Method and device for producing a membrane module for a fuel cell and membrane modules produced thereby

• US 9,314,744 B2
• Filed: 06/11/2012
• Issued: 04/19/2016
• Est. Priority Date: 12/09/2011
• Status: Active Grant

• Current Assignee: Hyundai Motor Company (Hyundai Motor Group), Kia Motors Corporation (Kia Corp.)
• Original Assignee: Hyundai Motor Company (Hyundai Motor Group), Kia Motors Corporation (Kia Corp.)
• Inventors: Kim, Hyun Yoo, Kwon, Hyuck Roul
• Primary Examiner(s): DOUYETTE, KENNETH J
• Application Number:
  US13/493,169
• Publication Number:
  US 20130149634A1
• Time in Patent Office: 1,408 Days
• Field of Search: 429/516, 429/535, 264/138, 425/542, 239/34
• US Class Current: 1/1
• CPC Class Codes: B01D 63/021 Manufacturing thereof
• CPC Class Codes: B01D 63/0233 forming the bundle
• CPC Class Codes: B01D 63/04 comprising multiple hollow fibre assemblies
• CPC Class Codes: H01M 2008/1095 Fuel cells with polymeric electrolytes
• CPC Class Codes: H01M 8/04149 by diffusion, e.g. making use of membranes
• 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

Disclosed is a method and device for producing a membrane module used in a membrane humidifier for humidifying air in a polymer fuel cell, in which a small amount of hollow fiber membranes are disposed in the center of the membrane module and a larger amount of hollow fiber membranes are disposed toward the edge based on the design of a potting cap. Dry air introduced from an air blower into the membrane can be distributed to the edge where the larger amount of hollow fiber membranes are disposed, thereby maintaining uniform humidification performance over the entire hollow fiber membranes.

Claims

1. A method for producing a membrane module for a fuel cell, the method comprising:

producing a case having outer walls, a top side and a bottom side;

disposing a first potting cap on the bottom side of the case, the first potting cap comprising an inner surface and a plurality of circular partitions protruding a predetermined height from the inner surface of the potting cap, the plurality of partitions having different diameters and being concentrically disposed and spaced apart at predetermined intervals;

placing a plurality of bundles of hollow fiber membranes in the case through the top side, wherein the hollow fiber membranes are divided by the plurality of partitions each of which has thickness larger than diameter of each hollow fiber membrane such that a first amount of hollow fiber membranes are disposed in a center portion of the case and a second amount of hollow fiber membranes are disposed toward an outer portion of the case, wherein the second amount is larger than the first amount;

disposing a second potting cap on the top side of the case;

injecting a polymer material into the case to fix the plurality of bundles of hollow fiber membranes;

drying the polymer material to thereby form a potted portion; and

cutting the potted portion,

wherein a plurality of gaps are formed between the plurality of partitions in a radial direction,

wherein the gap between the partitions formed in the potting cap is reduced from the partition disposed at the outermost side to the partitions disposed toward the center such that a smaller amount of hollow fiber membranes is disposed in the center portion of the module and a larger amount of hollow fiber membranes is disposed toward the outer edge portion to maintain humidification performance throughout the whole membrane module.

2. The method of claim 1, wherein the plurality of gaps reduce in size from an outermost gap to an innermost gap.

3. The method of claim 1, wherein a plurality of gaps are formed between the plurality of partitions, and wherein the plurality of gaps are varied in size by varying the widths of the plurality of partitions.

4. The method of claim 1, wherein the plurality of gaps are varied in size by varying the widths of the plurality of partitions.

5. The method of claim 1, wherein the plurality of gaps are varied in size by varying the widths of the plurality of partitions.

6. A membrane module formed by the method of claim 1.

7. A fuel cell comprising the membrane module of claim 6.

8. A device for producing a membrane module for a fuel cell by a potting method comprising:

a case having outer walls, a top side and a bottom side, a plurality of bundles of hollow fiber membranes being placed in the case through the top side;

a first potting cap disposable on the bottom side of the case, the first potting cap comprising an inner surface and a plurality of circular partitions protruding a predetermined height from the inner surface of the potting cap, the plurality of partitions having different diameters and being concentrically disposed and spaced apart at predetermined intervals, each of which has thickness larger than diameter of each hollow fiber membrane;

a second potting cap disposable on the top side of the case;

one or more injection inlets for injecting a polymer material into the case,

wherein a plurality of gaps are formed between the plurality of partitions in a radial direction,

wherein the gap between the partitions formed in the potting cap is reduced from the partition disposed at the outermost side to the partitions disposed toward the center such that a smaller amount of hollow fiber membranes is disposed in the center portion of the module and a larger amount of hollow fiber membranes is disposed toward the outer edge portion to maintain humidification performance throughout the whole membrane module.

9. The device of claim 8, wherein the plurality of gaps reduce in size from an outermost gap to an innermost gap.

10. The device of claim 8, wherein a plurality of gaps are formed between the plurality of partitions, and wherein the plurality of gaps are varied in size by varying the widths of the plurality of partitions.