CN102810681B - The process based on photosensitive polymer is used to manufacture fuel cell - Google Patents

The process based on photosensitive polymer is used to manufacture fuel cell Download PDF

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Publication number
CN102810681B
CN102810681B CN201210178065.6A CN201210178065A CN102810681B CN 102810681 B CN102810681 B CN 102810681B CN 201210178065 A CN201210178065 A CN 201210178065A CN 102810681 B CN102810681 B CN 102810681B
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Prior art keywords
radiation
sensitive materials
mask
flow field
diffusion media
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CN201210178065.6A
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CN102810681A (en
Inventor
J.A.罗克
Y-H.赖
K.E.纽曼
G.W.弗利
P.刘
A.J.雅各布森
W.B.卡特
P.D.布鲁尔
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HRL Laboratories LLC
GM Global Technology Operations LLC
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HRL Laboratories LLC
GM Global Technology Operations LLC
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Priority claimed from US13/151,734 external-priority patent/US9005847B2/en
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M8/00—Fuel cells; Manufacture thereof
    • H01M8/02—Details
    • H01M8/0202—Collectors; Separators, e.g. bipolar separators; Interconnectors
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/30—Hydrogen technology
    • Y02E60/50—Fuel cells
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
    • Y02P70/50—Manufacturing or production processes characterised by the final manufactured product

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  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Sustainable Development (AREA)
  • Sustainable Energy (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electrochemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Fuel Cell (AREA)

Abstract

Manufacture a method for fuel cell component, comprise step: provide there are multiple radiation transparent holes mask, to the radiation-sensitive materials of described multiple radiation beam sensitivity and flow field layer.Radiation-sensitive materials is arranged in flow field layer.Then, by the radiation transparent hole in mask, radiation-sensitive materials is exposed to described multiple radiation beam, to form the diffusion media layers with micro-truss structure.

Description

The process based on photosensitive polymer is used to manufacture fuel cell
the cross reference of related application
The application is the part continuity of the U.S. Patent Application Serial Number 12/341,062 that on December 22nd, 2008 submits to.Whole disclosures of above-mentioned application are herein incorporated by reference.
Technical field
The present invention relates to fuel cell, and relate more specifically to the fuel cell component that manufactured by photosensitive polymerization.
Background technology
Fuel cell proposes as a kind of power source that is clean, efficient and environmental protection for motor vehicle and other application various.Discrete fuel cell can in series be stacked to form fuel cell pack, for various application.Fuel cell pack can supply the electricity being enough to provide power to vehicle.Particularly, fuel cell pack has been considered to may substituting of the general internal combustion engine used in modern automotive.
A kind of fuel cell is polymer dielectric film (PEM) fuel cell.PEM fuel cell comprises three basic elements of character: dielectric film; And pair of electrodes, described electrode comprises negative electrode and anode.Dielectric film folder is between said electrodes to form membrane electrode assembly (MEA).MEA is arranged between porous diffusion media (DM) (e.g., carbon fiber paper) usually, and described DM is beneficial to the conveying of reactant, such as hydrogen is transported to anode and by oxygen infusion to negative electrode.Electrochemical fuel cell reaction in, hydrogen at anode-catalyzed oxidation, to produce free proton and electronics.Proton arrives negative electrode through electrolyte.The electronics coming from anode can not pass dielectric film, and being conducted through electric loading (such as, electro-motor) as electric current arrives negative electrode on the contrary.Oxygen in proton and negative electrode and electron reaction produce water.
Other reactant (such as, methyl alcohol) is used also to be known in a pem fuel cell.Methyl alcohol can catalytic oxidation to form carbon dioxide.The proton coming from methanol oxidation flows to negative electrode through dielectric film, and proton to react with the oxygen usually coming from air at negative electrode and produces water.As hydrogen PEM fuel cell, electronics flows to negative electrode as electric current from anode by external loading (such as, electro-motor).
Dielectric film is formed by ionomer layer usually.Typical ionomer is perfluorinated sulfonic acid (PFSA) polymer, such as, and the Nafion that can obtain from E.I. du Pont de Nemours and Company business.The electrode of fuel cell is formed by the catalyst segmented usually.Catalyst can be any eelctro-catalyst of catalysis support at least one in the reduction of the hydrogen of electrochemical reaction of fuel battery or the oxidation of methyl alcohol and oxygen.Catalyst is noble metal normally, such as platinum or other platinum group metal.Catalyst is usually arranged on carbon carrier (such as carbon black granules) and goes up and intersperse with ionomeric form.
Dielectric film, electrode and DM to be arranged between a pair fuel cell plate and such as to seal with sealing gasket, and sealing gasket provides roughly fluid-tight sealing.Fuel cell plate can have the multiple passages formed wherein, for by reactant and coolant distribution to fuel cell.Fuel cell plate, usually by being formed for the conventional process of formed sheet metal, such as compacting, machine work, to be molded or by the photoetch of mask.When bipolar fuel cell plate, fuel cell plate is formed by a pair unipolar plate usually, and described unipolar plate is then combined.Also known to composite material formation fuel cell plate, such as graphite composite or graphite-filled polymer.Unfortunately, be expensive with consuming time for the formation of each known method in dielectric film, electrode, dispersive medium and fuel cell plate.
Also knownly the fuel cell component comprising fuel cell plate is such as manufactured according to conventional polymer bubbling process by reticulated foam.But conventional blister process produces the three-dimensional microstructures of heterogeneity and random (unordered).Some technology produces the polymeric material with ordered three-dimensional micro-structural really, such as Introduction To Stereolithography; But these technology depend on upper and lower, the successively method that suppress to produce volume scalability usually.
The material with ordered three-dimensional micro-structural by Jacobsen etc. at " Compression behavior of micro-scale truss structures formed from self-propagating polymer waveguides ", Acta Materiallia 55, (2007) describe in 6724-6733, described entirety is by reference to being incorporated herein.Formation has the U.S. Patent No. 7,382 of a kind of method and system at Jacobsen of the polymeric material of orderly micro-truss structure, and open in 959, described entirety is by reference to being incorporated herein.Described system comprises: selected to produce at least one collimated light source of collimated light beam; There is the container of the photosensitive monomer being adapted to pass through collimated light beam polymerization; And mask, described mask has at least one hole and is positioned at described between at least one collimated light source and container.At least one hole described is suitable for a part for collimated light beam to import photosensitive monomer to form at least one polymer waveguide body by a part of volume of photosensitive monomer.The micro-truss material manufactured by described method and system also by Jacobsen at U.S. Patent Application Serial No. 11/801, open in 908, described application full content is by reference to being incorporated herein.Be exposed to radiation and by formed polymer waveguide body cause light self focusing or the polymeric material of certainly catching also by Kewitsch etc. in U.S. Patent No. 6, open in 274,288, described entirety is by reference to being incorporated herein.
Continue to need a kind ofly to optimize fuel cell durability, minimization tool cost, minimize manufacturing cost and minimize structure and the method for the manufacture fuel cell component of development time.Expect described method eliminate with according to the relevant heterogeneity of known method forming member and design constraint.
Summary of the invention
According to the present invention, be surprisingly found out that and a kind ofly optimize fuel cell durability, minimization tool cost, minimize manufacturing cost, minimize the development time and eliminate and the structure of the manufacture fuel cell component according to the relevant heterogeneity of known method forming member and design constraint and method.
In a first embodiment, a kind of fuel cell component comprises substrate and at least one flow field layer.Described flow field layer has at least one in multiple radiation curing reactant flow channel and multiple radiation curing coolant channel.Described flow field layer can be one of following setting: be arranged between described substrate and diffusion media layers; And be relatively arranged in diffusion media layers with substrate.
