Membrane electrode assembly, fuel cell comprising assembly of this type and motor vehicle comprising said fuel cell

Abstract

A membrane electrode assembly for a fuel cell that includes a membrane electrode unit with a membrane and two electrodes which make surface contact with both faces of the membrane. The membrane electrode assembly has a seal support that surrounds the periphery of the membrane and that overlaps the latter. The membrane electrode also has a connecting layer which continuously overlaps the membrane and the seal support, an inner edge section of the connecting layer being bonded to the membrane electrode unit and an outer edge section of the connecting layer being bonded to the seal support on the same flat face of the connecting layer. A seal is connected outside the membrane to the seal support. A fuel cell is provided that includes a plurality of membrane electrode assemblies. A motor vehicle includes the fuel cell and a method is provided for producing the membrane electrode assembly.

Claims

1. A membrane electrode arrangement for a fuel cell, comprising: a membrane electrode assembly that includes a membrane and two electrodes that make surface contact with both sides of the membrane; a seal support that circumferentially surrounds and overlaps the membrane, such that, in a fully assembled state of the membrane electrode arrangement, a first planar surface of the seal support, that extends continuously along a single plane, non-integrally contacts the membrane in an overlapping region of the seal support and the membrane; a connecting layer that circumferentially overlaps the membrane and the seal support, one side of the connecting layer being coated with an adhesive such that an inner edge section of the one side of the connecting layer is integrally connected to the membrane electrode assembly and an outer edge section of the one side of the connecting layer is integrally connected to the first planar surface of the seal support by an adhesive bond; and a seal that is connected to the seal support outside the membrane and outside the connecting layer, wherein a portion of the seal directly contacts the first planar surface of the seal support and a second portion of the seal directly contacts a second planar surface of the seal support, the second planar surface opposing the first planar surface.

2. The membrane electrode arrangement according to claim 1, wherein the connecting layer is disposed on a flat side of the membrane opposite the seal support.

3. The membrane electrode arrangement according to claim 1, wherein the connecting layer is a self-adhesive film.

4. The membrane electrode arrangement according to claim 1, wherein an inner edge of the connecting layer ends in an offset against an inner edge of the seal support or projects beyond it.

5. The membrane electrode arrangement according to claim 1, wherein the seal support has a perforation along which the seal extends on both sides of the seal support, wherein the seal includes a first subsection and a second subsection, wherein the first subsection of the seal is the portion of the seal that directly contacts the first planar surface of the seal support and the second subsection of the seal is the second portion of the seal that directly contacts the second planar surface of the seal support, and wherein the first and second subsections are connected to each other as a single piece via the perforation.

6. A fuel cell comprising a plurality of alternately stacked bipolar plates and a membrane electrode arrangement according to claim 1.

7. A motor vehicle comprising a fuel cell according to claim 6.

8. The membrane electrode arrangement according to claim 1, further comprising a first gas diffusion layer that overlaps the membrane and the connecting layer on a first side of the membrane and a second gas diffusion layer that overlaps the membrane and the seal support on a second side of the membrane.

9. The membrane electrode arrangement according to claim 1, wherein the seal is connected to the seal support outside the membrane and outside the connecting layer, such that the seal is directly connected solely to the seal support.

10. The membrane electrode arrangement according to claim 1, wherein an inner edge of the connecting layer projects beyond an inner edge of the seal support.

11. The membrane electrode arrangement according to claim 1, wherein the seal support and the connecting layer are each formed as flat, planar members.

12. A method for manufacturing a membrane electrode arrangement according to claim 1, the method comprising: manufacturing the seal in a region of the seal support, such that the portion of the seal directly contacts the first planar surface of the seal support and the second portion of the seal directly contacts the second planar surface of the seal support; placing the membrane electrode assembly on the seal support such that the first planar surface of the seal support, that extends continuously along a single plane, non-integrally contacts the membrane electrode assembly; and subsequently integrally connecting the inner edge section of the connecting layer to the membrane electrode assembly and the outer edge section of the connecting layer to the first planar surface of the seal support, wherein the seal support continues to non-integrally contact the membrane electrode assembly in a fully assembled state of the membrane electrode arrangement.

13. The method according to claim 12, wherein the seal is overmolded onto the seal support.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The present invention will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and thus, are not limitive of the present invention, and wherein:

(2) FIG. 1 shows a membrane electrode arrangement according to the invention according to one preferred embodiment of the invention;

(3) FIG. 2 shows an exploded view of the membrane electrode arrangement;

(4) FIG. 3 shows the seal support;

(5) FIG. 4 shows the seal support with the seal;

(6) FIG. 5 shows the seal support with the seal and the membrane;

(7) FIG. 6 shows the seal support with the seal, the membrane and the connecting layer;

(8) FIG. 7 shows the membrane electrode arrangement with the diffusion layers;

(9) FIG. 8 shows a fuel cell comprising the membrane electrode arrangement; and

(10) FIG. 9 shows a motor vehicle comprising the fuel cell.

