CN106660238B - 板材一体衬垫的制造方法 - Google Patents
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Abstract
本发明提供板材一体衬垫的制造方法,能够有效地防止当在板材(1)的周缘部(11、12)的厚度方向一侧一体成形衬垫主体时,位于型腔(43、44)内的板材(1)的周缘部(11、12)的变形。为了达成该目的,在板材(1)的周缘部(11、12)中的厚度方向一侧(11a、12a),以位于衬垫主体的成形区域的方式,以相对于衬垫主体的延长方向的适当的间隔形成由橡胶状弹性材料构成的多个封装部(23、33),接着,将板材(1)定位配置在模具(4)内并进行合模,从而将由板材(1)的周缘部(11、12)以及封装部(23、33)构成的部分夹持在模具(4)的型腔(43、44)的内面之间,使周缘部(11a、12a)中的厚度方向另一侧(11c、12c)紧密接触于型腔(43、44)的一个内面,向型腔(43、44)内填充液状橡胶材料并使其固化。
Description
技术领域
本发明涉及制造板材一体衬垫的方法,所述板材一体衬垫通过在例如构成燃料电池单元的隔板等板材的周缘部一体地设置有由橡胶状弹性材料构成的衬垫主体而形成。
背景技术
就燃料电池而言,在于电解质膜的两面设有一对电极层的膜电极复合体(MEA:Membrane Electrode Assembly)的厚度方向两侧配置气体扩散层,并且在该气体扩散层上层叠隔板而形成燃料电池单元,进一步,形成层叠多个该燃料电池单元的堆叠构造(スタック構造)。在各燃料电池单元中使用用于密封燃料气体和氧化气体等的衬垫,作为这种衬垫,先前以来已知有如图5以及图6所示的板材一体衬垫100。
在图5以及图6所示的板材一体衬垫100中,在金属制隔板等板材101的周缘部中的厚度方向单侧,一体地设置有由橡胶状弹性材料(橡胶材料或者具有橡胶状弹性的合成树脂材料)构成的衬垫主体102,衬垫主体102具有山形的隆起形状的密封唇102a。
在这种板材一体衬垫100的制造中,当使用模具在板材101的周缘部101a、101b的单面分别一体成形衬垫主体102时,板材101以其周缘部101a、101b位于成形用液状橡胶材料的赋形空间即型腔内的方式配置,所述周缘部101a、101b之间的中间部分101c被夹持在模具的内面之间,因此,在板材101如燃料电池的金属制隔板等那样薄且柔软的情况下,填充至型腔内的液状橡胶材料的一部分向板材101的周缘部101a、101b的背侧迂回,如图7所示,可能在所述周缘部101a、101b由于液状橡胶材料的流入压力而弯曲变形的状态下成形衬垫主体102(参照专利文献1)。最坏的情况是,可能发生已变形的板材101的一部分从衬垫主体102露出的不良情况,并且衬垫主体102的密封性受损。
现有技术文献
专利文献
专利文献1:日本特开2011-96419号公报
发明内容
(发明要解决的问题)
本发明为鉴于以上各点而完成,其技术问题在于提供一种板材一体衬垫的制造方法,能够有效地防止当在柔软的板材的周缘部的厚度方向单侧一体成形衬垫主体时,位于型腔内的板材的周缘部的变形。
(解决技术问题的技术方案)
作为有效地解决上述技术问题的技术方案,本发明技术方案所涉及的板材一体衬垫的制造方法如下:在板材一体衬垫的制造中,在板材的周缘部中的厚度方向一侧,一体地设置有由橡胶状弹性材料构成的衬垫主体,在所述板材的周缘部中的厚度方向一侧,以位于所述衬垫主体的成形区域的方式,以相对于所述衬垫主体的延长方向的适当的间隔形成由橡胶状弹性材料构成的多个封装部,接着,将所述板材定位配置在模具内并进行合模,由此,将由所述板材的周缘部以及所述封装部构成的部分夹持在所述模具的衬垫成形用型腔的内面之间,使所述周缘部中的厚度方向另一侧紧密接触于所述型腔的一方的内面,向所述型腔内填充液状橡胶材料并使其固化。
在上述的制造方法中,在板材的周缘部中的厚度方向一侧,位于衬垫主体的成形区域形成的由橡胶状弹性材料构成的封装部,通过将所述板材定位配置在模具内并进行合模而与板材的周缘部一起被夹持在衬垫成形用型腔的内面之间,将板材的周缘部的厚度方向另一侧按压于所述型腔的一方的内面,从而能够有效地防止填充至所述型腔的液状橡胶材料的赋形时板材的周缘部的弯曲变形和随之发生的液状橡胶材料的一部分向板材的周缘部的厚度方向另一侧迂回进入这些情况的发生。