In another embodiment, a kind of method manufacturing the repetitive being used for fuel cell, comprise step: provide the first fuel cell component, described first fuel cell component has the first substrate, have the first diffusion media layers of micro-truss structure and have the flow field layer of multiple reactant flow channel, and described flow field layer is arranged between described first substrate and the first diffusion media layers; Second fuel cell component is provided, described second fuel cell component comprises second diffusion media layers with micro-truss structure and second flow field layer with multiple reactant flow channel and multiple coolant channel, and described second diffusion media layers is arranged between the second substrate and the second flow field layer; Be set to by described first fuel cell component on described second fuel cell component, wherein, the first substrate is arranged near the second flow field layer; The second substrate is removed from described second fuel cell component; First microporous layers to be arranged in the first diffusion media layers and the second microporous layers is arranged in the second diffusion media layers; By the first application of electrode in the first microporous layers and by the second application of electrode in the second microporous layers, or polymer dielectric film is arranged on the first electrode; With on one that is arranged on by membrane electrode assembly in described first and second microporous layers, thus complete the repetitive for fuel cell.
In another embodiment, a kind of method manufacturing the repetitive being used for fuel cell, comprises step: provide the first substrate; Radiation-sensitive materials is applied to described first substrate; Be placed on by first mask between at least one radiation source and radiation-sensitive materials, described mask extends along single plane and has multiple hole; Radiation-sensitive materials is exposed to multiple radiation beam to form multiple negativity removable cartridge; The first mask is removed from described negativity removable cartridge; Second radiation-sensitive materials is applied to described negativity removable cartridge; Remove uncured radiation-sensitive materials volume; The first substrate and negativity removable cartridge is applied with conductive coating; 3rd radiation-sensitive materials is applied to described first substrate; Second mask is placed on described between at least one radiation source and the second radiation-sensitive materials; Second radiation-sensitive materials is exposed to multiple radiation beam to form first diffusion media layers with micro-truss structure; 3rd mask is placed on described between at least one radiation source and the 3rd radiation-sensitive materials; 3rd radiation-sensitive materials is exposed to multiple radiation beam to form second diffusion media layers with micro-truss structure; Remove described negativity removable cartridge and uncured second and the 3rd radiation-sensitive materials; The first and second diffusion media layers are applied with conductive coating; And one that to be applied to by membrane electrode assembly in the first and second diffusion media layers, thus complete the repetitive for fuel cell.
The present invention also describes the layered composite of the perforate truss structure as the dispersive medium in polymer dielectric film fuel cell and flow field in detail.Gas flow (normally the reactant gas of hydrogen and oxygen) on the anode-side of fuel cell and cathode side guides towards membrane electrode assembly by flow field and dispersive medium.Disclosed manufacture method allows the completely overall formation of flow field and dispersive medium perforate truss structure, and has nothing to do with size and materials variances.Disclosed method allows the engineering three-dimensional tissue structures manufacturing high complexity.The object of method is the required size realizing integrally formed function flow field and diffusion media layers.Such as, flow field may need the thickness more than 200 μm.Such as, the resolution needed for characteristic sum dispersive medium may be less than 10 μm.These characteristic sizes use the present invention easily to obtain.
Advantageously, disclosed manufacture method allows low temperature process process, minimizes to make the thermal strain of not mating generation from the thermal coefficient of expansion (CTE) between different radiation curable layer.Combining mechanism allows one in radiation curable layer to be formed at the scene on another in radiation curable layer, instead of forms two radiation curable layer independently before being bonded together.Field process does not need the key between different radiation curable layer to align.Multi-functional and reusable support chip (handle wafer) can also be used as photomask, and it forms pattern for giving one in radiation curable layer.
In addition, about multi-layer compound structure, the mutual interlocking gear between different radiation curable layer absorbs thermal strain and provides the strong bond between radiation curable layer.The size (member radius, spacing, thickness, density) of radiation curable layer also can regulate for optimum fuel battery performance.
Scheme 1. 1 kinds, for the manufacture of the method for fuel cell component, comprises the following steps:
There is provided the mask with multiple radiation transparent holes, described multiple radiation transparent hole allows multiple radiation beam to be guided through;
Radiation-sensitive materials to described multiple radiation beam sensitivity is provided;
Flow field layer is provided;
Radiation-sensitive materials is arranged in flow field layer; And
By the radiation transparent hole in mask, radiation-sensitive materials is exposed to described multiple radiation beam, to form the diffusion media layers with micro-truss structure.
The method of scheme 2. according to scheme 1, further comprising the steps of:
Sacrificial releasing layer is applied to mask, and described sacrificial releasing layer is roughly transparent to described multiple radiation beam; With
Radiation-sensitive materials is applied to sacrificial releasing layer.
The method of scheme 3. according to scheme 2, wherein, described sacrificial releasing layer is spun on mask.
The method of scheme 4. according to scheme 2, wherein, described sacrificial releasing layer is formed by polystyrene.
The method of scheme 5. according to scheme 2, further comprising the steps of:
After radiation-sensitive materials being exposed to described multiple radiation beam, remove mask and sacrificial releasing layer from diffusion media layers.
The method of scheme 6. according to scheme 5, wherein, described sacrificial releasing layer is removed by releasing layer and mask being immersed in dissolve releasing layer and allow to remove in the solvent of mask.
The method of scheme 7. according to scheme 6, wherein, before dissolving in a solvent by releasing layer, the uncured portion of radiation-sensitive materials remaining after radiation-sensitive materials is exposed to described multiple radiation beam is removed from diffusion media layers.
The method of scheme 8. according to scheme 1, wherein, when radiation-sensitive materials is arranged in flow field layer, flow field layer embeds in radiation-sensitive materials, and wherein, after formation diffusion media layers, micro-truss structure of diffusion media layers and flow field layer interlock.
The method of scheme 9. according to scheme 1, wherein, mask is the radiation transparent material with radiation opaque Material coating, and radiation opaque material has multiple holes in the radiation transparent hole limiting mask.
The method of scheme 10. according to scheme 9, wherein, the radiation transparent hole of mask is circular.
The method of scheme 11. according to scheme 9, wherein, radiation transparent material is glass, and radiation opaque material is band pattern chrome coating.
The method of scheme 12. according to scheme 1, wherein, before being arranged in flow field layer, radiation-sensitive materials is heated to minimize residual stress.
The method of scheme 13. according to scheme 1, wherein, during formation diffusion media layers, diffusion media layers is attached to flow field layer.
The method of scheme 14. according to scheme 1, wherein, when radiation-sensitive materials is exposed to described multiple radiation beam, mask is positioned at apart from radiation-sensitive materials a distance.
The method of scheme 15. according to scheme 1, wherein, flow field layer is formed in substrate.
The method of scheme 16. according to scheme 15, wherein, substrate is metal forming, and flow field layer comprises multiple radiation curing reactant flow channel.
The method of scheme 17. according to scheme 16, wherein, described multiple radiation curing reactant flow channel comprises the adhesion promoter promoting that radiation curing reactant flow channel is combined with metal forming.
The method of scheme 18. according to scheme 1, also comprises step: by least one in conductive coating coating diffusion media layers and flow field layer.
Scheme 19. 1 kinds, for the manufacture of the method for fuel cell component, comprises the following steps:
There is provided the mask with multiple radiation transparent holes, described multiple radiation transparent hole allows multiple radiation beam to be guided through;
Sacrificial releasing layer is applied to mask, and described releasing layer is roughly transparent to described multiple radiation beam;
Radiation-sensitive materials is applied to releasing layer, and described radiation-sensitive materials is responsive to described multiple radiation beam;
There is provided substrate, described substrate has and is arranged on suprabasil flow field layer, and flow field layer has multiple radiation curing reactant flow channel;
Radiation-sensitive materials is arranged in the flow field layer of fuel cell component;
By the radiation transparent hole in mask, radiation-sensitive materials is exposed to described multiple radiation beam, to form the diffusion media layers with micro-truss structure; And
Mask and releasing layer is removed from diffusion media layers.
Scheme 20. 1 kinds, for the manufacture of the method for fuel cell component, comprises the following steps:
There is provided the mask with multiple radiation transparent holes, described multiple radiation transparent hole allows multiple radiation beam to be guided through;
Radiation-sensitive materials to described multiple radiation beam sensitivity is provided;
The diffusion media layers with micro-truss structure is provided;
Radiation-sensitive materials is arranged in diffusion media layers; And
Radiation-sensitive materials is exposed to described multiple radiation beam, to form flow field layer by the radiation transparent hole in mask.
