CN108432020B - Apparatus and method for manufacturing membrane-electrode layer assembly - Google Patents

Apparatus and method for manufacturing membrane-electrode layer assembly Download PDF

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CN108432020B
CN108432020B CN201680077597.7A CN201680077597A CN108432020B CN 108432020 B CN108432020 B CN 108432020B CN 201680077597 A CN201680077597 A CN 201680077597A CN 108432020 B CN108432020 B CN 108432020B
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electrode layer
electrolyte membrane
catalyst particles
roller
loading amount
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CN108432020A (en
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高木善则
大森雅文
竹上克哉
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Screen Holdings Co Ltd
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Screen Holdings Co Ltd
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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
    • H01M4/00—Electrodes
    • H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N21/00—Investigating or analysing materials by the use of optical means, i.e. using sub-millimetre waves, infrared, visible or ultraviolet light
    • G01N21/84—Systems specially adapted for particular applications
    • G01N21/88—Investigating the presence of flaws or contamination
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N23/00—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00
    • G01N23/02—Investigating or analysing materials by the use of wave or particle radiation, e.g. X-rays or neutrons, not covered by groups G01N3/00 – G01N17/00, G01N21/00 or G01N22/00 by transmitting the radiation through the material
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
    • H01M4/88—Processes of manufacture
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
    • H01M4/88—Processes of manufacture
    • H01M4/8803—Supports for the deposition of the catalytic active composition
    • H01M4/881—Electrolytic membranes
    • 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
    • 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
    • H01M8/10—Fuel cells with solid electrolytes
    • H01M8/1004—Fuel cells with solid electrolytes characterised by membrane-electrode assemblies [MEA]
    • 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
    • H01M8/10—Fuel cells with solid electrolytes
    • 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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Abstract

The apparatus (1) for producing a membrane-catalyst assembly comprises: a plurality of conveying rollers for conveying the long strip-shaped electrolyte membrane (92) in the conveying direction which is the length direction of the electrolyte membrane (92), wherein a first electrode layer (9a) formed on the back surface of the electrolyte membrane contains first catalyst particles; an adsorption roller (10) which adsorbs and holds the back surface of the electrolyte membrane (92) by a part of the outer peripheral surface of the adsorption roller and rotates around the axis of the adsorption roller; a material supply unit that supplies an electrode material containing second catalyst particles to the surface of the electrolyte membrane (92) that moves while being held by the suction roller (10) so as to form a second electrode layer (9 b); and an inspection unit that inspects at least the first electrode layer (9a) after the electrolyte membrane (92) has been separated from the adsorption roller (10).

Description

Apparatus and method for manufacturing membrane-electrode layer assembly
Technical Field
The present invention relates to an apparatus and a method for manufacturing a membrane-electrode layer assembly in which an electrode layer is formed on the surface of an electrolyte membrane while conveying a long strip-shaped electrolyte membrane.
Background
In recent years, fuel cells have attracted attention as a driving power source for automobiles, cellular phones, and the like. The fuel cell is operated by hydrogen (H) contained in the fuel2) With oxygen (O) in the air2) And generating electric power by the electrochemical reaction of (1). Fuel cells have advantages of high power generation efficiency and less environmental burden as compared with other cells.
Fuel cells exist in several categories depending on the electrolyte used. One of them is a Polymer Electrolyte Fuel Cell (PEFC) using an ion exchange membrane (Electrolyte membrane) as an Electrolyte. Since the polymer electrolyte fuel cell can operate at room temperature and can be reduced in size and weight, it is expected to be applied to automobiles and portable devices.
A polymer electrolyte fuel cell generally has a structure in which a plurality of cells (cells) are stacked. One cell is configured by sandwiching both sides of a Membrane-Electrode layer Assembly (MEA) by a pair of separators. The membrane-electrode layer assembly includes an electrolyte membrane and a pair of electrode layers formed on both surfaces of the electrolyte membrane. One of the pair of electrode layers is an anode and the other is a cathode. When fuel gas containing hydrogen contacts the anode and air contacts the cathode, electricity is generated through an electrochemical reaction.
Typically, the membrane-electrode layer assembly is produced by applying a catalyst ink (electrode paste) in which catalyst particles containing platinum (Pt) are dispersed in a solvent such as alcohol to the surface of an electrolyte membrane and drying the catalyst ink. For example, patent document 1 describes a conventional technique for producing a membrane-electrode layer assembly.
In the manufacturing apparatus of patent document 1, the electrolyte membrane is held on the outer circumferential surface of the adsorption roller. Then, while the adsorption roller is rotated to convey the electrolyte membrane, the electrode ink is discharged from the application nozzle to apply the electrode ink to the surface of the electrolyte membrane.
Documents of the prior art
Patent document 1: japanese patent laid-open publication No. 2015-15258
Disclosure of Invention
Problems to be solved by the invention
The electrode layer formed on the electrolyte membrane is porous in order to efficiently diffuse the fuel gas and air. Therefore, it is known that the electrode layer is easily damaged by pressure from the outside, and the electrode layer is easily peeled off from the electrolyte membrane. Therefore, in terms of controlling the quality of the membrane-electrode layer assembly, it is important to be able to check and determine whether or not the electrode layer formed on the electrolyte membrane has defects when the membrane-electrode layer assembly is manufactured. In particular, the back surface of the electrolyte membrane is held by the suction roller. Therefore, in terms of managing the quality of the membrane-electrode layer assembly, it is more important to check whether or not a defect is generated in the electrode layer formed on the back surface of the electrolyte membrane after separation from the adsorption roll.
The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a technique for efficiently managing the quality of a membrane-electrode layer assembly by inspecting whether or not a defect has occurred in an electrode layer formed on the back surface of an electrolyte membrane after separation from an adsorption roll in a membrane-electrode layer assembly manufacturing apparatus.