DETAILED DESCRIPTION

(11) According to an exemplary embodiment of the invention, a membrane electrode arrangement 10 is illustrated in FIG. 1 in a top view, a sectional view (A-A) and a detailed view of the sectional view (A-A).

(12) Membrane electrode arrangement 10 comprises a membrane electrode assembly 12 (MEA), a seal support 14 and a seal 16, which is connected to seal support 14. Seal support 14 may have openings 18 for the passage of operating media.

(13) Membrane electrode assembly 12 (MEA) includes a membrane 20 and electrodes 22 disposed on both sides of membrane 20. (The electrodes themselves are not illustrated, only their positions are marked.) Membrane electrode arrangement 10 provides a chemically active region 26, to which reactants are applied during operation and in which the desired reactions take place. Both flat sides of membrane 20 are usually completely covered by electrodes 22. However, electrodes 22 may furthermore also be limited to the chemically active region and thus only partially cover the flat sides of membrane 20.

(14) As is apparent in sectional view A-A and the corresponding detailed view, membrane 20 is fitted into an opening region of seal support 14. Membrane 20 and, in the example, entire membrane electrode assembly 12 circumferentially overlap seal support 14, and it is connected to seal support 14 by a connecting layer 24. This is accomplished in that connecting layer 24 is integrally connected to membrane electrode assembly 12, i.e., to its membrane 20 and/or electrodes 22, and is also integrally connected to seal support 14. For this purpose connecting layer 24 circumferentially overlaps both membrane 20 and seal support 14. To implement the integral connection, connecting layer 24 may be designed as a self-adhesive film. As a rule, the latter is coated with an adhesive, which (on the same flat side of connecting layer 24) makes contact with membrane electrode assembly 12 in an inner edge section 28 and with seal support in an outer edge section 30. Since both seal support 14 and connecting layer 24 have a closed circumferential shape, they surround membrane 20 and, in particular, chemically active region 26. Due to the likewise closed, circumferential integral connection between connecting layer 24 and membrane electrode assembly 12, as well as between connecting layer 24 and seal support 14, circumferentially closed sealing regions are created, which prevent reactants from passing from one side of membrane 20 to the other side of membrane 20 during operation.

(15) As is apparent, membrane electrode assembly 12 may be disposed between seal support 14 and connecting layer 24, so that membrane 20 is stabilized in its edge regions between seal support 14 and connecting layer 24. In other words, connecting layer 24 may be disposed on a flat side of membrane 20 opposite seal support 14.

(16) In addition, an inner edge 32 of connecting layer 24 may end with an offset against an inner edge 34 of seal support 14, whereby the mechanical load on relatively sensitive membrane electrode assembly 12 is reduced. In the illustrated case, inner edge 32 of connecting layer 24 projects beyond inner edge 34 of seal support 14.

(17) Gas diffusion layers 36 may abut membrane electrode assembly 12 on both sides.

(18) Seal 16 may have a first subsection 38 and a second subsection 40, which extend on both sides of seal support 14. The two subsections 38, 40 may each form two sealing lips 42. The subsections can have sealing surfaces 44 for sealing a bipolar plate. To reduce a mechanical load on seal support 14, sealing surfaces 44 may be provided with a mirror-symmetrical design with respect to seal support 14.

(19) FIG. 2 shows an exploded view of membrane electrode arrangement 10, which is already known from FIG. 1 and which was already discussed above. The following FIGS. 3 through 7 shows the individual steps according to one preferred sequence for manufacturing membrane electrode arrangement 10.

(20) The manufacturing method can begins with seal support 14 shown in FIG. 3 (edge reinforcement or film support). It may have operating medium openings 18 and an opening region 46. In addition, seal support 14 may have a perforation 48, along which seal 16 is mounted onto seal support 14 in the next manufacturing step. Operating medium openings 18 as well as opening region 48 and recesses of perforation 48 are recesses which pass through seal support 14. These through-recesses 18, 46, 48 and the contour of seal support 14 may usually be produced by stamping seal support 14 out of a film (for example a plastic film) of the seal support.

