Method of manufacturing fuel cells and fuel cells manufactured by the method
First Claim
1. A method of manufacturing a fuel cell comprising a layer stack of unit cells each including a polymer electrolyte film and gas diffusion electrodes, said method comprising the steps of:
- causing the polymer electrolyte film to have a water content of not greater than 4, which is expressed as a molar fraction of H2O;
providing a gas-impermeable dense carbon separator which forms a gas flow path with the surface of each diffusion electrode; and
bonding the polymer electrolyte film directly to the carbon separator with an adhesive having a modulus of elasticity of not greater than 10 MPa after cure.
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Accused Products
Abstract
The method of the present invention enhances the adhesive strength of a polymer electrolyte film via an adhesive and thereby manufactures a fuel cell having a high reliability for a gas sealing property. The method provides a pair of separators and applies an adhesive on specific areas of the separators, which are directly joined with the polymer electrolyte film. The adhesive used here is a modified rubber adhesive that is a mixture of epoxy resin and modified silicone and has a modulus of elasticity of not greater than 10 MPa and a durometer A hardness of not greater than 90 after cure. The method subsequently lays the pair of separators upon the joint body and cures the adhesive for bonding the separators directly to the polymer electrolyte film.
28 Citations
13 Claims
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1. A method of manufacturing a fuel cell comprising a layer stack of unit cells each including a polymer electrolyte film and gas diffusion electrodes, said method comprising the steps of:
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causing the polymer electrolyte film to have a water content of not greater than 4, which is expressed as a molar fraction of H2O;
providing a gas-impermeable dense carbon separator which forms a gas flow path with the surface of each diffusion electrode; and
bonding the polymer electrolyte film directly to the carbon separator with an adhesive having a modulus of elasticity of not greater than 10 MPa after cure. - View Dependent Claims (2, 3, 4, 5)
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6. A method of manufacturing a fuel cell comprising a layer stack of unit cells each including a polymer electrolyte film and gas diffusion electrodes, said method comprising the steps of:
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providing a gas-impermeable dense carbon separator which forms a gas flow path with the surface of each diffusion electrode;
providing an adhesive having a modulus of elasticity of not greater than 10 MPa after cure; and
bonding the polymer electrolyte film directly to the carbon separator with the adhesive. - View Dependent Claims (7, 8, 9, 10)
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11. A fuel cell, comprising:
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a layer stack of unit cells each including a polymer electrolyte film and gas diffusion electrodes;
a gas-impermeable dense carbon separator which forms a gas flow path with the surface of each diffusion electrode; and
a polymer electrolyte film that has a water content of not greater than 4, which is expressed as a molar fraction of H2O, and is bonded directly to the carbon separator with an adhesive having a modulus of elasticity of not greater than 10 MPa after cure.
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12. A fuel cell, comprising:
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a layer stack of unit cells each including a polymer electrolyte film and gas diffusion electrodes;
a gas-impermeable dense carbon separator which forms a gas flow path with the surface of each diffusion electrode; and
an adhesive that is used to bond the polymer electrolyte film directly to the carbon separator and has a modulus of elasticity of not greater than 10 MPa after cure.
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13. A fuel cell, comprising:
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a layer stack of unit cells each including a polymer electrolyte film and gas diffusion electrodes;
a gas-impermeable dense carbon separator which forms a gas flow path with the surface of each diffusion electrode; and
an adhesive that is used to bond the polymer electrolyte film directly to the carbon separator and has a durometer A hardness of not greater than 90 after cure.
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Specification