Accompanying drawing explanation
Above-mentioned and other advantage of the present invention will be for those of ordinary skills from will be especially apparent in conjunction with accompanying drawing as herein described from following detailed description.
Fig. 1 is the partial side sectioned view of fuel cell component according to an embodiment of the invention;
Fig. 2 is the partial side sectioned view of fuel cell component according to another embodiment of the invention;
Fig. 3 manufactures the partial side sectioned view with the fuel cell repetitive of conductive coating having the fuel cell component shown in Fig. 1 and 2;
Fig. 4 is the partial side sectioned view of fuel cell component according to another embodiment of the invention;
Fig. 5 manufactures the partial side sectioned view having the fuel cell repetitive of the fuel cell component shown in Fig. 4;
Fig. 6 A-6G is the schematic side elevational sectional view of the method for the manufacture of fuel cell component illustrated according to another embodiment of the invention; With
Fig. 7 A-7B illustrates the modification of truss space, depends on the position of mask relative radiation sensitive material.
Embodiment
Below detailed description and accompanying drawing describe and illustrate each embodiment of the present invention.Described explanation and accompanying drawing are provided for those of ordinary skill in the art and can manufacture and use the present invention, and are not intended to limit the scope of the invention by any way.About disclosed method, shown step is only exemplary in essence, because of instead of necessary or crucial.
As illustrated in fig. 1 and 2, the process based on photosensitive polymer for the manufacture of one of the first fuel cell component 10 and the second fuel cell component 11 is provided.Fuel cell component 10,11 comprises substrate 12, has at least one diffusion media layers 14 of micro-truss structure 15 and at least one flow field layer 16.In FIG, show the first fuel cell component 10, wherein, flow field layer 16 is arranged between substrate 12 and diffusion media layers 14.In fig. 2, show the second fuel cell component 11, wherein, diffusion media layers 14 is arranged between substrate 12 and flow field layer 16.Substrate 12 removably or permanently can be attached to one of diffusion media layers 14 and flow field layer 16 according to expectation.
At least one in diffusion media layers 14 and flow field layer 16 is formed by radiation-sensitive materials.Radiation curing structure (such as diffusion media layers 14 and flow field layer 16) is formed by radiation-sensitive materials, such as at the U.S. Patent Application Serial No. 12/339 coexisted in examination of surrenderee, describe in 308, the full content of described application is by reference to being incorporated herein.
Substrate 12 can be formed by allowing any material forming paradigmatic structure thereon.Substrate 12 can be non-conductive or conduction according to being contemplated to be.Such as, if expection removes substrate 12 after formation one of diffusion media layers 14 and flow field layer 16, substrate 12 can be nonconducting.But if expection substrate 12 is retained in fuel cell, substrate 12 can be conduction.In one example, substrate 12 is formed from the metal such as can not significantly demoted under typical light photosensitive polymerization condition or conducing composite material.Substrate 12 is alternately formed by the electrically non-conductive material wherein with hole or path, electric conducting material can be arranged in described hole or path, such as, become conduction by plating to make substrate 12.In concrete example, substrate 12 is formed by stainless steel strip.Stainless steel strip can such as be set to coil steel bar, frame load steel bar or independent base substrate in one.In certain embodiments, substrate 12 is general plane stainless steel strips.Substrate 12 also can wherein arrange lines or pattern according to being desirably in.
Substrate 12 also can be provided with from one of diffusion media layers 14 and flow field layer 16 combine and depart from coating or surface treatment.As non-limiting example, substrate 12 can have the coating being suitable for being combined with uncured polymer material during the manufacture of fuel cell component 10,11.Surface treatment also can be beneficial to cure polymer and depart from from substrate 12.Particularly, the rear side of the substrate 12 usually arranged on flat surfaces during the manufacture of fuel cell component 10,11 can have coating to prevent not wishing pollution or electroplating of substrate 12.Technical staff can select suitable surface treatment according to expecting, comprises coating.
In another embodiment, substrate 12 can have the through hole (not shown) formed wherein.Through hole can be beneficial to the liquid photosensitive monomer and the discharge of solvent or the removal of solid state radiation sensitive polymer that adopt during the manufacture of fuel cell component 10,11.Through hole also can provide typical end product feature, such as port and collector opening, and as the U.S. Application Serial No. 11762 coexisted in examination of applicant, described in 845, described application full content is by reference to being incorporated herein.In other embodiments, through hole can with flow field layer 16(as shown in Figures 4 and 5) cooperate.Through hole such as can be formed by machine drilling or by laser cutting before one of diffusion media layers 14 and flow field layer 16 are applied to substrate 12.Also other appropriate means for the formation of through hole can be used.
Diffusion media layers 14 according to the present invention has micro-truss structure 15.Micro-truss structure 15 comprises along multiple first truss members of first direction extension, along multiple second truss members of second direction extension and multiple 3rd truss members along third direction extension.First, second, and third truss members can at multiple node 18 places IPN each other.Should be understood that, first, second, and third truss members can not IPN each other, or can according to expectation intermittently at multiple node 18 places IPN each other.First, second, and third truss members forms the three-dimensional self-supporting honeycomb of continuous print.
Although micro-truss structure 15 with multiple first truss members, multiple second truss members and multiple 3rd truss members can have above-mentioned 4 folded structure symmetries (4-fold architectural symmetry), but technical staff will understand, can use other structure within the scope of the invention, such as 3 foldings are symmetrical and 6 foldings are symmetrical.Such as, concrete structure can be selected to increase micro-truss structure 15 connectedness and to reduce micro-truss structure 15 under a load to easy acceptabilily that is bending and warpage.According to expectation, selected structure can be symmetrical or asymmetric.Also can choice structure to optimize the strength and stiffness of micro-truss structure 15.Those of ordinary skill in the art it is also understood that can according to other structure expecting to adopt micro-truss structure 15.
The example arrangement of micro-truss structure 15 by Jacobsen in U.S. Patent No. 7,382,959 and U.S. Patent Application Serial No. 11/801, describe in 908.Such as, described multiple first truss members can be limited by multiple first self propagation polymer truss wave conductor.Described multiple second truss members can be limited by multiple second self propagation polymer truss wave conductor.Described multiple 3rd truss members can be limited by multiple 3rd self propagation polymer truss wave conductor.Such as, first, second, and third wave conductor can be formed by liquid photosensitive monomer, and liquid photosensitive monomer represents the change of refractive index when photosensitive polymerization.Alternatively, should be understood that, the material that micro-truss structure 15 can form polymer waveguide body by the change of obstructed superrefraction index is formed, such as, by controlling the radioactive exposure of roughly solid state radiation sensitive polymer as herein described.Other appropriate means forming micro-truss structure 15 can be adopted according to expecting.
Those skilled in the art will appreciate that, micro-truss structure 15 that can be concrete according to desired design, such as by the following method at least one: 1) selective polymer truss members angle relative to each other and pattern, 2) compactness of honeycomb obtained or relative density is regulated, and 3) section shape and size of selective polymer truss members.Particularly, the polymer truss members with oval truss cross sectional shape can eliminate the degradation that the difference due to thermal coefficient of expansion causes.Also other cross sectional shape can be adopted according to expectation.
In some illustrative embodiment, the polymer of micro-truss structure 15 can be converted into metal oxide or pottery to provide the bending strength of aspiration level.Such as, ceramic micro-truss structure 15 and the method for the preparation of the micro-truss structure 15 of pottery are disclosed in U.S. Patent Application Serial No. 12/074,727 by Gross etc., and described patent application full content is by reference to being incorporated herein.