Technical scheme for solving problems
In order to solve the above problems, a first aspect of the present invention is an apparatus for manufacturing a membrane-electrode layer assembly having a first electrode layer on a back surface of an electrolyte membrane and a second electrode layer on a front surface of the electrolyte membrane, the apparatus comprising: a plurality of conveying rollers for conveying the long strip-shaped electrolyte membrane in a conveying direction which is a longitudinal direction of the electrolyte membrane, wherein the first electrode layer formed on the back surface of the electrolyte membrane contains first catalyst particles; an adsorption roller that adsorbs and holds the back surface of the electrolyte membrane conveyed by the plurality of conveying rollers by a part of the outer peripheral surface of the adsorption roller, and that rotates around the axis of the adsorption roller; a material supply unit that supplies an electrode material containing second catalyst particles to the surface of the electrolyte membrane that moves while being held by the suction roller, thereby forming a second electrode layer; and one or more inspection units for inspecting the first electrode layer after the electrolyte membrane is separated from the adsorption roller.
A second aspect of the present invention is the manufacturing apparatus of the first aspect, wherein the inspection unit has an appearance inspection unit for inspecting an appearance of the first electrode layer.
A third aspect of the present invention is the manufacturing apparatus according to the first or second aspect, wherein the inspection unit includes:
a total loading amount inspection unit that inspects a loading amount of the first catalyst particles contained in the first electrode layer and a loading amount of the second catalyst particles contained in the second electrode layer after the electrolyte membrane is separated from the adsorption roller; and a calculation unit configured to calculate a loading amount of the second catalyst particles by subtracting a first loading amount of the first catalyst particles contained in the first electrode layer, which is acquired in advance, from the total loading amount obtained by the total loading amount inspection unit.
A fourth aspect of the present invention is the manufacturing apparatus according to the third aspect, wherein the inspection unit further includes a first loading amount inspection unit that inspects the first loading amount of the first catalyst particles contained in the first electrode layer on the back surface of the electrolyte membrane before the electrolyte membrane reaches the adsorption roller.
A fifth aspect of the present invention is the manufacturing apparatus according to the third or fourth aspect, wherein the calculation unit obtains a second loading amount of the second catalyst particles based on the total loading amount and the first loading amount, and the inspection unit inspects the first electrode layer based on whether or not the second loading amount is an abnormal value.
A sixth aspect of the present invention is the manufacturing apparatus according to any one of the first to fifth aspects, wherein the porous substrate conveying section conveys the porous substrate while interposing an elongated strip-shaped porous substrate between the adsorption roller and the electrolyte membrane.
A seventh aspect of the present invention is the manufacturing apparatus according to any one of the first to sixth aspects, wherein a conveying roller on a downstream side in a conveying direction from the inspection unit among the plurality of conveying rollers is disposed on a surface side of the electrolyte membrane.
An eighth aspect of the present invention is the manufacturing apparatus according to any one of the first to seventh aspects, further comprising a marking unit that marks a vicinity of the first electrode layer determined to have a defect based on an inspection result of the inspection unit.
A ninth aspect of the present invention provides the manufacturing apparatus of any one of the first to eighth aspects, wherein the suction roller sucks and holds the back surface of the electrolyte membrane and the first electrode layer in an exposed state.
A tenth aspect of the present invention is a method for manufacturing a membrane-electrode layer assembly having an electrolyte membrane with a first electrode layer on a back surface thereof and a second electrode layer on a front surface thereof, the method comprising: a conveying step a) of conveying the electrolyte membrane while holding the back surface of the long strip-shaped electrolyte membrane by suction with a part of the outer peripheral surface of a suction roller and rotating the suction roller around the axis of the suction roller, wherein the first electrode layer formed on the back surface of the electrolyte membrane contains first catalyst particles; a step b) of forming the second electrode layer by supplying an electrode material containing second catalyst particles to the surface of the electrolyte membrane that moves while being held by the suction roller; and a step c) of inspecting the first electrode layer after the electrolyte membrane is separated from the suction roll.
An eleventh aspect of the present invention is the manufacturing method according to the tenth aspect, wherein the step c) includes a step d) of inspecting an appearance of the first electrode layer.
A twelfth aspect of the present invention is the manufacturing method of the tenth or eleventh aspect, wherein the step c) includes: a step e) of checking a loading amount of the first catalyst particles contained in the first electrode layer and a loading amount of the second catalyst particles contained in the second electrode layer; and a step f) of obtaining a second supporting amount of the second catalyst particles by subtracting the previously obtained supporting amount of the first catalyst particles contained in the first electrode layer from the total supporting amount obtained in the step e).
A thirteenth invention of the present invention is the manufacturing method of the twelfth invention, further comprising: a step of checking a first loading amount of the first catalyst particles contained in the first electrode layer on the back surface of the electrolyte membrane before the electrolyte membrane reaches the adsorption roller, wherein in the step f), the first loading amount is subtracted from the total loading amount to obtain the second loading amount of the second catalyst particles.
A fourteenth aspect of the present invention is the manufacturing method according to the twelfth or thirteenth aspect, wherein in the step c), the first electrode layer is inspected based on whether or not the second loading amount is an abnormal value.
A fifteenth aspect of the present invention is the production method according to any one of the tenth to fourteenth aspects, wherein in the step a), the porous substrate is conveyed while a long strip-shaped porous substrate is interposed between the adsorption roll and the electrolyte membrane.
A sixteenth aspect of the present invention is the manufacturing method according to any one of the tenth to fifteenth aspects, wherein after the step c), the electrolyte membrane is conveyed by a plurality of conveying rollers disposed on a front surface side of the electrolyte membrane.
A seventeenth aspect of the present invention is the manufacturing method according to any one of the tenth to sixteenth aspects, further comprising a step g) of marking a vicinity of the first electrode layer determined to have a defect based on a result of the inspection in the step c).
An eighteenth aspect of the present invention is the manufacturing method according to any one of the tenth to seventeenth aspects, wherein in the step a), the back surface of the electrolyte membrane and the first electrode layer are held by the suction roll in an exposed state.
Effects of the invention
According to the first to eighteenth aspects of the present invention, after the electrolyte membrane is separated from the adsorption roller, defects such as damage or adhesion of foreign matter to the first electrode layer formed on the electrolyte membrane can be detected. This enables efficient quality control of the membrane-electrode layer assembly and reduction of the defect rate of the membrane-electrode layer assembly. Further, it is possible to determine whether or not processing in the next step is necessary based on the inspection result. Therefore, the production efficiency of the membrane-electrode layer assembly can be improved.
In particular, according to the second and eleventh aspects of the present invention, defects such as the shape and positional accuracy of the first electrode layer formed on the electrolyte membrane can be inspected. Therefore, the quality of the membrane-electrode layer assembly can be more effectively controlled.
