gas diffusion layers to the first gasket layer.

Claims

1. A method of making gas diffusion layer incorporating a gasket (GIG) fuel cell subassemblies via a roll-to-roll process, comprising:

transporting a material processable by one or both of heat and pressure and having spaced apart apertures to a bonding station;

transporting a first gasket layer having gas diffusion layers arranged in relation to spaced apart apertures of the first gasket layer to the bonding station;

aligning the heat/pressure processable material with the first gasket layer and the gas diffusion layers; and

at the bonding station, bonding the heat/pressure processable material to the first gasket layer and the gas diffusion layers, the heat/pressure processable material, after bonding, forming a second gasket layer that attaches the gas diffusion layers to the first gasket layer.

2. The method of claim 1, wherein aligning the heat/pressure processable material comprises aligning the apertures of the heat/pressure processable material with the apertures of the first gasket layer so that the heat/pressure processable material overlaps at least a portion of the first gasket layer and gas diffusion layers.

3. The method of claim 1, wherein the gas diffusion layers are disposed within the spaced apart apertures of the first gasket layer.

4. The method of claim 1, wherein the gas diffusion layers overlap the first gasket layer.

5. The method of claim 1, wherein:

transporting the heat/pressure processable material comprises transporting the heat/pressure processable material on a first carrier web; and

transporting the first gasket layer and the gas diffusion layers comprises transporting the first gasket layer and the gas diffusion layers on a second carrier web.

6. The method of claim 5, wherein a first adhesive adheres the heat/pressure processable material to the first carrier web and a second adhesive adheres the gas diffusion layers and the first gasket layer to the second carrier web.

7. The method of claim 6, wherein the second adhesive comprises a heat deactivated pressure sensitive adhesive.

8. The method of claim 5, further comprising removing the second carrier web from the gas diffusion layers and the first gasket layer, wherein removing the second carrier web exposes an adhesive layer or an adhesive liner of the first gasket layer.

9. The method of claim 6, wherein:

removing the second carrier web exposes the adhesive liner; and

further comprising removing the adhesive liner from the adhesive layer of the first gasket layer.

10. The method of claim 1, wherein bonding the heat/pressure processable material to the gas diffusion layers and the first gasket layer comprises applying at least one of heat and pressure to the heat/pressure processable material via bonding rollers in a continuous process.

11. The method of claim 1, wherein the gas diffusion layers comprise catalyst coated gas diffusion layers.

12. A method of forming membrane electrode assemblies via a roll-to-roll process, comprising:

forming first and second gas diffusion layer incorporating a gasket (GIG) subassemblies, the formation of each GIG subassembly comprising;

transporting a material processable by one or both of heat and pressure having spaced apart apertures to a bonding station;

transporting a first gasket layer having gas diffusion layers arranged in relation to spaced apart apertures of the first gasket layer to the bonding station;

aligning the heat/pressure processable material with the first gasket layer and the gas diffusion layers;

at the bonding station, bonding the heat/pressure processable material to the first gasket layer and the gas diffusion layers, the heat/pressure processable material, after bonding, forming a second gasket layer that attaches the gas diffusion layers to the first gasket layer; and

exposing an adhesive layer on the first gasket layer;

delivering one or more electrolyte membranes;

bonding the first GIG subassembly to a surface of the one or more electrolyte membranes; and

bonding the second GIG subassembly to an opposite surface of the one or more electrolyte membranes.

13. The method of claim 12, wherein the one or more electrolyte membranes are at least partially catalyst coated.

14. The method of claim 12, wherein the gas diffusion layers of the first and second GIGs are at least partially catalyst coated.

15. The method of claim 12, wherein the one or more electrolyte membranes comprises a continuous electrolyte membrane.

16. The method of claim 12, wherein:

delivering the one or more electrolyte membranes comprises delivering a plurality of electrolyte membranes;

bonding the first GIG subassembly comprises aligning the first subassembly with the plurality of electrolyte membranes; and

bonding the second GIG subassembly comprises aligning the second subassembly with the plurality of electrolyte membranes.

17. The method of claim 12, wherein the one or more electrolyte membranes comprise an electrolyte membrane web having patterned catalyst areas;

bonding the first GIG subassembly comprises aligning the first GIG subassembly with the patterned electrolyte membrane web; and

bonding the second GIG subassembly comprises aligning the second GIG subassembly with the patterned electrolyte membrane web.

18. The method of claim 12, wherein:

bonding the first GIG subassembly to the electrolyte membrane comprises bonding the first GIG subassembly to the electrolyte membrane via the adhesive layer of the first GIG subassembly; and

bonding the second GIG subassembly to the electrolyte membrane comprises bonding the second GIG subassembly to the electrolyte membrane via the adhesive layer of the second GIG subassembly.

19. The method of claim 18, wherein:

the adhesive layer of at least one of the first and second GIG subassemblies comprises an adhesive liner; and

further comprising removing the adhesive liner prior to bonding.

20. The method of claim 18, wherein bonding the first and second GIG subassemblies to the electrolyte membrane comprises bonding the first and second GIG subassemblies to each other via their respective adhesive layers.

21. The method of claim 12, further comprising:

removing the first carrier web of the first GIG subassembly;

removing the first carrier web of the second GIG subassembly; and

cutting the electrolyte membrane having the first and second GIG subassemblies bonded thereto into individual membrane electrode assemblies.

22. The method of claim 12, wherein bonding the heat/pressure processable material to the gas diffusion layers and the first gasket layer comprises applying one or both of heat and pressure to the heat/pressure processable material, the gas diffusion layers and the first gasket layer via bonding rollers in a continuous process.