Flow field layer 16 according to the present invention comprises multiple reactant flow channel 20.Multiple first passage walls 24 that reactant flow channel 20 is extended by the length along fuel cell component 10,11 are formed.As shown in Figure 2, flow field layer 16 also can comprise multiple coolant channel 22.Coolant channel 22 is formed by described multiple first passage wall 24 and multiple second channel walls 26 of also extending along the length of fuel cell component 10,11.When flow field layer 16 is by when such as liquid photosensitive monomer is formed, first passage wall 24 can be limited by the multiple first self propagation polymer wall wave conductors extended along a direction, and second channel wall 26 can be limited by the multiple second self propagation polymer wall wave conductors extended along another direction.First and second conduit walls 24,26 can at multiple junction surface 28 place IPN each other.As non-limiting example, the first and second conduit walls 24,26 can form the coolant channel 22 of roughly V-arrangement.In certain embodiments, reactant flow channel also can be formed by the first and second conduit walls 24,26.Should be understood that, reactant flow channel and coolant channel 20,22 are formed as the recovery that open V-shape can allow the too much radiation-sensitive materials used during the manufacture of fuel cell component 10,11.Junction surface 28 can arrange near one of substrate 12 and diffusion media layers 12 according to expectation, as shown in Figure 2.
Flow field layer 16 also can comprise the multiple support ligaments (support ligament) 30 separated, support ligaments 30 be beneficial to by the reactant of flow field layer 16 or cooling agent stream and eliminate under typical fuel cells operating condition the first and second conduit walls 24,26 do not wish warpage.Support ligaments 30 also can be suitable for carrying the electric current in fuel cell.Be similar to the truss members of micro-truss structure 15, support ligaments 30 can have elliptical shape in cross-section or other cross sectional shape according to expectation.
Support ligaments 30 is arranged on the first and second conduit walls 24,26 and between one of substrate 12 and diffusion media layers 14.When flow field layer 16 is by when such as liquid photosensitive monomer is formed, support ligaments 30 can be limited by multiple self propagation polymer ligament wave conductor.In certain embodiments, at least one in support ligaments 30 can be crossing with another support ligaments 30 near one of substrate 12 and diffusion media layers 14.Particularly, support ligaments 30 can be designed to intersect near diffusion media layers 14, avoids not wishing warpage and breaking of the first and second conduit walls 24,26 for rigidity.
Radiation curing material and RADIATION DECOMPOSITION material is comprised for the formation of the radiation-sensitive materials of at least one in diffusion media layers 14 according to the present invention and flow field layer 16.Term " radiation curing material " be defined through be herein exposed to radiation be initiated, be polymerized and be cross-linked in any material of at least one.Should be understood that, by being exposed to after radiation causes, temperature increase also can be adopted to complete the polymerization or crosslinked of radiation curing material at least partly.Term " RADIATION DECOMPOSITION material " be defined through be herein exposed to radiation and represent polymer backbone separately and go crosslinked in any material of at least one.As non-limiting example, RADIATION DECOMPOSITION material be can be made into and fully to be disconnected by the polymer backbone of RADIATION DECOMPOSITION material crosslinked and/or separately can by dissolution with solvents.
As non-limiting example, radiation curing material can comprise liquid photosensitive monomer and the one roughly in solid state radiation cure polymer.Liquid photosensitive monomer can be at the U.S. Patent No. 7,382,959 of Jacobsen and U.S. Application Serial No. 11/801, the monomer described in 908.The non-limiting example of suitable photosensitive monomer is included in when being exposed to UV radiation (wavelength is at about 250nm with about between 400nm) via the monomer that free radial polymerization process is polymerized.Photosensitive monomer can comprise the radial photopolymerizable material of any suitable freedom, such as urethanes (polyurethane), acrylate, methacrylate and cationic polymer (such as photo-curing epoxy resin).Also other suitable photosensitive monomer can be adopted.
Suitable roughly solid state radiation cure polymer can comprise negativity resist polymer.Negativity resist polymer stands light-initiated process, and described light-initiated process is by be such as polymerized or polycondensation causes the solidification of negativity resist polymer.When generation polymerization roughly simultaneously or polycondensation reaction, process is called " photocuring ".When only producing reactant by light-initiated process and need step subsequently (such as heating) to produce polymerization or polycondensation, process is called " light-initiated ".Should be understood that, although solidification after-baking may be necessary for completing polymerization procedure, radiation curing feature roughly stable in negativity resist polymer also can generate during initiation radioactive exposure.Roughly solid state radiation cure polymer can stand only elicitation procedure, and due to the limited diffusion rates of intrinsic stability and the chemicals in solid state radiation cure polymer, also can be cured process more rearward, and can not cause significant characteristics degrade.Should be understood that, originally most of light initiation polymerization thing starts solidification process in elicitation procedure, but the kinetics under Exposure Temperature is so slow, make polymerization or polycondensation that seldom (if any) can occur before negativity resist polymer being heated to expect curing temperature.
Concrete negativity resist polymer is can the epoxy resin-matrix SU-8 2000 negativity resist polymer that obtains of business from the Microchem Corporatioin of a Newton, Massachusetts.SU-8 2000 negativity resist polymer is by UV radiation curing.Should be understood that, other roughly solid state radiation cure polymer can be adopted.Such as, similar above-mentioned photosensitive monomer, selected radiation curable polymer can use the radiation of the wavelength outside UV radiation to solidify according to expecting.Radiation curable polymer also can select to have ratio solidification rate as slower in liquid photosensitive monomer, to prevent the feature manifested in slower cured layer when very fast cured layer is exposed to radiation source.
As non-limiting example, RADIATION DECOMPOSITION material can comprise positive resist polymer.Positive resist polymer starts from cross-linked polymer, but can comprise light trigger, and when being exposed to concrete radiation, light trigger produces chemicals, and described chemicals carry out decomposing copolymer by disconnecting crosslinked and separately in polymer backbone at least one.Described decomposition makes positive resist polymer being soluble solution be exposed in the region of radiation.Positive resist polymer keeps the region of solidification to be covered instead of exposes (be exactly like this at above-mentioned negativity resist polymer).In certain embodiments, positive resist polymer is responsive to radiation (such as, ultraviolet or electron beam), and does not need light trigger.Such as, but positive resist polymer self by radiation destruction and remaining chain solubilized of separating in a solvent.Also other similar positive resist polymer can be adopted according to expectation.
The radiation that one of solidification Sum decomposition radiation-sensitive materials adopts can comprise the UV bundle such as coming from Mercury arc lamp.Radiation can according to being contemplated to be electromagnetic radiation or particular radiation.Technical staff should be appreciated that the radiation that also can adopt and have other wavelength (such as, infrared, visible ray and X-radiation) and come from other source (such as, incandescent lamp and laser).Also can adopt particular radiation, such as, come from the electron beam in cathode-ray source.It is to be further understood that according to expectation, radiation can be collimation, partly collimation or uncollimated.
Radiation is usually via at least one mask guiding radiation-sensitive materials with hole or the opening formed wherein, and radiation is by described hole or openings contact radiation-sensitive materials.Such as, hole can be the roughly radiation transparent hole formed in the opaque of other form or radiation-blocking material.Such as, mask can be formed from glass planar or Mylar sheet material, and is beneficial to and is led at a certain angle relative to mask or lower floor's substrate 12 by radiation beam.Mask can be taken away after exposure and be cleaned to reuse.The hole formed in the mask or opening have the shape providing radiation beam, to form the polymer architecture having and expect cross sectional shape.Hole can be circular to form elliptical shape in cross-section, thus can the difference of thermal coefficient of expansion (CTE) better in fuel metering battery component 10,11.
In an illustrative embodiment, mask surface has multiple hole.Described Kong Jun has the diameter of such as about 10 microns.In another embodiment, described hole is to provide the elongated slot of radiation fin, to form the polymer wall such as with substantially rectangular cross sectional shape, to form at least one in the reactant flow channel 20 of fuel cell component 10,11 and coolant channel 22.Being exposed to radiation can such as a succession of short exposure or intermittently carry out providing desired structure to design with the longer duration.Technical staff can according to the structural allocation expecting to select suitable mask material, hole and opening size and shape and obtain.