在此,由于封装部沿着板材的周缘部中的衬垫主体的成形区域以适当的间隔形成多个,因此,没有将衬垫成形用型腔截断,从而没有像连续形成封装部的情况那样遮断型腔内的液状橡胶材料的流动,所以不需要增加液状橡胶向型腔内的注入口。另外,所述封装部与通过填充至所述型腔的液状橡胶材料固化而成形的衬垫主体一体化,成为该衬垫主体的一部分。
(发明的效果)
根据本发明所涉及的板材一体衬垫的制造方法,通过形成于板材的周缘部的厚度方向一侧的封装部将所述周缘部的厚度方向另一侧按压于型腔的内面,因此,即使在如燃料电池的金属制隔板等薄且柔软的情况下,也能够防止由于向型腔内填充的液状橡胶材料的流入压力而使板材的周缘部弯曲变形,以及液状橡胶材料的一部分向板材的周缘部的厚度方向另一侧迂回进入的情况,并且能够提高板材一体衬垫的品质。
附图说明
图1是在本发明所涉及的板材一体衬垫的制造方法的优选的实施方式中,示出形成于板材的周缘部的封装部(ポッティング部)的配置的一例的部分俯视图。
图2是在本发明所涉及的板材一体衬垫的制造方法的优选的实施方式中,在图1的A-A’位置将板材切断示出的截面图。
图3是在本发明所涉及的板材一体衬垫的制造方法的优选的实施方式中,在与图2对应的位置切断示出将板材定位配置在模具内并合模的状态的截面图。
图4是在本发明所涉及的板材一体衬垫的制造方法的优选的实施方式中,将成形的板材一体衬垫在与图2对应的位置切断示出的截面图。
图5是示出通过现有的技术制造的板材一体衬垫的俯视图。
图6是将通过现有的技术制造的板材一体衬垫在图5的A-A’位置切断示出的截面图。
图7是在通过现有的技术制造的板材一体衬垫中,在图5的A-A’位置切断示出在板材的周缘部产生变形的状态的截面图。
符号说明
1 板材
11 外周缘部(周缘部)
12 开口周缘部(周缘部)
2、3 衬垫主体
23、33 封装部
4 模具
41、42 分开模具
41a、42a 模具按压面
43、44 型腔。
具体实施方式
以下,一边参照附图一边对将本发明所涉及的板材一体衬垫的制造方法应用于燃料电池单元中的隔板一体衬垫的制造的优选的实施方式进行说明。
图4示出通过本发明制造的板材一体衬垫(燃料电池单元中的隔板一体衬垫)的一例,参考符号1是作为构成燃料电池单元的金属隔板的板材,参考符号2、3是分别一体成形于板材1的外周缘部11以及在该板材1中作为燃料电池单元的气体流路等而开设的开口1a的周缘部(以下称为开口周缘部)12的衬垫主体。此外,外周缘部11以及开口周缘部12相当于技术方案中记载的周缘部。
衬垫主体2、3分别由橡胶状弹性材料(橡胶材料或者具有橡胶状弹性的合成树脂材料)构成,其中,衬垫主体2由沿着板材1的外周缘部11的厚度方向一侧11a以及端缘部11b延伸的板状的基部21和从其宽度方向中间部隆起成山形的密封唇22构成,衬垫主体3由沿着开口周缘部12的厚度方向一侧12a以及端缘部12b延伸的板状的基部31和从其宽度方向中间部隆起成山形的密封唇32构成。
上述构成的板材一体衬垫作为构成燃料电池单元的层叠部件使用,衬垫主体2、3中的密封唇22、32在适当的压缩状态下与其他的层叠部件紧密接触,由此,实现对于供给至燃料电池单元的燃料气体和氧化气体、通过电化学反应生成的水等的密封功能。
并且,在该板材一体衬垫的制造中,首先,在板材1的外周缘部11以及开口周缘部12中的厚度方向一侧11a、12a分别形成由橡胶状弹性材料构成的多个封装部23、23。详细而言,该封装部23、33中沿着板材1的外周缘部11的两列封装部23以位于先前说明的图4的隔板一体衬垫中的衬垫主体2的成形区域的方式形成,并且,沿着开口周缘部12的两列封装部33以位于图4的隔板一体衬垫中的衬垫主体3的成形区域的方式形成。
就封装部23、33而言,能够通过在板材1的外周缘部11以及开口周缘部12中的厚度方向一侧11a、12a,利用丝网印刷法(シルクスクリーン印刷法)、分配法(ディスペンサー法)或者刮刀涂布法(ブレード法)以例如半球状的突起形状以规定间隔点存在的方式涂布低粘度的液状橡胶材料并使其固化而形成。
接着,如图3所示,将通过上述工序形成有封装部23、33的板材1定位配置在衬垫成形用的模具4内。模具4具有彼此接合/分离的分开模具41、42,在其对向面之间,通过形成于一个分开模具41的内面的槽状凹部41b、41c而形成有合模时沿着板材1的外周缘部11的型腔43和沿着开口周缘部12的型腔44。型腔43、44为填充用于成形图4所示的衬垫主体2、3的液状橡胶材料的空间,形成为与衬垫主体2、3对应的形状。另外,在所述型腔43、44之间,形成能够夹持板材1中的外周缘部11和开口周缘部12之间的部分13的模具按压面41a、42a。
