PROCESSING METHODS AND SYSTEMS FOR ASSEMBLING FUEL CELL PERIMETER GASKETS

• US 20080145712A1
• 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: Miller, David J., Pierpont, Daniel M., Hanson, Eric J., Ripley, Scott A., Hicks, Michael T., Iverson, Eric J.
• Granted Patent: US 8,288,059 B2
• Time in Patent Office: Days
• US Class Current: 429/12
• CPC Class Codes: B32B 2457/18 Fuel cells
• CPC Class Codes: B32B 37/025 Transfer laminating
• CPC Class Codes: B32B 37/203 One or more of the layers being plastic
• CPC Class Codes: B32B 38/0004 Cutting, tearing or severing, e.g. bursting; Cutter details cutting in general B26D; laminating combined with punching or perforating B32B38/04; removing all or part of the layers B32B38/10; cutting in combination with laying up and registration B32B38/185 takes precedence
• 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 8/0284 Organic resins; Organic polymers
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 156/1056 Perforating lamina
• CPC Class Codes: Y10T 156/1304 Means making hole or aperture in part to be laminated

Abstract

A method and apparatus for making fuel cell components via a roll to roll process are described. Spaced apart apertures are cut in first and second gasket webs that each include adhesives. The first and second gasket webs are transported to a bonding station on conveyers. A membrane web that includes at least an electrolyte membrane is also transported to the bonding station. At the bonding station, a gasketed membrane web is formed by attaching the first and second gasket webs to the membrane web. The first gasket web is attached to a first surface of the membrane web via the adhesive layer of the first gasket web. The second gasket web is attached to a second surface of the membrane web via the adhesive layer of the second gasket web.

Claims

1. A method of making fuel cell components in a roll to roll process, comprising:

cutting spaced apart apertures in a first gasket web, the first gasket web comprising a first gasket layer having an adhesive;

transporting the first gasket web having spaced apart apertures to a bonding station;

cutting spaced apart apertures in a second gasket web, the second gasket web comprising a second gasket layer having an adhesive;

transporting the second gasket web having spaced apart apertures to the bonding station;

transporting a membrane web comprising at least an electrolyte membrane to the bonding station; and

at the bonding station, forming a gasketed membrane web, comprising;

attaching the first gasket web to a first surface of the membrane web via the adhesive of the first gasket layer; and

attaching the second gasket web to a second surface of the membrane web via the adhesive of the second gasket layer.

2. The method of claim 1, wherein attaching the first gasket web to the first surface of the membrane web and attaching the second gasket web to the second surface of the membrane web are effected substantially concurrently.

3. The method of claim 1, wherein the first gasket web is attached to the membrane web before the second gasket web is attached to the membrane web.

4. The method of claim 1, further comprising placing catalyst layers on the membrane web before or after attaching the first and second gasket webs to the membrane web.

5. The method of claim 1, wherein:

the electrolyte membrane comprises a catalyst coated electrolyte membrane; and

attaching the first and second gasket webs to the membrane web comprises forming a gasketed catalyst coated membrane web.

6. The method of claim 1, further comprising:

attaching first gas diffusion layers over active areas of the gasketed membrane web; and

attaching second gas diffusion layers over active areas of the gasketed membrane web.

7. The method of claim 6, wherein the first and second gas diffusion layers are attached substantially concurrently.

8. The method of claim 6, wherein the first and second gas diffusion layers are attached sequentially.

9. The method of claim 6, wherein:

the first gas diffusion layers are disposed within apertures of the first gasket layer; and

the second gas diffusion layers are disposed within apertures of the second gasket layer.

10. The method of claim 6, wherein:

the first gas diffusion layers overlap inner edges of the first gasket layer at the apertures of the first gasket layer; and

the second gas diffusion layers overlap inner edges of the second gasket layer at the apertures of the second gasket layer.

11. The method of claim 6, wherein the first and second gas diffusion layers include catalyst layers.

12. The method of claim 1, further comprising removing adhesive liners from the adhesives of the first and second gasket layers prior to attaching the first and second gasket webs to the membrane web at the bonding station.

13. The method of claim 1, wherein attaching the first and second gasket webs to the membrane web comprises attaching the first and second gasket webs to the membrane web so that the electrolyte membrane does not extend to the edges of the first and second gasket webs in a cross web direction.

14. The method of claim 1, wherein:

the adhesive of the first gasket layer comprises a pressure sensitive adhesive;

attaching the first gasket web to the first surface of the membrane web comprises attaching the first gasket web to the first surface of the membrane web via the pressure sensitive adhesive of the first gasket layer using bonding rollers;

the adhesive of the second gasket layer comprises a pressure sensitive adhesive; and

attaching the second gasket web to the second surface of the membrane web comprises attaching the second gasket web to the second surface of the membrane web via the pressure sensitive adhesive of the second gasket layer using the bonding rollers.

