FUEL CELL SUBASSEMBLIES INCORPORATING SUBGASKETED THRIFTED MEMBRANES

• US 20110151350A1
• Filed: 12/20/2010
• Published: 06/23/2011
• Est. Priority Date: 12/22/2009
• Status: Active Grant

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: Obradovich, Stephan J., Iverson, Eric J., Pierpont, Daniel M., Hamrock, Steven J., Peterson, Donald G., Yandrasits, Michael A.
• Granted Patent: US 8,637,205 B2
• Time in Patent Office: Days
• US Class Current: 429/480
• 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 8/0276 Sealing means characterised by their form H01M8/0273 takes precedence
• 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 8/1016 characterised by the electrolyte material H01M8/12 takes precedence
• CPC Class Codes: H01M 8/2418 Grouping by arranging unit cells in a plane H01M8/2425, H01M8/244 take precedence
• CPC Class Codes: H01M 8/242 comprising framed electrodes or intermediary frame-like gaskets H01M8/2425, H01M8/244 take precedence
• 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

A fuel cell roll good subassembly is described that includes a plurality of individual electrolyte membranes. One or more first subgaskets are attached to the individual electrolyte membranes. Each of the first subgaskets has at least one aperture and the first subgaskets are arranged so the center regions of the individual electrolyte membranes are exposed through the apertures of the first subgaskets. A second subgasket comprises a web having a plurality of apertures. The second subgasket web is attached to the one or more first subgaskets so the center regions of the individual electrolyte membranes are exposed through the apertures of the second subgasket web. The second subgasket web may have little or no adhesive on the subgasket surface facing the electrolyte membrane.

Claims

1. A fuel cell roll good subassembly, comprising:

a plurality of individual electrolyte membranes, each electrolyte membrane comprising a center region;

one or more first subgaskets attached to the individual electrolyte membranes, each of the first subgaskets having at least one aperture, the first subgaskets arranged so that the center regions of the individual electrolyte membranes are exposed through the apertures of the first subgaskets; and

a second subgasket comprising an web having a plurality of apertures, the second subgasket web arranged so that center regions of the individual electrolyte membranes are exposed through the apertures of the second subgasket web.

2. The roll good subassembly of claim 1, wherein;

each of the one or more first subgaskets comprises a first subgasket layer having a first subgasket surface oriented toward the electrolyte membrane, the first subgasket having a first adhesive layer disposed on the first subgasket surface; and

the second subgasket comprises a second subgasket layer having a second subgasket surface oriented toward the electrolyte membrane, wherein a second adhesive layer is not disposed on substantial portions of the second subgasket surface.

3. The roll good subassembly of claim 2, wherein the first adhesive layer of each of the first subgaskets is attached to the second subgasket surface.

4. The roll good subassembly of claim 1, wherein:

each of the first subgaskets comprises a first subgasket layer having a first subgasket surface oriented toward the electrolyte membrane, each of the first subgaskets having a first adhesive layer disposed on the first subgasket surface; and

the second subgasket comprises a second subgasket layer having a second subgasket surface oriented toward the electrolyte membrane, the second subgasket having a second adhesive layer disposed on the second subgasket surface.

5. The roll good subassembly of claim 1, wherein the one or more first subgaskets is one first subgasket comprising an web having a plurality of apertures.

6. The roll good assembly of claim 1, wherein at least some of the individual electrolyte membranes are catalyst coated membranes.

7. The roll good assembly of claim 1, further comprising gas diffusion layers or catalyst coated gas diffusion layers disposed over the center regions of the individual electrolyte membranes.

8. The roll good subassembly of claim 1, wherein;

each of the one or more first subgaskets comprises a first subgasket layer having a first subgasket surface oriented toward an individual electrolyte membrane, each of the one or more first subgaskets having a first adhesive layer disposed on the first subgasket surface;

the second subgasket comprises a second subgasket layer having a second subgasket surface oriented toward the individual electrolyte membranes, wherein a second adhesive layer is not disposed on the second subgasket surface.

9. A fuel cell roll good subassembly, comprising:

a plurality of individual electrolyte membranes, each individual electrolyte membrane comprising a center region; and

a subgasket web attached to the plurality of individual electrolyte membranes, the subgasket web having a plurality of apertures and arranged so that the center regions of the individual electrolyte membranes are exposed through the apertures of the subgasket web.

10. The fuel cell roll good assembly of claim 9, wherein the subgasket web comprises a ladder web.

11. A fuel cell subassembly, comprising:

an electrolyte membrane; and

a first subgasket adhesively attached to the electrolyte membrane, the first subgasket having a first subgasket surface oriented toward the electrolyte membrane and a first adhesive layer disposed on the first subgasket surface; and

a second subgasket having a second subgasket surface oriented toward the electrolyte membrane, wherein the second subgasket does not include a second adhesive layer on substantial portions of the second subgasket surface.