In particular, according to the third and twelfth aspects of the present invention, the amount of the second catalyst particles contained in the second electrode layer can be checked.
In particular, according to the fourth and thirteenth aspects of the present invention, the amount of the first catalyst particles contained in the first electrode layer can be checked before the electrolyte membrane is suction-supported by the suction roller.
In particular, according to the fifth and fourteenth aspects of the present invention, the first electrode layer can be inspected based on the inspection result of the supported amount of the second catalyst particles. As a result, the defect of the first electrode layer can be inspected at more angles.
In particular, according to the sixth invention and the fifteenth invention of the present invention, the electrolyte membrane is suction-supported by the suction roller through the porous base material. Therefore, foreign matter and the like adhering to the suction roller can be suppressed from being transferred to and adhering to the electrolyte membrane.
In particular, according to the seventh invention and the sixteenth invention of the present invention, after the electrolyte membrane is separated from the adsorption roller, the back surface of the electrolyte membrane does not contact the conveying roller. Therefore, after the separation from the suction roll, defects such as damage and foreign matter transfer and adhesion can be prevented from occurring on the first electrode layer. As a result, the reliability of the inspection by the inspection unit can be improved.
In particular, according to the eighth and seventeenth aspects of the present invention, the marking can be performed on the electrolyte membrane based on the inspection result of the inspection section. This enables more effective quality control of the membrane-electrode layer assembly.
In particular, according to the ninth and eighteenth aspects of the invention, it is possible to inspect the first electrode layer which is once sucked and held by the suction roller and exposed on the back surface of the electrolyte membrane after the electrolyte membrane is separated from the suction roller. This enables more effective quality control of the membrane-electrode layer assembly.
Drawings
Fig. 1 is a diagram showing the structure of an apparatus for producing a membrane-electrode layer assembly.
Fig. 2 is an enlarged view of the vicinity of the lower portion of the suction roller.
Fig. 3 is a block diagram showing connections between the control unit and each unit.
Fig. 4 is a diagram showing how the supported amount inspection unit inspects the catalyst particles.
Fig. 5 is a diagram showing the amount of catalyst particles supported calculated by the control unit.
Fig. 6 is a view showing how the supported amount inspection unit inspects the catalyst particles.
Fig. 7 is a diagram showing the amount of catalyst particles supported, which is calculated by the control unit.
Detailed Description
Embodiments of the present invention will be described below with reference to the drawings.
1. Structure of manufacturing apparatus
Fig. 1 is a diagram showing the structure of a manufacturing apparatus 1 for a membrane-electrode layer assembly according to an embodiment of the present invention. In this manufacturing apparatus 1, an electrolyte membrane as a long strip-shaped base material is conveyed in the longitudinal direction (conveying direction) by a plurality of conveying rollers, and an electrode layer is formed on the surface of the electrolyte membrane, thereby manufacturing a membrane-electrode layer assembly for a polymer electrolyte fuel cell. As shown in fig. 1, the apparatus 1 for producing a membrane-electrode layer assembly according to the present embodiment includes an adsorption roll 10, a porous substrate conveying unit 20, an electrolyte membrane supply unit 30, a material supply unit 40, a drying furnace 50, an assembly collection unit 60, an inspection unit 70, a labeling unit 79, and a control unit 80.
The suction roller 10 is a roller that rotates while sucking and holding the porous base material 91 and the electrolyte membrane 92 conveyed by a plurality of conveying rollers. The suction roller 10 has a cylindrical outer peripheral surface having a plurality of suction holes. The diameter of the suction roller 10 is, for example, 200mm to 1600 mm. Fig. 2 is an enlarged view of the vicinity of the lower portion of the suction roller 10. As shown by a broken line in fig. 2, the suction roller 10 is connected to a rotation driving section 11 having a driving source such as a motor. When the rotation driving unit 11 is operated, the suction roller 10 rotates about a horizontally extending shaft center. In the manufacturing apparatus 1 of the present embodiment, the plurality of conveyance rollers are composed of a plurality of laminated substrate conveyance rollers 32 and a plurality of joined body conveyance rollers 64, which will be described later.
As a material of the adsorption roller 10, for example, a porous material such as porous carbon or porous ceramic is used. Specific examples of the porous ceramic include alumina (Al)2O3) Or a sintered body of silicon carbide (SiC). The pore diameter of the pores in the porous adsorption roll 10 is, for example, 5 μm or less, and the porosity is, for example, 15% to 50%.
Note that, instead of the porous material, metal may be used as the material of the adsorption roller 10. Specific examples of the metal include stainless steel such as SUS and iron. When a metal is used as the material of the suction roller 10, the outer circumferential surface of the suction roller 10 may be formed with minute suction holes by machining. In order to prevent the generation of adsorption marks, the diameter of the adsorption holes is preferably 2mm or less.
The suction roll 10 is provided with a suction port 12 on an end surface thereof. The suction port 12 is connected to a suction mechanism (for example, an exhaust pump) outside the drawing. When the suction mechanism is operated, a negative pressure is generated in the suction port 12 of the suction roller 10. Then, a negative pressure is also generated in the plurality of suction holes provided in the outer circumferential surface of the suction roller 10 via the air holes in the suction roller 10. The negative pressure causes the porous base material 91 and the electrolyte membrane 92 to be sucked and held on the outer circumferential surface of the suction roller 10, and to be conveyed in an arc-like state as the suction roller 10 rotates.
Further, as shown by a dotted line in fig. 2, a plurality of water-cooled tubes 13 are provided inside the adsorption roller 10. The cooling water adjusted to a predetermined temperature is supplied to the water cooling tubes 13 from a water supply mechanism outside the figure. When the manufacturing apparatus 1 is operated, heat of the adsorption roller 10 is absorbed by cooling water as a heat transfer medium. Thereby, the adsorption roller 10 is cooled. The cooling water having absorbed the heat is discharged to the liquid discharge mechanism outside the figure.
Instead of the drying furnace 50 described later, a heating mechanism such as a hot water circulating mechanism or a heater may be provided inside the adsorption roller 10. In this case, the temperature of the outer peripheral surface of the adsorption roller 10 may be controlled by controlling a heating mechanism provided inside the adsorption roller 10 without providing a water cooling pipe inside the adsorption roller 10.