15. The method of claim 1, wherein:

the adhesive of the first gasket layer comprises a heat activated adhesive;

attaching the first gasket web to the first surface of the membrane web comprises attaching the first gasket web to the first surface of the membrane web via the heat activated adhesive of the first gasket layer using heated bonding rollers;

the adhesive of the second gasket layer comprises a heat activated adhesive; and

attaching the second gasket web to the second surface of the membrane web comprises attaching the second gasket web to the second surface of the membrane web via the heat activated adhesive of the second gasket layer using the heated bonding rollers.

16. The method of claim 1, wherein:

the adhesive of the first gasket layer comprises a UV curable adhesive;

attaching the first gasket web to the first surface of the membrane web comprises attaching the first gasket web to the first surface of the membrane web via the UV curable adhesive of the first gasket layer using bonding rollers and a UV source;

the adhesive of the second gasket layer comprises a UV curable adhesive; and

attaching the second gasket web to the second surface of the membrane web comprises attaching the second gasket web to the second surface of the membrane web via the UV curable adhesive of the second gasket layer using the bonding rollers and a the UV source.

17. The method of claim 1, wherein at least one of the first and second conveyers comprises a vacuum belt, a roller, or a carrier web.

18. The method of claim 1, wherein at least one of the first gasket web, the second gasket web, and the membrane web is transported a vacuum conveyor.

19. The method of claim 1, wherein cutting spaced apart apertures in one or both of the first gasket web and the second gasket web comprises cutting the spaced apart apertures using a vacuum rotary die, the vacuum rotary die facilitating removal of aperture slugs.

50. The method of claim 19 additionally comprising the step of transporting aperture slugs to an aperture slug collection tray.

51. The method of claim 19 additionally comprising the step of transporting aperture slugs to a vacuum scrap disposal plenum.

20. An apparatus for fabricating fuel cell components, comprising:

a first cutting station configured to cut spaced apart apertures in a first gasket web, the first gasket web comprising a first gasket layer having an adhesive;

a second cutting station configured to cut spaced apart apertures in a second gasket web, the second gasket web comprising a second gasket layer having an adhesive;

a transport mechanism configured to transport and support the first gasket web, the second gasket web, and a membrane web including at least an electrolyte membrane; and

a bonding station at which the first gasket web, the second gasket web, and the membrane web are brought together by the transport mechanism, the bonding station configured to attach the first gasket web and the second gasket web, respectively, to first and second surfaces of the membrane web via the adhesives of the first and second gasket webs.

21. The apparatus of claim 20, wherein the bonding station comprises bonding rollers configured to attach the first gasket web to the first surface of the membrane web and to attach the second gasket web to the second surface of the membrane web substantially concurrently.

22. The apparatus of claim 20, wherein the bonding station comprises:

first bonding rollers configured to attach the first gasket web to the first surface of the membrane web; and

second bonding rollers configured to attach the second gasket web to the second surface of the membrane web.

23. The apparatus of claim 20, wherein the membrane web comprises a catalyst coated membrane web.

24. The apparatus of claim 20, further comprising a mechanism configured to attach gas diffusion layers over exposed active areas of the membrane web.

25. The apparatus of claim 24, wherein the gas diffusion layers include catalyst layers.

26. The apparatus of claim 24, wherein catalyst is disposed partially on the membrane web and partially on the gas diffusion layers.

27. The apparatus of claim 20, further comprising mechanisms configured to remove adhesive liners of the adhesives of each of the first and second gasket layers prior to bringing the first gasket web, the second gasket web, and the membrane web together at the bonding station.

28. The apparatus of claim 27, wherein the mechanisms comprise peel bars or idlers.

29. The apparatus of claim 20, wherein:

the adhesives of the first and second gasket webs comprise pressure sensitive adhesives; and

the bonding station is configured to facilitate attachment of the first and second gasket webs to the membrane web by application of pressure.

30. The apparatus of claim 20, wherein:

the adhesives of the first and second gasket webs comprise heat activated adhesives; and

the bonding station is configured to facilitate attachment of the first and second gasket webs to the membrane web by application of heat.

31. The apparatus of claim 20, wherein:

the adhesives of the first and second gasket webs comprise UV curable adhesives; and

the bonding station is configured to facilitate attachment of the first and second gasket webs to the membrane web by a UV curing process.

32. The apparatus of claim 20, wherein at least one of the first and second conveyer mechanisms comprises a vacuum belt, a roller, or a carrier web.

33. The apparatus of claim 20, wherein the bonding station comprises one or more cylindrical rollers.

34. The apparatus of claim 20, wherein at least one of the first gasket web, the second gasket web and the membrane web is transported on a releasable adhesive carrier web.