With reference to figure 3, for the sake of clarity, similar with Fig. 1 and 2 structure has identical Reference numeral and single quotation marks (') or double quotation marks (").Diffusion media layers 14 ', 14 " and flow field layer 16 ', 16 " at least one go back available conductive material 38 ', 38 " coating.Such as, diffusion media layers 14 ', 14 " and flow field layer 16 ', 16 " at least one electrodepositable have roughly anti-oxidant, anti-reduction and antacid metal coating.Metal coating can multiple plating step be formed.Such as, metal coating, by application ground floor electroless nickel plating matrix, is then electroplated the erosion-resisting second layer NiCr or Cr and has for minimizes diffusion dielectric layer 14 ', 14 " and flow field layer 16 ', 16 " between the third layer outer coating formation of Au or Pd of contact resistance.Such as, ground floor and second layer electrodepositable, third layer is applied to limit coverage by physical vapour deposition (PVD).Also can according to expecting to adopt for by electric conducting material 38 ', 38 " coating is to diffusion media layers 14 ', 14 " and flow field layer 16 ', 16 " at least one on other method.
In certain embodiments, electric conducting material 38 ', 38 " comprise the noble metal being selected from following group: ruthenium (Ru), rhodium (Rh), palladium (Pd), silver (Ag), iridium (Ir), platinum (Pt), osmium (Os) and alloy thereof.In a particular embodiment, electric conducting material 38 ', 38 " be gold (Au).In another specific embodiment, electric conducting material 38 ', 38 " be tantalum (Ta).Other suitable metal coating can comprise nickel (Ni) alloy, the alloy of such as nickel and chromium (Cr) or nickel and cobalt (Co).It should be understood by one skilled in the art that electric conducting material 38 ', 38 " mixture or the alloy of above-mentioned metal can be comprised.Also other conducting metal and material can be used according to expectation.
Electric conducting material 38 ', 38 " deposit to diffusion media layers 14 ', 14 by one of following methods " and flow field layer 16 ', 16 " at least one on: such as electron beam evaporation, magnetron sputtering, physical vapour deposition (PVD), chemical vapour deposition (CVD), ald, electrolytic deposition, electroless deposition, flame jet deposition, brush plating and other similar procedure.Also can adopt the electroplating technology based on solution, comprise diffusion media layers 14 ', 14 " and flow field layer 16 ', 16 " at least one be immersed in electroplating pool.Also can use the electric conducting material 38 ', 38 of slurry powder type " also igniting starch is last to form coating subsequently in application.Technical staff can select more than one deposition technique to consider the difference between the sight line of selected deposition technique and non-collimating line characteristic.In certain embodiments, electric conducting material can be deposited on diffusion media layers 14 ', 14 roughly equably " and flow field layer 16 ', 16 " inner surface and outer surface on.In other embodiments, diffusion media layers 14 ', 14 " on electric conducting material 38 ', 38 " coating layer thickness can be less than flow field layer 16 ', 16 " on electric conducting material 38 ', 38 " coating layer thickness.Can according to expect select electric conducting material 38 ', 38 " suitable coating mode and thickness.
Should be understood that diffusion media layers 14 ', 14 " and flow field layer 16 ', 16 " at least one can be formed by radiation-sensitive materials, solidify time, radiation-sensitive materials be conduction.Radiation-sensitive materials be conduction time, if expect can not adopt diffusion media layers 14 ', 14 " and flow field layer 16 ', 16 " at least one on electric conducting material 38 ', 38 " coating.
First and second fuel cell components 10,11 also can have at least one microporous layers 32 ', 32 " and at least one electrode 34 ', 34 ".Microporous layers 32 ', 32 " diffusion media layers 14 ', 14 can be arranged on " on.Electrode 34 ', 34 " can with diffusion media layers 14 ', 14 " be relatively arranged on microporous layers 32 ', 32 " on.Should be understood that, electrode 34 ', 34 " also can be set directly at diffusion media layers 14 ', 14 according to expectation " on.Electrode 34 ', 34 " one of can also have polymer dielectric film (PEM) 36 disposed thereon.
As shown in Figure 3, the first and second fuel cell components 10,11 can assemble the single repetitive 40 forming fuel cell.Multiple repetitive 40 can be stacked to form fuel cell pack (not shown).Repetitive 40 comprises the first diffusion media layers 14 ' and the second diffusion media layers 14 '.First diffusion media layers 14 ' has the micro-truss structure 15 ' with node 18 '.Micro-truss structure 15 ' of the second diffusion media layers 14 ' ' comprise with node 18 ' ' '.Repetitive 40 also comprises flow field layer 16 ' and the second flow field layer 16 ".Flow field layer 16 ' comprises crossing first passage wall 24 ' and multiple support ligaments 30 '.Second flow field layer 16 " be included in junction surface 28 " place intersect the first and second conduit walls 24 ", 26 " and multiple support ligaments 30 ".The substrate 12 ' of the first fuel cell component 10 is arranged on the first flow field layer 16 ' and the second flow field layer 16 " between.Substrate 12 ' and the first flow field layer 16 ' and the second flow field layer 16 " be also arranged on the first diffusion media layers 14 ' and the second diffusion media layers 14 " between.Diffusion media layers 14 ', 14 " in each there is a microporous layers 32 ', 32 disposed thereon ".Microporous layers 32 ', 32 " in eachly to have and diffusion media layers 14 ', 14 " electrode 34 ', 34 that is relatively applied thereon " one of.Electrode 34 ', 34 " one of there is polymer dielectric film 36 disposed thereon.
With reference to Figure 4 and 5, for the sake of clarity, with Fig. 1,2 and 3 similar structures, there is identical Reference numeral and single quotation marks (') or double quotation marks (").Alternative fuel battery component 10 ' according to the present invention is shown in Figure 4 and be provided for forming the single repetitive 40 ' of the fuel cell shown in Fig. 5.
Fuel cell component 10 ' comprises the first diffusion media layers 14 ' and the second diffusion media layers 14 " and single flow field layer 16.Flow field layer 16 is formed by multiple conductive wall 42, and conductive wall 42 limits multiple reactant flow channel 20 and multiple coolant channel 22.Conductive wall 42 can such as be formed as wall 42 to leave electric conducting material 38 by electric conducting material 38 coating to be arranged on multiple detachable negativity core and to remove core subsequently.Also the alternate manner for the formation of conductive wall 42 can be used.
Substrate 12 can connect with flow field layer 16.As non-limiting example, the coating 38 forming conductive wall 42 also can be arranged on the base 12 substrate 12 to be combined with flow field layer 16.Flow field layer 16 is arranged on the first diffusion media layers 14 ' and the second diffusion media layers 14 " between.Diffusion media layers 14 ', 14 " in one there is membrane electrode assembly (MEA) 44 disposed thereon.Membrane electrode assembly 44 comprises microporous layers 32 ', 32 ", electrode 34 ', 34 " and PEM36.Flow field layer 16 provides multiple reactant flow channel 20 and multiple coolant channel 22.As shown in the figure, the multiple reactant flow channel 20 formed by flow field layer in alternative fuel battery component 10 ' comprise the reactant flow channel 20 that formed near the first diffusion media layers 14 ' and near the second diffusion media layers 14 " reactant flow channel 20 that formed.Perforation, groove or a series of hole 46 are formed through substrate 12 and cooperate with flow field layer 16 with in close second diffusion media layers 14 " multiple reactant flow channel 20 provide fluid to be communicated with.Thus should be understood that, the alternate configurations of fuel cell 10 ' is beneficial to the single repetitive 40 ' forming fuel cell, and does not need the assembly of the first and second fuel cell components 10,11 as Figure 1-3.
The present invention includes a kind of method manufacturing the repetitive 40 of fuel cell.First described method comprises step: provide the first fuel cell component 10 and provide the second fuel cell component 11.First fuel cell component 10 is arranged on the second fuel cell component 11.First substrate 12 ' arranges the second flow field layer 16 near the second fuel cell component 11 ".Second substrate 12 of the second fuel cell component 11 " according to be desirably in the second fuel cell component 11 be arranged on the first fuel cell component 10 before or after remove from the second fuel cell component 11.First fuel cell component 10 and the second fuel cell component 11 can such as combine with heavy electroplating process, with closed V-arrangement coolant channel 22 ".Conduction location binding agent can be used in conjunction with the first fuel cell component 10 and the second fuel cell component 11.Also can adopt to expect to seal and electrically conducting manner in conjunction with other appropriate means of the first fuel cell component 10 and the second fuel cell component 11.