The porous base material conveying unit 20 is a part for supplying the long strip-shaped porous base material 91 to the suction roller 10 and recovering the used porous base material 91. The porous substrate 91 is a breathable substrate having many fine pores. Preferably, the porous base material 91 is formed of a material that is less likely to generate foreign matter. As shown in fig. 1, the porous substrate conveying unit 20 includes a porous substrate supply roller 21, a plurality of porous substrate carrying-in rollers 22, a plurality of porous substrate carrying-out rollers 23, and a porous substrate recovery roller 24. The porous substrate supply roller 21, the plurality of porous substrate carry-in rollers 22, the plurality of porous substrate carry-out rollers 23, and the porous substrate recovery roller 24 are all disposed parallel to the adsorption roller 10.
The porous base material 91 before supply is wound around the porous base material supply roller 21. The porous base material supply roller 21 is rotated by power of a motor not shown. When the porous base material supply roller 21 rotates, the porous base material 91 is discharged from the porous base material supply roller 21. The discharged porous base material 91 is conveyed to the outer peripheral surface of the suction roller 10 along a predetermined conveyance path while being guided by the plurality of porous base material conveyance rollers 22. Then, the porous base material 91 is sucked and held on the outer peripheral surface of the suction roller 10, and is conveyed in an arc-like state as the suction roller 10 rotates. For the sake of easy understanding, the suction roller 10 and the porous base material 91 held by the suction roller 10 are shown with a space therebetween in fig. 2.
The porous base material 91 is conveyed by 180 ° or more, preferably 270 ° or more, around the axial center of the suction roller 10. Then, the porous base material 91 is separated from the outer circumferential surface of the adsorption roller 10. The porous substrate 91 separated from the suction roller 10 is guided by the plurality of porous substrate carry-out rollers 23 and conveyed to the porous substrate recovery roller 24 along a predetermined carry-out path. The porous substrate recovery roller 24 is rotated by the power of a motor not shown. Thus, the used porous base material 91 is taken up by the porous base material recovery roll 24.
The electrolyte membrane supply unit 30 is a portion that supplies a laminated base material 94 composed of two layers of the electrolyte membrane 92 and the first support film 93 to the periphery of the adsorption roller 10, and peels the first support film 93 from the electrolyte membrane 92.
For example, a fluorine-based or hydrocarbon-based polymer electrolyte membrane is used as the electrolyte membrane 92. Specific examples of the electrolyte membrane 92 include a polymer electrolyte membrane containing Perfluorocarbon Sulfonic Acid (perfluor Sulfonic Acid) (for example, Nafion (registered trademark) manufactured by DuPont, usa, fiemion (registered trademark) manufactured by asahi glass (co., ltd.), Aciplex (registered trademark) manufactured by asahi chemical corporation, and Goreselect (registered trademark) manufactured by Gore (co.)). The thickness of the electrolyte membrane 92 is, for example, 5 μm to 30 μm. The electrolyte membrane 92 expands due to moisture in the atmosphere, and on the other hand, contracts as the humidity decreases. That is, the electrolyte membrane 92 has a property of being easily deformed in accordance with the humidity in the atmosphere.
The first support film 93 is a film for suppressing deformation of the electrolyte membrane 92. As a material of the first support film 93, a resin having higher mechanical strength than the electrolyte membrane 92 and superior shape-retaining function is used. Specific examples of the first support film 93 include a PEN (Polyethylene Naphthalate) film and a PET (Polyethylene Terephthalate) film. The first supporting film 93 has a film thickness of, for example, 25 μm to 100 μm.
As shown in fig. 1, the electrolyte membrane supply unit 30 includes a laminated substrate supply roller 31 (electrolyte membrane supply roller), a plurality of laminated substrate carrying-in rollers 32, a peeling roller 33, a plurality of first support film carrying-out rollers 34, and a first support film collecting roller 35. The laminated substrate supply roller 31, the plurality of laminated substrate carrying-in rollers 32, the peeling roller 33, the plurality of first supporting film carrying-out rollers 34, and the first supporting film recovery roller 35 are all disposed parallel to the suction roller 10.
The laminate base material 94 before being supplied is wound around the laminate base material supply roller 31 so that the first support film 93 is positioned outside. In the present embodiment, the first electrode layer 9a is formed in advance on the surface of the electrolyte membrane 92 opposite to the first support film 93 (hereinafter referred to as "back surface"). The first electrode layer 9a contains first catalyst particles. In an apparatus different from the manufacturing apparatus 1, while a laminated base material 94 composed of two layers of the first support film 93 and the electrolyte membrane 92 is conveyed by a roll-to-roll method, an electrode material is intermittently applied to the back surface of the electrolyte membrane 92, and the applied electrode material is dried, thereby forming the first electrode layer 9 a.
The laminated base material supply roller 31 is rotated by power of a motor not shown. When the laminated base material supply roller 31 rotates, the laminated base material 94 is paid out by the laminated base material supply roller 31. The discharged laminated substrate 94 is guided by the plurality of laminated substrate carrying-in rollers 32 as carrying rollers and carried along a predetermined carrying-in path to the peeling roller 33. The back surface of the electrolyte membrane 92 and the first electrode layer 9a are exposed without being covered with a support film.
The peeling roller 33 is a roller for peeling the first support film 93 from the electrolyte membrane 92. The peeling roller 33 has a cylindrical outer peripheral surface having a smaller diameter than the suction roller 10. At least the outer peripheral surface of the peeling roller 33 is formed of an elastic body. The peeling roller 33 is disposed adjacent to the suction roller 10 on a slightly downstream side of an introduction position of the porous substrate 91 into the suction roller 10 in a rotation direction of the suction roller 10. Further, the peeling roller 33 is pressed toward the suction roller 10 by an air cylinder not shown.
As shown in fig. 2, the laminated substrate 94 carried in by the plurality of laminated substrate carrying-in rollers 32 is introduced between the suction roller 10 and the peeling roller 33. At this time, the back surface of the electrolyte membrane 92 comes into contact with the surface of the porous substrate 91 held by the suction roller 10 together with the first electrode layer 9a, and the first support film 93 comes into contact with the outer peripheral surface of the peeling roller 33. The laminated base material 94 is pressed toward the suction roller 10 by the pressure received from the peeling roller 33. A negative pressure is generated on the surface of the porous substrate 91 held by the suction roller 10 by the suction force from the suction roller 10. The electrolyte membrane 92 is adsorbed on the surface of the porous substrate 91 by this negative pressure. Then, the electrolyte membrane 92 is held by the suction roller 10 together with the porous base material 91, and is conveyed in an arc-like state as the suction roller 10 rotates. In fig. 2, the porous substrate 91 held by the suction roller 10 is shown with a space from the electrolyte membrane 92 for the sake of understanding.