23. The method of claim 12, wherein:

bonding the first GIG subassembly to the electrolyte membrane comprises applying one or both of heat and pressure to the first GIG subassembly and the electrolyte membrane via a first set of rollers in a continuous process; and

bonding the second GIG subassembly to the electrolyte membrane comprises applying one or both of heat and pressure to the second GIG subassembly and the electrolyte membrane via a second set of rollers in the continuous process.

24. An apparatus for producing fuel cell subassemblies, comprising:

a transport system configured to move a web of material processable by one or both of heat and pressure and a web including a first gasket layer having gas diffusion layers disposed within spaced apart apertures of the first gasket layer;

an alignment system configured to align the apertures of the heat/pressure processable material with the apertures of the first gasket layer and the gas diffusion layers; and

a first bonding station configured to bond the heat/pressure processable material to the gas diffusion layers and the first gasket layer, the heat/pressure processable material, after bonding, forming a second gasket layer that attaches the gas diffusion layers to the first gasket layer.

25. The apparatus of claim 24, wherein:

the heat/pressure processable material is transported on a first carrier web;

the first gasket layer and gas diffusion layers are transported on a second carrier web;

a first adhesive adheres the heat/pressure processable material to the first carrier web; and

a heat deactivated adhesive adheres the first gasket layer and the gas diffusion layers to the second carrier web.

26. The apparatus of claim 25, further comprising an apparatus configured to remove the second carrier web from the gas diffusion layers and the first gasket layer, removal of the second carrier web exposing an adhesive layer or an adhesive release liner of the first gasket layer.

27. The apparatus of claim 26, further comprising a mechanism configured to remove the adhesive liner from the adhesive layer of the first gasket layer.

28. An apparatus for producing fuel cell membrane electrode assemblies, comprising:

first and second systems configured to produce first and second gasketed gas diffusion layer (GIG) subassemblies, each of the systems comprising;

a transport system configured to move first and second carrier webs in a roll-to-roll process, a material processable by one or both of heat and pressure having spaced apart apertures disposed on the first carrier web and a first gasket layer having gas diffusion layers disposed within spaced apart apertures of the first gasket layer disposed on the second carrier web;

an alignment system configured to align the apertures of the heat/pressure processable material with the apertures of the first gasket layer and the gas diffusion layers;

a bonding station configured to bond the heat/pressure processable material to the gas diffusion layers and the first gasket layer, the heat/pressure processable material, after bonding, forming a second gasket layer that attaches the gas diffusion layers to the first gasket layer; and

a delaminating station configured to remove the second carrier web from the gas diffusion layers and the first gasket layer, removal of the second carrier web exposing an adhesive layer or adhesive liner of the first gasket layer;

a electrolyte membrane transport system configured to move one or more electrolyte membranes in a continuous roll-to-roll process; and

a membrane bonding station configured to bond the first and second GIG subassemblies to the one or more electrolyte membrane.

29. The apparatus of claim 28, wherein the membrane bonding station comprises:

a first membrane bonding station configured to bond the first GIG subassembly to a surface of the membrane; and

a second membrane bonding station configured to bond the second GIG subassembly to an opposite surface of the membrane.

30. The apparatus of claim 28, wherein the first and second GIG subassemblies are bonded to the one or more electrolyte membranes substantially concurrently.

31. The apparatus of claim 28, further comprising a membrane alignment system configured to align one or both of the first and second GIG subassemblies with the one or more membranes.

32. The apparatus of claim 31, wherein:

the electrolyte membrane comprises a continuous membrane having patterned catalyst areas; and

the membrane alignment system is configured to align the patterned catalyst areas with one or both of the first GIG subassembly and the second GIG subassembly.

33. A method of making gas diffusion layer incorporating a gasket (GIG) fuel cell subassemblies, comprising:

transporting a first gasket layer having spaced apart apertures to a deposition station;

depositing a heat/pressure processable material on the first gasket layer;

aligning the first gasket layer having the heat/pressure processable material disposed thereon with gas diffusion layers; and

at a bonding station, bonding the heat/pressure processable material to the first gasket layer and the gas diffusion layers, the heat/pressure processable material, after bonding, forming a second gasket layer that attaches the gas diffusion layers to the first gasket layer.

34. The method of claim 33, wherein aligning the first gasket layer having the heat/pressure processable material disposed thereon with the gas diffusion layers comprises arranging the gas diffusion layers within the apertures of the first gasket layer.

35. The method of claim 33, wherein aligning the first gasket layer having the heat/pressure processable material disposed thereon with the gas diffusion layers comprises arranging the gas diffusion layers so that the gas diffusion layers overlap the heat/pressure processable material.

36. The method of claim 33, wherein depositing the heat/pressure processable material on the first gasket layer comprises silk screen printing the heat/pressure processable material on the first gasket layer.

37. An apparatus for producing fuel cell subassemblies, comprising:

a transport system configured to move a web including a first gasket layer having spaced apart apertures and a web including gas diffusion layers;

a deposition system configured to deposit a material processable by on or both of heat and pressure on the first gasket layer;

an alignment system configured to align the gas diffusion layers and the first gasket layer having the heat/pressure processable material disposed thereon; and

a bonding station configured to bond the heat/pressure processable material to the gas diffusion layers and the first gasket layer, the heat/pressure processable material, after bonding, forming a second gasket layer that attaches the gas diffusion layers to the first gasket layer.

38. The apparatus of claim 37, wherein the alignment system is configured to align the gas diffusion layers so that the gas diffusion layers are arranged within the apertures of the first gasket layer.

39. The apparatus of claim 37, wherein the alignment system is configured to align the gas diffusion layers so that the gas diffusion layers overlap the heat/pressure processable material.

40. The apparatus of claim 37, wherein the deposition systems comprises a silk screen printing station.