Then, the first microporous layers 32 ' is arranged in the first diffusion media layers 14 ', the second microporous layers 32 " be arranged on the second diffusion media layers 14 " on.First electrode 34 ' is arranged in the first microporous layers 32 ', the second electrode 34 " be arranged on the second microporous layers 32 " on.Then PEM36 is arranged on the first and second electrodes 34 ', 34 " one of on to complete the repetitive 40 of fuel cell.Microporous layers 32 ', 32 ", electrode 34 ', 34 " and PEM36 assembling can according to be desirably in the first fuel cell component 10 is combined with the second fuel cell component 11 before or after carry out.
There is provided the step of the first fuel cell component 10 also can comprise step: provide the first substrate 12 ' and be arranged in the first substrate 12 ' by radiation-sensitive materials.Such as, the first substrate 12 ' can be immersed in the liquid photosensitive monomer of certain volume.Then first mask is placed on described between at least one radiation source and radiation-sensitive materials.First mask extends along single plane and has the multiple elongated slots formed wherein.First mask can be selected to provide the expectation flow field geometry with multiple first polymer wall 24 '.Then radiation-sensitive materials is exposed to the multiple radiation fins guided by the elongated slot of the first mask, to form the flow field layer 16 ' with multiple reactant flow channel 20 '.
After formation flow field layer 16 ', the second radiation-sensitive materials is applied to flow field layer 16 '.Second radiation-sensitive materials can be identical or different according to expectation and radiation-sensitive materials.As non-limiting example, roughly solid state radiation sensitive material can be stacked in flow field layer 16 '.Second mask is placed on described between at least one radiation source and the second radiation-sensitive materials.Second mask can be provided by selection expects dispersive medium geometry.Second mask extends along single plane and has multiple hole.Multiple radiation beams that the hole that second radiation-sensitive materials is exposed to the second mask guides are to form the first diffusion media layers 14 ' having and expect micro-truss structure 15 '.
There is provided the step of the second fuel cell component 11 also can comprise step: to provide the second substrate 12 " and the 3rd radiation-sensitive materials is applied to the second substrate 12 ".3rd radiation-sensitive materials can be identical or different with the first and second radiation-sensitive materials.As non-limiting example, the second substrate 12 " available roughly solid state radiation sensitive polymer lamination.Be applied to the second substrate 12 " the 3rd radiation-sensitive materials thickness can based on the 3rd radiation-sensitive materials manufacture uncompressed diffusion media layers 14 " expectation thickness select.Then, the 3rd mask is placed between at least one radiation source and the 3rd radiation-sensitive materials.3rd mask extends along single plane and has the multiple holes formed wherein.3rd radiation-sensitive materials is such as simultaneously or in a sequence exposed to according to expectation the multiple radiation beams coming from radiation source from one or more direction subsequently.Hole guiding three radiation-sensitive materials of radiation beam by being formed in the 3rd mask.Radiation beam makes micro-truss structure 15 " form the second diffusion media layers 14 ".
At the micro-truss structure 15 of formation " after, the 3rd mask is from the second diffusion media layers 14 " remove.Then 4th radiation-sensitive materials is applied to the second diffusion media layers 14 ".4th radiation-sensitive materials can be identical or different with first, second, and third radiation-sensitive materials.As non-limiting example, the 4th radiation-sensitive materials is the liquid photosensitive monomer of certain volume.4th mask is placed between at least one radiation source and the 4th radiation-sensitive materials.4th mask extends along single plane and has the multiple elongated slots formed wherein.4th radiation-sensitive materials be exposed to subsequently the 4th mask elongated slot guide multiple radiation fins with formed there is multiple reactant flow channel 20 " and multiple V-arrangement coolant channel 22 " the second flow field layer 16 ".
Should be understood that, expecting micro-truss structure 15 ', 15 to be formed ", radiation beam can comprise the first radiation beam, the second radiation beam and the 3rd radiation beam.First radiation beam, the second radiation beam and the 3rd radiation beam lead from least one radiation source described towards at least one hole described, to form first, second, and third polymer truss members respectively in a part of volume of radiation-sensitive materials.When photosensitive monomer, polymer truss members can be formed from the polymer waveguide body with the refractive index different from photosensitive monomer around.
As non-limiting example, the first radiation beam leads with the first angle relative to described single plane, and the second radiation beam leads with the second angle relative to described single plane; Second angle is different from the first angle.3rd radiation beam can lead with the 3rd angle relative to described single plane; 3rd angle is different from the first angle and the second angle.First polymer truss members forms the 4th angle relative to described single plane; 4th angle corresponds to the first angle.Second polymer truss members forms the 5th angle relative to described single plane; 5th angle corresponds to the second angle.Terpolymer truss members forms hexagonal degree relative to described single plane; Hexagonal degree corresponds to the 3rd angle.Each intersecting each other in first, second, and third polymer truss members forms micro-truss structure 15 ', 15 ".It is to be understood, however, that, truss members at least partially can be selected non-intersect according to expectation.
Method for the manufacture of the repetitive 40 of fuel cell also comprises step: by the first diffusion media layers 14 ', the second diffusion media layers 14 ", flow field layer 16 ' and the second flow field layer 16 " at least one with electric conducting material 38 ', 38 " coating, as mentioned above.Should be understood that, electric conducting material 38 ', 38 " can contact resistance be minimized and optimize the efficiency of fuel cell.
The present invention includes the another kind of method of the repetitive 40 ' for the manufacture of fuel cell.Described method comprises step: provide substrate 12 and radiation-sensitive materials is applied to substrate 12.Such as, substrate 12 can be immersed in the liquid photosensitive monomer of certain volume.Substrate 12 can be provided with the multiple perforation or hole 46 that are formed wherein.Then, the first mask is placed between at least one radiation source and radiation-sensitive materials.Described first mask extends along single plane and has multiple hole.Then, radiation-sensitive materials is exposed to multiple radiation beams of the hole guiding radiation-sensitive materials of the first mask to form multiple negativity removable cartridge.Also negativity removable cartridge can be formed by other means, such as silk screen printing.The first mask is removed from described negativity removable cartridge and remaining uncured radiation-sensitive materials.Should be understood that, within the scope of the invention, term " uncured radiation-sensitive materials " also can comprise the radiation-sensitive materials of decomposition.Remaining uncured radiation-sensitive materials volume can such as be removed by discharging when photosensitive monomer and be recycled subsequently.The step removing remaining uncured radiation-sensitive materials volume can comprise with solvent washing substrate and core.It will be appreciated by the skilled addressee that suitable solvent can not significantly demote expose negativity removable cartridge.
Removable cartridge has the negative shape forming multiple reactant flow channel 20 and the wall desired by multiple coolant channel 22 42.The step forming multiple negativity removable cartridge can comprise radiation-sensitive materials is exposed to such as multiple inclination and vertical radiation beam.
Second radiation-sensitive materials is arranged in described negativity removable cartridge and the 3rd radiation-sensitive materials is arranged in described substrate 12.As non-limiting example, second and the 3rd radiation-sensitive materials can be roughly solid state radiation sensitive polymer on to be stacked in negativity removable cartridge and substrate 12 each.Substrate 12 and negativity removable cartridge conductive coating 38 apply.Should be understood that, to prevent from forming undesirable heavy plating thereon during application conductive coating 38 on the outer surface that mask or other physics lid (such as having the physical contact on another surface) can be used on lamination radiation sensitive polymer.