In this manner, in the present embodiment, the porous base material 91 is interposed between the outer peripheral surface of the adsorption roller 10 and the electrolyte membrane 92. Therefore, the outer peripheral surface of the adsorption roller 10 does not directly contact the first electrode layer 9a formed on the back surface of the electrolyte membrane 92. Therefore, it is possible to suppress adhesion of a part of the first electrode layer 9a to the outer circumferential surface of the adsorption roller 10, or adhesion of foreign matter transferred from the outer circumferential surface of the adsorption roller 10 to the electrolyte membrane 92.
On the other hand, the first support film 93 having passed between the suction roller 10 and the peeling roller 33 is separated from the suction roller 10 and conveyed toward the plurality of first support film carry-out rollers 34. Thereby, the first support film 93 is peeled off from the electrolyte membrane 92. As a result, the surface (hereinafter referred to as "front surface") of the electrolyte membrane 92 opposite to the back surface is exposed. The peeled first support film 93 is conveyed to the first support film collecting roller 35 along a predetermined conveyance path while being guided by the plurality of first support film conveyance rollers 34. The first supporting film recovery roller 35 is rotated by power of a motor not shown. Thereby, the first supporting film 93 is wound up by the first supporting film recovery roller 35.
The material supply unit 40 is a mechanism for applying an electrode material to the surface of the electrolyte membrane 92 around the adsorption roller 10. As the electrode material, for example, a catalyst ink (electrode paste) in which second catalyst particles containing platinum (Pt) are dispersed in a solvent such as alcohol is used. As shown in fig. 1, the material supply portion 40 has a nozzle 41. The nozzle 41 is provided on the downstream side of the peeling roller 33 in the conveyance direction in which the adsorption roller 10 conveys the electrolyte membrane 92. The nozzle 41 has a discharge port 411 facing the outer peripheral surface of the suction roller 10. The discharge port 411 is a slit-shaped opening extending horizontally along the outer circumferential surface of the adsorption roller 10.
The nozzle 41 is connected to an electrode material supply source, not shown. When the material supply portion 40 is driven, the electrode material is supplied from the electrode material supply source to the nozzle 41 through the pipe. Then, the electrode material is discharged from discharge port 411 of nozzle 41 toward the surface of electrolyte membrane 92. Thereby, the electrode material is applied to the surface of the electrolyte membrane 92.
In this embodiment, the supply line is connected to the flow path of the nozzle 41, and the valve inserted in the supply line is opened and closed at a constant cycle, whereby the electrode material is intermittently discharged from the discharge port 411 of the nozzle 41. Thereby, the electrode material is intermittently applied to the surface of the electrolyte membrane 92 at regular intervals in the conveying direction. However, the valve may be continuously opened, and the electrode material may be applied to the surface of the electrolyte membrane 92 in the transport direction without any gap.
As the catalyst particles in the electrode material, a material that causes a fuel cell reaction in the anode or cathode of the polymer electrolyte fuel cell is used. Specifically, particles of platinum (Pt), platinum alloy, platinum compound, or the like can be used as the catalyst particles. Examples of the platinum alloy include an alloy of platinum and at least one metal selected from the group consisting of ruthenium (Ru), palladium (Pd), nickel (Ni), molybdenum (Mo), iridium (Ir), iron (Fe), and the like. Generally, platinum is used as an electrode material for a cathode, and a platinum alloy is used as an electrode material for an anode. The electrode material ejected from the nozzle 41 may be used for the cathode or the anode. However, electrode materials having polarities opposite to each other are used for the electrode layers 9a and 9b formed on the front surface and the back surface of the electrolyte membrane 92.
The nozzle 41 and the pipe of the material supply unit 40 need to be periodically maintained, for example, disassembled and cleaned. Therefore, the manufacturing apparatus 1 has a maintenance site 2 for maintaining the material supply unit 40. In the present embodiment, the maintenance site 2 is disposed between the material supply unit 40 and the first supporting film recovery roller 35. When performing maintenance of the material supply unit 40, the operator 3 stands on the stand 201 provided in the maintenance site 2, and cleans and the like the components constituting the material supply unit 40.
The drying furnace 50 is a part that dries the electrode material coated on the surface of the electrolyte membrane 92. The drying furnace 50 of the present embodiment is disposed downstream of the material supplying unit 40 in the conveying direction in which the adsorption roller 10 conveys the electrolyte membrane 92. The drying furnace 50 is provided in an arc shape along the outer peripheral surface of the suction roller 10. The drying furnace 50 blows heated gas (hot air) to the surface of the electrolyte membrane 92 around the adsorption roller 10. Then, the electrode material coated on the surface of the electrolyte membrane 92 is heated, and the solvent in the electrode material is vaporized. Thereby, the electrode material is dried, and an electrode layer (hereinafter, referred to as "second electrode layer 9 b") is formed on the surface of the electrolyte membrane 92. As a result, a membrane-electrode layer assembly 95 including the electrolyte membrane 92, the first electrode layer 9a, and the second electrode layer 9b was obtained.
The joined body collecting section 60 is a section for attaching the second support film 96 to the membrane-electrode layer joined body 95 and collecting the membrane-electrode layer joined body 95. As shown in fig. 1, the joined body collecting section 60 includes a second support film supply roller 61, a plurality of second support film carrying-in rollers 62, a laminating roller 63, a plurality of joined body carrying-out rollers 64 as carrying rollers, and a joined body collecting roller 65. The second supporting film supply roller 61, the plurality of second supporting film carrying-in rollers 62, the laminating roller 63, the plurality of joined body carrying-out rollers 64, and the joined body collecting roller 65 are all arranged in parallel with the suction roller 10.