12. The fuel cell subassembly of claim 11, wherein the second subgasket is devoid of adhesive on the second subgasket surface.

13. The fuel cell subassembly of claim 11, wherein the first adhesive layer is in contact with the second gasket surface.

14. The fuel cell subassembly of claim 11, wherein the second subgasket is not adhesively attached to the electrolyte membrane and is adhesively attached by the first adhesive layer to the first subgasket.

15. A fuel cell roll good subassembly, comprising:

a plurality of individual electrolyte membranes, each electrolyte membrane comprising a center region;

one or more first subgaskets adhesively attached to the individual electrolyte membranes, each of the first subgaskets having at least one aperture, the first subgaskets arranged so the center regions of the individual electrolyte membranes are exposed through the apertures of the first subgaskets; and

a second subgasket comprising an web having a plurality of apertures, the second subgasket web arranged so that second surfaces of the center regions of the individual electrolyte membranes are exposed through the apertures of the second subgasket web, wherein an adhesive layer is not disposed on substantial portions of the second subgasket surface.

16. The fuel cell roll good subassembly of claim 15, wherein the first adhesive layer of each of the first subgaskets is in contact with the second subgasket surface.

17. The fuel cell roll good subassembly of claim 15, wherein the one or more one or more first subgaskets comprises a web having a plurality of apertures.

18. The fuel cell roll good assembly of claim 15, wherein the electrolyte membrane comprises a catalyst coated membrane.

19. The fuel cell roll good assembly of claim 15, further comprising gas diffusion layers or catalyst coated gas diffusion layers disposed over the center regions of the individual electrolyte membranes.

20. An automated roll to roll method of making a fuel cell roll good subassembly, comprising:

providing relative motion between an elongated first subgasket web having a plurality of apertures and a plurality of individual electrolyte membranes, each individual electrolyte membrane having a center region;

aligning the individual electrolyte membranes with the first subgasket web so that a center region of each electrolyte membrane is aligned with an aperture of the first subgasket web; and

attaching the individual electrolyte membranes to the first subgasket web.

21. The method of claim 20, wherein the first subgasket web is disposed on a repositionable adhesive carrier web.

22. The method of claim 20, further comprising:

cutting the first subgasket web having the individual electrolyte membranes attached thereto into a plurality of individual subgasketed membranes;

providing relative motion between a second subgasket web having a plurality of apertures and the plurality of individual subgasketed membranes;

aligning the individual subgasketed membranes with the second subgasket web so that a center region of each electrolyte membrane is aligned with an aperture of the second subgasket web; and

attaching the individual subgasketed membranes to the second subgasket web.

23. The method of claim 22, wherein the second subgasket web is disposed on repositionable adhesive carrier web.

24. The method of claim 22, wherein:

the first subgasket web includes a first subgasket surface oriented toward the individual electrolyte membranes and a first adhesive layer is disposed on a first subgasket surface; and

the second subgasket web includes a second subgasket surface oriented toward the individual electrolyte membranes and a substantial portion of the second subgasket surface does not include a second adhesive layer.

25. The method of claim 22, wherein:

the first subgasket web includes a first subgasket surface oriented toward the individual electrolyte membranes and a first adhesive layer is disposed on a first subgasket surface; and

the second subgasket web includes a second subgasket surface oriented toward the individual electrolyte membranes the second subgasket surface does not include a second adhesive layer.

26. The method of claim 20, further comprising:

providing relative motion between an second subgasket web having a plurality of apertures and the first subgasket web having the individual electrolyte membranes attached thereto;

aligning the second subgasket web with the first subgasket web having the individual electrolyte membranes attached thereto so that a center region of each electrolyte membrane is aligned with an aperture of the second subgasket web; and

attaching the first subgasket web having the individual electrolyte membranes attached thereto to the second subgasket web.

27. The method of claim 26, wherein:

the first subgasket web includes a first subgasket surface oriented toward the individual electrolyte membranes and a first adhesive layer is disposed on a first subgasket surface; and

the second subgasket web includes a second subgasket surface oriented toward the individual electrolyte membranes and the second subgasket surface does not include a second adhesive layer.

28. The method of claim 26, wherein one or both of the first subgasket web and the second subgasket web are disposed on a repositionable carrier web.

29. The process of claim 20, further comprising:

moving an electrolyte membrane web into contact with a rotating die; and

cutting the electrolyte membrane web into the individual electrolyte membranes using the rotating die.

30. The process of claim 29, wherein the rotating die comprises a rotating vacuum die that retains the individual electrolyte membranes on a surface of the rotating die and moves the individual electrolyte membranes into contact with the first subgasket web.

31. The method of claim 30, wherein the rotating die comprises:

a cylindrical core;

die blades on the cylindrical core defining die cavities and gaps between the die cavities; and

compliant die cavity inserts disposed within the die cavities.