35. The apparatus of claim 20, wherein at least one of the cutting stations comprises a rotary die cutter, a laser cutter, or a die press.

36. The apparatus of claim 20, wherein the first gasket web comprises a different material from the second gasket web.

37. The apparatus of claim 20, wherein a thickness of the first gasket web differs from a thickness of the second gasket web.

52. The apparatus of claim 20, wherein one or both of said first cutting station and said second cutting station comprise a vacuum rotary die.

53. The apparatus of claim 52, wherein one or both of said first cutting station and said second cutting station comprise an aperture slug collection tray configured so as to receive aperture slugs transported by said vacuum rotary die.

54. The apparatus of claim 52, wherein one or both of said first cutting station and said second cutting station comprise a vacuum scrap disposal plenum configured so as to receive aperture slugs transported by said vacuum rotary die.

38. A fuel cell roll good subassembly, comprising:

a membrane web comprising first and second surfaces;

a first catalyst layer disposed on the first surface of the membrane web;

a second catalyst layer disposed on the second surface of the membrane web;

a first gasket web comprising a gasket layer and an adhesive, the first gasket web attached via the adhesive of the first gasket web to the first surface of the membrane, one or more apertures in the first gasket web exposing one or more active areas of the first catalyst layer; and

a second gasket web comprising a gasket layer and an adhesive, the second gasket web attached via the adhesive of the second gasket web to the second surface of the membrane, one or more apertures in the second gasket web exposing one or more active areas of the second catalyst layer.

39. The subassembly of claim 38, wherein the first gasket web overlaps least a portion of the first catalyst layer.

40. The subassembly of claim 38, further comprising:

one or more first gas diffusion layers disposed over the one or more active areas of the first catalyst layer and overlapping at least a portion of the first gasket web; and

one or more second gas diffusion layers disposed over the one or more active areas of the second catalyst layer and overlapping at least a portion of the second gasket web.

41. The subassembly of claim 38, further comprising:

one or more first gas diffusion layers disposed over the one or more active areas of the first catalyst layer and within apertures of the first gasket web; and

one or more second gas diffusion layers disposed over the one or more active areas of the second catalyst layer and within apertures of the second gasket web.

42. The subassembly of claim 38, wherein the gasket layers of the first and second gasket webs are attached together via their respective adhesives.

43. The subassembly of claim 38, wherein the membrane web does not extend to one or more outside edges of the first and second gasket webs.

44. The subassembly of claim 38, wherein the first catalyst layer does not extend to one or more outside edges of the first gasket web.

45. A method of making a half gasketed membrane web in a roll to roll process, comprising:

cutting spaced apart apertures in a gasket web, the gasket web comprising a gasket layer having an adhesive;

transporting the gasket web having spaced apart apertures to a bonding station;

transporting a membrane web comprising at least an electrolyte membrane to the bonding station; and

at the bonding station, attaching the gasket web to a surface of the membrane web via the adhesive of the gasket layer.

46. The method of claim 45, further comprising placing catalyst layers on the membrane web before or after attaching the gasket web to the membrane web.

47. The method of claim 45, wherein:

the adhesive of the gasket layer comprises a pressure sensitive adhesive; and

attaching the gasket web to the surface of the membrane web comprises attaching the gasket web to the surface of the membrane web via the pressure sensitive adhesive of the gasket layer using bonding rollers.

48. The method of claim 45, wherein:

the adhesive of the gasket layer comprises a heat activated adhesive;

attaching the gasket web to the surface of the membrane web comprises attaching the gasket web to the surface of the membrane web via the heat activated adhesive of the gasket layer using heated bonding rollers.

49. The method of claim 45, wherein:

the adhesive of the gasket layer comprises a UV curable adhesive; and

attaching the gasket web to the first surface of the membrane web comprises attaching the gasket web to the surface of the membrane web via the UV curable adhesive of the gasket layer using bonding rollers and a UV source.

55. The method of claim 45, further comprising:

attaching first gas diffusion layers over active areas of the gasketed membrane web; and

attaching second gas diffusion layers over active areas of the gasketed membrane web.

56. An apparatus for fabricating a half gasketed membrane web in a roll to roll process, comprising:

a cutting station configured to cut spaced apart apertures in a gasket web, the gasket web comprising a gasket layer having an adhesive;

a transport mechanism configured to transport and support the gasket web and a membrane web including at least an electrolyte membrane; and

a bonding station at which the gasket web and the membrane web are brought together by the transport mechanism, the bonding station configured to attach the gasket web to a surface of the membrane web via the adhesive of the gasket layer.

57. A fuel cell roll good subassembly, comprising:

a membrane web comprising a first surface;

a gasket web comprising a gasket layer and an adhesive, the gasket web attached via the adhesive of the gasket web to the first surface of the membrane, one or more apertures in the first gasket web exposing one or more areas of the membrane web.