The second support film 96 before feeding is wound around the second support film feeding roller 61. The second support film supply roller 61 is rotated by power of a motor not shown. When the second support film supply roller 61 rotates, the second support film 96 is paid out from the second support film supply roller 61. The discharged second support film 96 is guided by the plurality of second support film carrying-in rollers 62 and carried to the laminating roller 63 along a predetermined carrying-in path.
A resin having a mechanical strength higher than that of the electrolyte membrane 92 and excellent in shape-retaining function is used as the material of the second support film 96. Specific examples of the second support film 96 include PEN (polyethylene naphthalate) and PET (polyethylene terephthalate) films. The film thickness of the second support film 96 is, for example, 25 μm to 100 μm. The second support film 96 may be identical to the first support film 93. The first support film 93 wound up by the first support film recovery roller 35 may be discharged from the second support film supply roller 61 as the second support film 96.
The laminating roller 63 is a roller for attaching the second support film 96 to the film-electrode layer joined body 95. As a material of the laminating roller 63, for example, rubber having high heat resistance is used. The laminating roller 63 has a cylindrical outer peripheral surface having a smaller diameter than the suction roller 10. The laminating roller 63 is disposed adjacent to the suction roller 10 on the downstream side of the drying furnace 50 and on the upstream side of the position where the porous substrate 91 is separated from the suction roller 10 in the rotation direction of the suction roller 10. The laminating roller 63 is pressed toward the suction roller 10 by an air cylinder not shown.
As shown in fig. 2, inside the laminating roller 63, a heater 631 that generates heat by energization is provided. As the Heater 631, for example, a package Heater (Sheath Heater) is used. When the heater 631 is energized, the outer peripheral surface of the laminating roller 63 is adjusted to a predetermined temperature higher than the ambient temperature by the heat generated by the heater 631. The temperature of the outer peripheral surface of the laminating roller 63 may be measured using a temperature sensor such as a radiation thermometer, and the output of the heater 631 may be controlled based on the measurement result so that the outer peripheral surface of the laminating roller 63 is at a constant temperature.
As shown in fig. 2, the second support film 96 carried in by the plurality of second support film carrying-in rollers 62 is introduced around the suction roller 10 between the film-electrode layer assembly 95 and the laminating roller 63. At this time, the second support film 96 is pressed against the film-electrode layer joined body 95 by the pressure from the laminating roller 63, and is heated by the heat of the laminating roller 63. As a result, the second support film 96 is attached to the surface of the electrolyte membrane 92. The second electrode layer 9b formed on the surface of the electrolyte membrane 92 is sandwiched between the electrolyte membrane 92 and the second support film 96.
The film-electrode layer assembly 95 having the second support film 96 attached thereto, which has passed between the suction roller 10 and the laminating roller 63, is conveyed in a direction away from the suction roller 10. Thereby, the membrane-electrode layer assembly 95 is peeled off from the porous substrate 91.
In the present embodiment, the pressing roller 66 is disposed in the vicinity of the laminating roller 63. The pressing roller 66 is disposed adjacent to the laminating roller 63 on the downstream side in the transport direction of the film-electrode layer assembly 95 with respect to the gap between the suction roller 10 and the laminating roller 63. The pressing roller 66 is pressed toward the laminating roller 63 by an air cylinder not shown. The membrane-electrode layer assembly 95 with the second support film 96 attached thereto, which has been separated from the porous base material 91, then passes between the laminating roller 63 and the pressing roller 66. This improves the adhesion between the second support film 96 and the surface of the electrolyte membrane 92.
Then, the membrane-electrode layer assembly 95 with the second support film 96 attached thereto is guided by the plurality of assembly delivery rollers 64 while being inspected by the inspection unit 70, which will be described later. Then, the membrane-electrode layer assembly 95 with the second support film 96 attached thereto is conveyed to the assembly collection roller 65 along a predetermined conveyance path. The joined body collecting roller 65 is rotated by power of a motor not shown. Thus, the membrane-electrode layer assembly 95 with the second support film 96 attached thereto is wound around the assembly collecting roll 65 so that the second support film 96 is positioned outside.
In this manner, in the manufacturing apparatus 1 of the present embodiment, the steps of releasing the laminate substrate 94 from the laminate substrate supply roll 31, peeling the first support film 93 from the electrolyte membrane 92, coating the electrode material on the electrolyte membrane 92, drying in the drying furnace 50, attaching the second support film 96 to the electrolyte membrane 92, inspecting in the inspection section 70, and winding the membrane-electrode layer assembly 95 around the assembly recovery roll 65 are sequentially performed. In this way, a membrane-electrode layer assembly 95 used for an electrode of a polymer electrolyte fuel cell is produced. The electrolyte membrane 92 is always held by the first support film 93, the adsorption roller 10, or the second support film 96. This suppresses deformation such as expansion and contraction of the electrolyte membrane 92 in the manufacturing apparatus 1.
The control unit 80 is a unit for controlling the operation of each unit in the manufacturing apparatus 1. Fig. 3 is a block diagram showing an electrical connection relationship between the control unit 80 and each part in the manufacturing apparatus 1. As schematically shown in fig. 3, the control unit 80 is constituted by a computer having an arithmetic unit 81 such as a CPU, a memory 82 such as a RAM, and a storage unit 83 such as a hard disk drive. In the storage unit 83, a computer program P for executing a process of manufacturing the membrane-electrode layer assembly is installed.
As shown in fig. 3, the control unit 80 is communicably connected to the rotation driving unit 11 of the adsorption roller 10, the suction mechanism of the adsorption roller 10, the motor of the porous substrate supply roller 21, the motor of the porous substrate collection roller 24, the motor of the laminated substrate supply roller 31, the cylinder of the peeling roller 33, the motor of the first support film collection roller 35, the material supply unit 40, the drying oven 50, the motor of the second support film supply roller 61, the cylinder of the lamination roller 63, the heater 631 of the lamination roller 63, the cylinder of the pressing roller 66, the motor of the joined body collection roller 65, the inspection unit 70, and the marking unit 79, which will be described later.
The control unit 80 controls the operations of the above-described respective units by temporarily reading the computer program P and data stored in the storage unit 83 into the memory 82 and performing an arithmetic process by the arithmetic unit 81 based on the computer program P. Thereby, the film-electrode layer assembly manufacturing process in the manufacturing apparatus 1 is performed.
2. About inspection part and marking part
Next, the inspection unit 70 and the marking unit 79 in the manufacturing apparatus 1 will be described.