在一个分开模具41上开设有分别用于向型腔43、44填充液状橡胶材料的注入浇口45、46。该注入浇口45、46在型腔43、44的内面中在与图4所示的衬垫主体2、3的基部21、31对应的位置并且不与封装部23、33接触的位置开口。
并且,将板材1定位在分开模具41、42之间后,对模具4(分开模具41、42)进行合模,由此,由板材1的外周缘部11及其厚度方向一侧11a的封装部23构成的部分被夹持在型腔43的内面之间,同时,由板材1的开口周缘部12及其厚度方向一侧12a的封装部33构成的部分被夹持在型腔44的内面之间,并且所述外周缘部11和开口周缘部12之间的部分13被夹持在分开模具41、42的按压面41a、42a之间。因此,板材1的外周缘部11的厚度方向另一侧11c以紧密接触的状态被与型腔43的内面中分开模具41侧的面接触的封装部23按压于型腔43的内面中分开模具42侧的面,板材1的开口周缘部12的厚度方向另一侧12c以紧密接触的状态被与型腔44的内面中分开模具41侧的面接触的封装部33按压于型腔44的内面中分开模具42侧的面。
合模后,穿过注入浇口45、46向型腔43、44射出液状橡胶材料。该液状橡胶材料使用与封装部23、33的成形所使用的材料相同材质的材料。
射出至型腔43的液状橡胶材料穿过向该型腔43的延长方向以规定间隔点存在的封装部23之间,向型腔43内的整个区域赋形,射出至型腔44的液状橡胶材料穿过向该型腔44的延长方向以规定间隔点存在的封装部33之间,向型腔44的整个区域赋形。
此时,如上所述,位于型腔43内的板材1的外周缘部11的厚度方向另一侧11c以紧密接触的状态被封装部23按压于型腔43的内面中分开模具42侧的面,位于型腔44内的板材1的开口周缘部12以紧密接触的状态被封装部33按压于型腔44的内面中分开模具42侧的面,因此,能够有效地防止由于液状橡胶材料的压力等使板材1的外周缘部11和开口周缘部12鼓起而弯曲变形、液状橡胶材料的一部分迂回进入所述外周缘部11以及开口周缘部12的厚度方向另一侧11c、12c这些情况发生。
并且,通过在型腔43、44内使液状橡胶材料交联固化,如图4所示,成形与板材1一体化的由橡胶状弹性材料构成的衬垫主体2、3。此时,如图4中虚线所示,由相同的橡胶状弹性材料构成的封装部23、33作为衬垫主体2、3的一部分被一体化。并且,如上所述,在衬垫主体2、3的成形过程中,板材1的外周缘部11和开口周缘部12不会鼓起而弯曲变形,因此也不会发生所述外周缘部11和开口周缘部12从衬垫主体2、3露出这种成形不良的情况,因此,能够得到高品质的板材一体衬垫。
此外,优选的是,封装部23、33在板材1的外周缘部11或者开口周缘部12直线状延伸的部分以等间隔(例如30mm以下)配置,并且在呈曲线状的部分(角部)比直线状延伸的部分紧密地配置(例如20mm以下)。其理由是,薄壁且柔软的板材1在夹持于模具4的按压面41a、42a之间时在曲线部产生变形的情况较多。因此,通过使封装部23、33的间隔在曲线部紧密能够有效地抑制变形。
此外,在图示的实施方式中,对封装部23、33呈半球状的突起形状的情况进行了说明,但是封装部23、33也可以向沿着板材1的外周缘部11以及开口周缘部12的方向(图1的点划线示出的方向)具有适当的长度而断续,在这种情况下,可以考虑呈半圆柱体状(かまぼこ状)、或者山形的截面形状。
另外,作为板材1,除了燃料电池单元的金属隔板之外,也能够适用燃料电池单元的膜电极复合体或者设置于膜电极复合体的外周的合成树脂薄膜等。
Claims (2)
1.一种板材一体衬垫的制造方法,在所述板材一体衬垫的制造方法中,在具有开口的板材中包括所述板材的外周缘部和所述开口的周缘部的周缘部中的厚度方向一侧,在所述板材的外周缘部和所述开口的周缘部分别一体地设置有由橡胶状弹性材料构成的衬垫主体,其特征在于,
在所述板材的周缘部中的厚度方向一侧,以位于设置在邻接的一对所述周缘部之间的所述衬垫主体的成形区域的方式,在连接所述周缘部的虚拟直线上以适当的间隔形成由橡胶状弹性材料构成的多个封装部,
将所述板材定位配置在模具内并进行合模,从而将由所述板材的周缘部以及所述封装部构成的部分夹持在所述模具的衬垫成形用型腔的内面之间,使所述周缘部中的厚度方向另一侧紧密接触于所述型腔的一个内面,向所述型腔内填充液状橡胶材料并使其固化。
2.根据权利要求1所述的板材一体衬垫的制造方法,其特征在于,
相向的所述一对周缘部的组为多个时,排列多个所述封装部的所述虚拟直线的个数为:相比相向的区域的距离相对短的所述一对的周缘部的组,距离长的所述一对的周缘部的组更多。
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