Then, the second mask is placed on described between at least one radiation source and the second radiation-sensitive materials; And the second radiation-sensitive materials is exposed to multiple radiation beam to form first diffusion media layers 14 ' with micro-truss structure 15 '.3rd mask is placed on described between at least one radiation source and the 3rd radiation-sensitive materials; 3rd radiation-sensitive materials is exposed to multiple radiation beam with formed there is micro-truss structure 15 " the second diffusion media layers 14 ".First, second, and third radiation-sensitive materials can be identical or different according to expectation.Remove described photosensitive polymerization negativity removable cartridge and uncured second and the 3rd radiation-sensitive materials to leave the wall 42 formed by conductive coating 38.
Described method also comprises step: apply the first and second diffusion media layers 14 ', 14 with conductive coating 38 ".But, should be understood that, be arranged on diffusion media layers 14 ', 14 " the thickness of coating can be less than the thickness of the coating in the negativity removable cartridge being arranged on the wall 42 forming flow field layer 16 '.Those of ordinary skill in the art can according to the suitable conductive thickness expecting to select to be used for every layer.
In order to complete the repetitive 40 ' for fuel cell, MEA44 is applied to the first and second diffusion media layers 14 ', 14 " in one.The step of application MEA44 comprises step: be arranged in the first diffusion media layers 14 ' by the first microporous layers 32 '; First electrode 34 ' is applied in the first microporous layers 32 '; PEM36 is arranged on the first electrode 34 '; By the second electrode 34 " be applied to PEM36; With by the second microporous layers 32 " be arranged on the second electrode 34 " on.
About repetitive 40,40 ' as herein described, the manifold hole (not shown) be usually associated with the formation of the entrance and exit manifold of fuel cell also can be set.Similarly, the seal being beneficial to fuel cell assembling and operation and port diagnostic can be set.Manifold hole, seal and port diagnostic are formed by conventional means or are formed by the polymerization technique that use is mentioned above.
Be surprisingly found out that, micro-truss structure 15,15 ', 15 " use allow to manufacture fuel cell component 10,10 ', 11 in a cost efficient manner; fuel cell component 10,10 ', 11 for the formation of for motor vehicle and other application fuel cell, such as, for the micro fuel cell of mancarried device.Fuel cell component 10,10 ', 11 of the present invention uses the polymer formed with the shape expecting fuel cell component, relative with formation negative shape removable cartridge.The present invention extend known micro-truss process can design feature to produce the various more multiple features for manufacturing desired by fuel cell component (such as, dispersive medium, separating plate and film reinforcement).
Compared with conventional polymer foams parts, the higher order structures of the fuel cell component 10,10 ', 11,40,40 ' manufactured by method of the present invention provides the more compression of homogeneous and the durability of increase.This manufacture method is also more cheap than common manufacturing method, and allows the time of delivery with significantly reducing to manufacture fuel cell component.Particularly, manufacturing cost reduces and owing to replacing conventional carbon paper dispersive medium, and usually between fuel cell component that is conventional and that manufacture separately can form the cost expecting that contact resistance interface is relevant by eliminating.
The method manufacturing fuel cell component 100 in accordance with another embodiment of the present invention illustrates in Fig. 6 A-6G and Fig. 7 A-7B.Shown in Fig. 1-5 as described above, fuel cell component 100 is the compounds with the structure striding across its varied in thickness.In order to know object, with the structure similar or relevant to Fig. 1-5 shown in Fig. 7 A-7B, there is the same reference numerals of 100 series at Fig. 6 A-6G.
As shown in Figure 6A, the method manufacturing fuel cell component 100 can comprise the step providing the mask 102 with at least one radiation transparent hole 104.At least one radiation transparent hole 104 described allows multiple radiation beam 106(as illustrated in fig. 6e) be guided through.Mask 102 can comprise the radiation transparent material with radiation opaque Material coating.Radiation opaque material can have multiple hole, and it limits the radiation transparent hole 104 of mask 102.Such as, the radiation transparent hole of mask 102 can be circular.In concrete example, radiation transparent material is glass, such as Pyrex sheet glass, and radiation opaque material is the band pattern chrome coating be spun on glass.Within the scope of the invention, the shape in other radiation transparent for mask 102 and radiation opaque material and at least one radiation transparent hole 104 described can also be used.
Also provide the radiation-sensitive materials 108 to described multiple radiation beam 106 sensitivity, such as, shown in Fig. 6 C.Radiation-sensitive materials 108 can be selected from the arbitrary class above-disclosed radiation-sensitive materials.In concrete example, radiation-sensitive materials 108 is negativity resist polymers, and such as, based on the SU-8 2000 negativity resist polymer of epoxy resin, radiation beam 106 comprises collimated UV radiation.Technical staff should be appreciated that radiation beam 106 and radiation-sensitive materials 108 according to expecting to use other types.
The method comprises the step providing flow field layer 116.Flow field layer 116 has multiple radiation curing flow channel.Flow field layer 116 such as can be provided as stand-alone configuration or be formed in substrate 112 completely.When adopting substrate 112, flow field layer 116 can comprise adhesion promoter, and it is beneficial to flow field layer 116 and is combined with substrate 112.Substrate 112 can be formed by such as metal, and is also used as fuel cell plate, such as, bipolar plates in fuel cell stack assembly.In a particular embodiment, substrate 112 is stainless steel foils.Substrate can also be formed by other metals and conducing composite material according to expectation.
Radiation-sensitive materials 108 is arranged in flow field layer 116.Such as, flow field layer 116 can be pressed in radiation-sensitive materials 108, as shown in Figure 6 D.In a particular embodiment, when radiation-sensitive materials 108 is arranged in flow field layer 116, flow field layer 116 embeds in radiation-sensitive materials 108.Such as, radiation-sensitive materials 108 can be heated or " soft baking ", to minimize residual stress before being pressed in radiation-sensitive materials 108 by flow field layer 116.When using the SU-8 2000 negativity resist polymer based on epoxy resin, soft baking temperature can be about 95 ° of C, but can also use other temperature.In other embodiments, radiation-sensitive materials 108 can be provided as soft solid phase material, and flow field layer 116 is pressed in radiation-sensitive materials 108, and does not preheat radiation-sensitive materials 108.
After flow field layer 116 is pressed in radiation-sensitive materials 108, radiation-sensitive materials 108 is exposed to described multiple radiation beam 106 by the radiation transparent hole 104 in mask 102.Radiation-sensitive materials 108 is exposed to radiation beam 106 in radiation-sensitive materials 108, forms the diffusion media layers 114 with micro-truss structure.Additional heating after can also using exposure, to accelerate the formation of diffusion media layers 114.After formation diffusion media layers 114, because flow field layer 116 embeds in radiation-sensitive materials 108, thus micro-truss structure of diffusion media layers 108 and flow field layer 116 interlock and combine.Thus fuel cell component 100 is provided.
The method can also adopt sacrificial releasing layer 148, such as shown in Figure 6B.Sacrificial releasing layer 148 is applied on mask 102 before can arranging radiation-sensitive materials 108 on mask 102.Such as, sacrificial releasing layer 148 can be spun on mask 102, but technical staff is appreciated that the additive method that can also use for applying sacrificial releasing layer 148.Sacrificial releasing layer 148 is arranged between mask 102 and radiation-sensitive materials 108 particularly.Thus, after sacrificial releasing layer has been applied on mask 102, radiation-sensitive materials 108 can be such as applied on sacrificial releasing layer 148 by spin coating or other application processes.
Sacrificial releasing layer 148 is formed by the material roughly transparent to described multiple radiation beam 106, and radiation-sensitive materials 108 is responsive to described multiple radiation beam 106.Also select the material forming sacrificial releasing layer 148 to dissolve in a solvent, solvent can not be demoted the radiation curing structure formed by radiation-sensitive materials 108 in other respects.Such as, when using UV radiation, sacrificial releasing layer 148 can be polystyrene.Polystyrene can deposit by being spin-coated on mask 102 by the dilute solution of polystyrene-toluene.According to other suitable materials expecting can also adopt for sacrificial releasing layer 148.