The inspection unit 70 is a mechanism for inspecting the electrode layers 9a and 9b formed on the electrolyte membrane 92. The inspection unit 70 of the present embodiment includes a first inspection unit 71 and a second inspection unit 72. The first inspection unit 71 is disposed downstream of the laminating roller 63 in the conveying direction, and after the electrolyte membrane 92 is separated from the suction roller 10, the first inspection unit 71 inspects the electrode layers 9a and 9b formed on the electrolyte membrane 92.
The first inspection unit 71 includes an appearance inspection unit 73 and a total load amount inspection unit 74 a. The appearance inspection unit 73 is a mechanism for inspecting the appearance such as the shape and the formation position of the electrode layers 9a and 9b formed on the electrolyte membrane 92. The appearance inspection unit 73 is implemented by, for example, an optical system such as a lens and a line sensor having an imaging element such as a CCD or a CMOS. However, the appearance inspection unit 73 may be implemented by another unit. The image acquired by the appearance inspection unit 73 is input to the control unit 80 and subjected to image processing. Then, the control unit 80 determines whether or not defects such as position abnormality, adhesion of foreign matter, and damage are formed in the electrode layers 9a and 9b based on the image after the image processing.
As shown in fig. 1, the appearance inspection unit 73 of the present embodiment includes an appearance inspection unit 73a for inspecting the first electrode layer 9a and an appearance inspection unit 73b for inspecting the second electrode layer 9 b. The appearance inspecting section 73b is disposed downstream of the laminating roller 63 in the transport direction and on the surface side of the film-electrode layer assembly 95, and inspects the appearance of the second electrode layer 9b through the second support film 96. The appearance inspecting unit 73a is disposed on the downstream side in the transport direction of the appearance inspecting unit 73b and on the back side of the film-electrode layer assembly 95, and inspects the appearance of the first electrode layer 9 a. This makes it possible to determine the presence or absence of a defect in the external appearance of each of the first electrode layer 9a and the second electrode layer 9 b. Further, by suction-supporting the electrolyte membrane 92 by the suction roller 10, it is also possible to determine whether or not a defect has occurred in the first electrode layer 9 a.
The appearance inspecting section 73a of the present embodiment inspects the appearance of the first electrode layer 9a from the back side of the electrolyte membrane 92 that abuts the joined body carry-out roller 64 as a carrying roller. The electrolyte membrane 92 during conveyance is prevented from being bent at a position where it abuts against the joined body carry-out roller 64. Therefore, the appearance inspection unit 73b can inspect the appearance of the first electrode layer 9a more accurately by inspecting the position from the back surface.
The total loading amount inspection unit 74a inspects the loading amounts of the first catalyst particles and the second catalyst particles in the electrode layers 9a and 9 b. Fig. 4 is a diagram showing a state in which the total supported amount inspection unit 74a inspects the first catalyst particles and the second catalyst particles in the electrode layers 9a and 9 b. Fig. 5 is a diagram showing the carrying distances of the first catalyst particles and the second catalyst particles in the electrode layers 9a and 9b with respect to the electrolyte membrane 92, which are calculated by the control unit 80.
As shown in fig. 1 and 4, the total loading amount inspection unit 74a according to the present embodiment includes an X-ray irradiation unit 75a and an X-ray detection unit 76 a. The X-ray radiation unit 75a is disposed on the front surface side of the electrolyte membrane 92. The X-ray detection unit 76a is disposed on the back side of the electrolyte membrane 92. However, the X-ray irradiation unit 75a may be disposed on the back side of the electrolyte membrane 92, and the X-ray detection unit 76a may be disposed on the front side of the electrolyte membrane 92. The X-rays irradiated from the X-ray irradiation unit 75a pass through the second support film 96, the second electrode layer 9b, the electrolyte membrane 92, and the first electrode layer 9a, and are emitted from the back surface side. Then, the X-ray emitted from the back surface side of the electrolyte membrane 92 is detected by the X-ray detection unit 76 a.
A part of the X-rays irradiated by the X-ray irradiation portion 75a is absorbed by the first catalyst particles in the first electrode layer 9a and the second catalyst particles in the second electrode layer 9 b. Therefore, the intensity of the X-rays detected by the X-ray detection unit 76a is lower than the intensity of the X-rays irradiated by the X-ray irradiation unit 75 a. The X-ray detector 76a inputs the intensity of the detected X-rays to the controller 80. The control unit 80 calculates the X-ray transmittance based on the difference between the intensity of the X-rays irradiated by the X-ray irradiation unit 75a and the intensity of the X-rays detected by the X-ray detection unit 76 a. Then, the control unit 80 calculates a total loading amount D0, which is a total loading amount of the first catalyst particles in the first electrode layer 9a and the second catalyst particles in the second electrode layer 9b, based on the calculated X-ray transmittance, the pre-stored data, and the computer program.
The second inspection unit 72 is disposed on the upstream side of the suction roller 10 in the conveyance direction, and inspects the first electrode layer 9a formed on the back surface of the electrolyte membrane 92. The second inspection unit 72 of the present embodiment includes a first load amount inspection unit 74 b. Fig. 6 is a diagram showing a state in which the first catalyst particles in the first electrode layer 9a are inspected by the first loading amount inspection portion 74 b. Fig. 7 is a diagram showing the amount of the first catalyst particles supported in the first electrode layer 9a calculated by the control unit 80 with respect to the transport distance of the electrolyte membrane 92.
The first loading amount inspecting unit 74b includes an X-ray irradiation unit 75b and an X-ray detection unit 76b, as in the case of the total loading amount inspecting unit 74 a. The X-ray radiation unit 75b is disposed on the front surface side of the electrolyte membrane 92. The X-ray detection unit 76b is disposed on the back side of the electrolyte membrane 92. The X-rays irradiated from the X-ray irradiation unit 75b are emitted from the back surface side through the electrolyte membrane 92, the first electrode layer 9a, and the first support film 93. Then, the X-ray emitted from the back surface side of the electrolyte membrane 92 is detected by the X-ray detection unit 76 b. The control unit 80 calculates the X-ray transmittance based on the difference between the intensity of the X-rays irradiated by the X-ray irradiation unit 75b and the intensity of the X-rays detected by the X-ray detection unit 76 b. Then, the control unit 80 calculates a first loading amount D1, which is the loading amount of the first catalyst particles in the first electrode layer 9a, based on the calculated X-ray transmittance, and the data and the computer program stored in advance.