(21) One option for mounting seal 16 onto seal support 14 is to overmold seal 16 onto seal support 14. This takes place within an injection molding die, by injecting a reaction mixture, comprising a polymer to be cross-linked or monomers and possibly a cross-linking agent into the injection molding die. Thanks to perforation 48, a pressure compensation may take place within the reaction mixture of the two subsections 38, 40 during the overmolding process. A deformation of seal support 14, due to possible, different pressures on both sides of seal support 14, may be prevented thereby. After overmolding, a cross-linking and/or polymerization process usually occur(s), which take(s) place by heating the reaction mixture over a predefined period, Thanks to perforation 48, the two subsections 38, 40 are connected to each other as a single piece through perforation 48, whereby seal 16 is connected to seal support 14 in a form-locked manner.

(22) Seal 16, which is already connected to seal support 14, i.e., can be overmolded thereon, is apparent in FIG. 4. This unit may also be referred to as a film sealing frame.

(23) A joining of seal support 14 and membrane electrode assembly 12 can takes place as the next step—see FIG. 5. For this purpose, membrane electrode assembly 12 is positioned above seal support 14 in the illustrated example, opening region 46, which is still visible in FIG. 4, being closed by membrane electrode assembly 12. Membrane 20 overlaps seal support 14 in its edge regions.

(24) FIG. 6 shows membrane electrode arrangement 10 after another manufacturing step. Connecting layer 24 (adhesive frame), e.g., a self-adhesive film, is integrally connected to membrane electrode assembly 12 and seal support 14, overlapping therewith, in the illustrated frame mold.

(25) Alternatively, seal support 14 may also be integrally connected directly to membrane electrode assembly 12 in the edge region overlapping membrane 20 by applying an adhesive (on seal support 14 and/or membrane electrode assembly 12, e.g., its membrane 20). Implementing this variant, however, requires a relatively complex step of applying the adhesive to the particular edge region. A bonding with the aid of connecting layer 24 is therefore preferred.

(26) In the final step, gas diffusion layers 36 may still be integrally connected or laminated onto both sides of membrane electrode assembly 12. FIG. 7 shows membrane electrode arrangement 10 after this step.

(27) A fastening of membrane 20 thus takes place on seal support 14 (i.e., on a single layer of edge reinforcement), which is already provided with seal 16, by applying connecting layer 24 (for example an adhesive frame).

(28) Due to the invention, a connection of seal 16 to seal support 14, i.e., an overmolding of seal 16 onto seal support 14 (or even an insert-molding of seal support 14 with seal 16) takes place before seal support 14 is connected to membrane 20. At the same time, this connection of seal support 14 to membrane 20 takes place in a conceivably easy manner with the aid of connecting layer 24. Due to the subsequent mounting of membrane electrode assembly 12, the reject costs are reduced and the process times for overmolding seal 16 are shortened.

(29) Due to the one-sided bonding, a stable membrane electrode arrangement 10 is achieved, which is more cost-effective and more reliable to manufacture.

(30) FIG. 8 shows a schematic representation of a fuel cell 50 comprising multiple membrane electrode arrangements 10 according to the invention. Membrane electrode arrangements 10 are stacked, alternating with bipolar plates 52, to form a fuel cell stack 54 comprising multiple individual cells 56.

(31) Bipolar plates 52 supply membrane electrode assemblies 12 of membrane electrode arrangements 10 with reactants via gas diffusion layers 36, for which purpose suitable channels are usually provided in bipolar plates 52. In addition, bipolar plates 52 electrically conductively connect two adjacent membrane electrode assemblies 12, whereby they are connected in series. The two end bipolar plates are also referred to as monopolar plates, since they supply adjacent membrane electrode assembly 12 only on one side and, for this purpose, have corresponding channels only on one of their sides.

(32) Seals 16 of membrane electrode arrangements (10) seal the spaces between membrane electrode assemblies 12 and bipolar plates 52 to the outside and thus prevent the operating media from exiting fuel cell stack 54 during the operation of fuel cell 50.

(33) To ensure the proper functioning of seals 16 as well as an electrically conductive contact of bipolar plates 52 to membrane electrode assemblies 12, even during vibrations (e.g., due to a use in a motor vehicle), fuel cell stack 54 can be pressed. This is usually done with the aid of two end plates 58, which are disposed on both ends of fuel cell stack 54, in combination with multiple tension elements 60. Tension elements 60 conduct tensile forces into end plates 58, so that end plates 58 press fuel cell stack 54 together.

(34) FIG. 9 shows a motor vehicle 62 comprising fuel cell 50. Fuel cell 50 provides electrical energy during operation of motor vehicle 62, for example, for an electrical drive system of motor vehicle 62.

(35) The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are to be included within the scope of the following claims.