See Fig. 7 A and 7B, show the shape selecting the thickness of sacrificial releasing layer 148 can affect the radiation curing structure obtained formed in radiation-sensitive materials 108.Such as, when using small thickness (such as about 2 μm) of sacrificial releasing layer 148 (Fig. 7 A), form each trussmember of micro-truss structure of diffusion media layers 114 from individual node 150 branch.Individual node 150 can be limited by the position of in the radiation transparent hole 104 of mask 102.When using the comparatively heavy thickness of sacrificial releasing layer 148 (Fig. 7 B), each truss is formed between the node 150 of truss net.Which increase the contact surface area of the diffusion media layers 114 when being formed.
It will be appreciated by the skilled addressee that the contact surface area expecting to increase, because the contact surface area increased makes the local stress during fuel battery operation on adjacent MEAs (not shown) minimize, and not suppression fluid stream.In illustrated embodiment specifically, about 35 μm of the thickness of sacrificial releasing layer 148.Between the Formation period of diffusion media layers 114, by by mask 102 spacer radiation-sensitive materials 108 certain distance, technical staff according to expecting other thickness can selecting sacrificial releasing layer 148, or otherwise can regulate the spacing between mask 102 and radiation-sensitive materials 108.
Continue with reference to figure 6A-6G, method of the present invention also comprises step: after radiation-sensitive materials 108 has been exposed to described multiple radiation beam 106, removes at least one mask 102 and sacrificial releasing layer 148 from diffusion media layers 114.Sacrificial releasing layer 148 can be removed by releasing layer 148 and mask 102 being immersed in dissolve releasing layer 148 and allow to remove in the solvent of mask 102.Such as, before dissolving in a solvent by releasing layer, the uncured portion of radiation-sensitive materials 108 remaining after radiation-sensitive materials 108 is exposed to described multiple radiation beam 106 can be removed from diffusion media layers 114, as fig 6 f illustrates.
As above further disclosed in, the method can also comprise step: by least one in conductive coating coating diffusion media layers 114 and flow field layer 116.
Although the manufacture method shown in Fig. 6 A-6G is presented in prefabricated flow field layer 116 and forms diffusion media layers 114, should be understood that, flow field layer 116 can form the combination providing equal in quality between which alternatively in prefabricated diffusion media layers 114.Such as, the method for the manufacture of fuel cell component 100 can comprise step: provide the diffusion media layers 114 with micro-truss structure; And radiation-sensitive materials 108 is set in diffusion media layers 114.Then radiation-sensitive materials 108 is exposed to described multiple radiation beam 106 by the radiation transparent hole 104 in mask 102, to form flow field layer 116.
In other embodiment, the diffusion media layers 114 of fuel cell component 100 and flow field layer 116 can expose independently and produce, and are combined by plating subsequently.Such as, one in diffusion media layers 114 and flow field layer 116 can process in substrate 112, and another processes as free-standing layer.In another example, one in diffusion media layers 114 and flow field layer 116 can process in substrate 112, and another is attached to process substrate (not shown), has or do not assist in removing the sacrificial releasing layer 148 of process substrate.In other examples, each in diffusion media layers 114 and flow field layer 116 processes as free-standing layer, and is then bonded to each other or is attached to substrate, or one is attached to substrate 112 and another is attached to of being attached in substrate 112.Independent adhesive or adhesive phase can also be used with in conjunction with equivalent layer.
Multiple layers of entirety are formed to form fuel cell component 100 by disclosed method.Should be understood that, each layer uses different materials system and correlation technique manufacture to realize in prior art otherwise the combination of irrealizable thickness and characteristic size, and wherein, this technology and material can use independently.
Advantageously, the method flow field layer 116 directly being formed diffusion media layers 114 eliminates the many problems combined between equivalent layer.Use adhesive phase by attached for two the full form stratification with different units honeycomb be the process steps be difficult to carry out, even at described layer close to being also like this when desired alignment.The method causes diffusion media layers 114 to be attached to flow field layer 116 as a part for diffusion media layers 114 forming process, does not thus need adhesive phase.
Although in order to illustrate that the present invention has shown some representative embodiment and details, it will be appreciated by the skilled addressee that and can make various change when not departing from the scope of the present invention further described by claims.

Claims (18)

1., for the manufacture of a method for fuel cell component, comprise the following steps:
There is provided the mask with multiple radiation transparent holes, described multiple radiation transparent hole allows multiple radiation beam to be guided through;
Sacrificial releasing layer is applied to mask, and described sacrificial releasing layer is roughly transparent to described multiple radiation beam;
Sacrificial releasing layer is applied to by the radiation-sensitive materials of described multiple radiation beam sensitivity;
Flow field layer is provided;
Radiation-sensitive materials is arranged in flow field layer; And
By the radiation transparent hole in mask, radiation-sensitive materials is exposed to described multiple radiation beam, to form the diffusion media layers with micro-truss structure, wherein, the thickness of described sacrificial releasing layer is selected, to increase the contact surface area of diffusion media layers.
2. method according to claim 1, wherein, described sacrificial releasing layer is spun on mask.
3. method according to claim 1, wherein, described sacrificial releasing layer is formed by polystyrene.
4. method according to claim 1, further comprising the steps of:
After radiation-sensitive materials being exposed to described multiple radiation beam, remove mask and sacrificial releasing layer from diffusion media layers.
5. method according to claim 4, wherein, described sacrificial releasing layer is removed by releasing layer and mask being immersed in dissolve releasing layer and allow to remove in the solvent of mask.
6. method according to claim 5, wherein, before dissolving in a solvent by releasing layer, the uncured portion of radiation-sensitive materials remaining after radiation-sensitive materials is exposed to described multiple radiation beam is removed from diffusion media layers.
7. method according to claim 1, wherein, when radiation-sensitive materials is arranged in flow field layer, flow field layer embeds in radiation-sensitive materials, and wherein, after formation diffusion media layers, micro-truss structure of diffusion media layers and flow field layer interlock.
8. method according to claim 1, wherein, mask is the radiation transparent material with radiation opaque Material coating, and radiation opaque material has multiple holes in the radiation transparent hole limiting mask.
9. method according to claim 8, wherein, the radiation transparent hole of mask is circular.
10. method according to claim 8, wherein, radiation transparent material is glass, and radiation opaque material is band pattern chrome coating.
11. methods according to claim 1, wherein, before being arranged in flow field layer, radiation-sensitive materials is heated to minimize residual stress.
12. methods according to claim 1, wherein, during formation diffusion media layers, diffusion media layers is attached to flow field layer.
13. methods according to claim 1, wherein, when radiation-sensitive materials is exposed to described multiple radiation beam, mask is positioned at apart from radiation-sensitive materials a distance.
14. methods according to claim 1, wherein, flow field layer is formed in substrate.
15. methods according to claim 14, wherein, substrate is metal forming, and flow field layer comprises multiple radiation curing reactant flow channel.
16. methods according to claim 15, wherein, described multiple radiation curing reactant flow channel comprises the adhesion promoter promoting that radiation curing reactant flow channel is combined with metal forming.
17. methods according to claim 1, also comprise step: by least one in conductive coating coating diffusion media layers and flow field layer.
18. 1 kinds, for the manufacture of the method for fuel cell component, comprise the following steps:
There is provided the mask with multiple radiation transparent holes, described multiple radiation transparent hole allows multiple radiation beam to be guided through;
Sacrificial releasing layer is applied to mask, and described releasing layer is roughly transparent to described multiple radiation beam;
Radiation-sensitive materials is applied to releasing layer, and described radiation-sensitive materials is responsive to described multiple radiation beam;
There is provided substrate, described substrate has and is arranged on suprabasil flow field layer, and flow field layer has multiple radiation curing reactant flow channel;
Radiation-sensitive materials is arranged in the flow field layer of fuel cell component;
By the radiation transparent hole in mask, radiation-sensitive materials is exposed to described multiple radiation beam, to form the diffusion media layers with micro-truss structure, wherein, the thickness of described sacrificial releasing layer is selected, to increase the contact surface area of diffusion media layers; And
Mask and releasing layer is removed from diffusion media layers.
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