The calculation unit 81 in the control unit 80 calculates a second loading amount, which is the loading amount of the second catalyst particles, based on the difference between the total loading amount D0 and the first loading amount D1. This makes it possible to determine whether or not the second electrode layer 9b has defects. Further, since the possibility of occurrence of defects in the second electrode layer 9b is low, if the amount of the second catalyst particles to be supported is assumed to be substantially constant, the amount of the first catalyst particles in the first electrode layer 9a separated from the adsorption roll 10 can also be calculated by subtracting the amount of the second catalyst particles assumed to be substantially constant from the total amount of support D0. In this case, the calculation unit 81 can compare the first loading amount D1 of the first catalyst particles before the electrolyte membrane 92 is adsorbed and supported by the adsorption roller 10 with the loading amount of the first catalyst particles after the electrolyte membrane 92 is separated from the adsorption roller 10. This makes it possible to determine whether or not the first electrode layer 9a has defects at a greater angle.
When the calculated second loading amount is an abnormal value such as an extreme change, the control unit 80 determines that a defect such as a fall-off may occur in the first electrode layer 9 a. In this way, the inspection unit 70 of the present embodiment can inspect the first electrode layer 9a based on whether or not the second loading amount is an abnormal value. As a result, the defects of the first electrode layer 9a can be inspected at more angles.
The marking portion 79 is a mechanism for marking the electrolyte membrane 92 or the second support film 96. The marking by the marking portion 79 is realized by, for example, ejecting ink for marking by an inkjet ejection mechanism. The marking portion 79 marks the result of the inspection performed by the inspection portion 70 on the electrolyte membrane 92 or the second support film 96 in the vicinity of the electrode layers 9a, 9b that are determined to have defects.
Then, the film-electrode layer assembly 95 manufactured by the manufacturing apparatus 1 is cut, and gas diffusion films are attached to the electrode layers 9a, 9b formed on the front and back surfaces of the electrolyte membrane 92. Here, the electrode layers 9a and 9b judged to have defects can be easily removed using the marks as marks before the step of attaching the gas diffusion film. Therefore, the film-electrode layer assembly 95 having the defective electrode layers 9a, 9b can be prevented from being used in the final product. As a result, the quality of the membrane-electrode layer assembly 95 manufactured by the manufacturing apparatus 1 can be effectively controlled.
In particular, in the manufacturing apparatus 1, after the membrane-electrode layer assembly 95 is separated from the suction roll 10, it is possible to check whether or not a defect such as damage or adhesion of foreign matter has occurred in the first electrode layer 9a formed on the electrolyte membrane 92 in advance. Therefore, the quality of the first electrode layer 9a is degraded by being attracted to the attraction roller 10 in the manufacturing apparatus 1. This enables quality control of the membrane-electrode layer assembly 95 to be effectively performed, and the defect rate of the membrane-electrode layer assembly 95 to be reduced. Further, it is possible to determine whether or not processing in the next step is necessary based on the inspection result of the inspection unit 70. Therefore, the production efficiency of the membrane-electrode layer assembly 95 can be improved.
Further, maintenance such as cleaning of the suction roller 10, the plurality of conveyance rollers, and the nozzle 41 can be performed based on the inspection result of the inspection section 70. Further, the coating ink (catalyst ink) can be replaced, and the formulation of the coating ink can be confirmed. As a result, the defect rate of the membrane-electrode layer assembly 95 can be reduced, and the yield can be improved.
In the present embodiment, of the plurality of conveying rollers, all of the plurality of joint body carrying-out rollers 64 located on the downstream side of the laminating roller 63 in the conveying direction are disposed on the front side of the electrolyte membrane 92. That is, after the inspection by the first inspection unit 71, the back surface of the electrolyte membrane 92 does not contact the joined body carry-out roller 64. Therefore, after the inspection by the first inspection unit 71, the first electrode layer 9a can be prevented from being defective due to the contact of the first electrode layer 9a with the conveying roller. Further, the joint body carry-out roller 64 located on the downstream side of the laminating roller 63 in the conveying direction is in contact with the surface of the electrolyte membrane 92 via the second support film 96. Therefore, the second electrode layer 9b can be suppressed from being defective. As a result, the reliability of the inspection by the inspection unit 70 can be improved.
3. Modification example
One embodiment of the present invention has been described above, but the present invention is not limited to the above embodiment.
In the above embodiment, the second inspection unit 72 has only the first load amount inspection unit 74 b. However, the second inspection portion 72 may also have an appearance inspection portion for inspecting the appearance of the first electrode layer 9 a. Then, the appearance of the first electrode layer 9a before the electrolyte membrane 92 is sucked and supported by the suction roller 10 can be compared with the appearance of the first electrode layer 9a after the electrolyte membrane 92 is separated from the suction roller 10. In this way, the presence or absence of a defect in the first electrode layer 9a caused by the adsorption of the electrolyte membrane 92 by the adsorption roller 10 can be determined with higher accuracy.
In the above embodiment, the first inspection portion 71 has one appearance inspection portion 73a for inspecting the first electrode layer 9a and one appearance inspection portion 73b for inspecting the second electrode layer 9 b. However, the first inspection unit 71 may have a plurality of appearance inspection units 73a and 73b, respectively. In addition, in the appearance inspection portions 73a and 73b, since the appearance of the first electrode layer 9a and the second electrode layer 9b can be inspected by either one of them, the other one can be omitted.
In the plurality of conveying rollers of the above embodiment, a part of the conveying rollers may be bonding rollers. The conveying roller can remove foreign matter adhering to the electrolyte membrane 92 while conveying the electrolyte membrane 92.
In the above embodiment, the case where the laminated base 94 composed of two layers of the electrolyte membrane 92 and the first support film 93 is supplied from the laminated base supply roller 31 as the electrolyte membrane supply roller has been described. However, the electrolyte membrane supply roller may also discharge the electrolyte membrane 92 to which the first support film 93 is not attached.
In the above embodiment, the case where the electrolyte membrane 92 to which the second support film 96 is attached is wound by the joined body collecting roll 65 is described. However, the joined body collecting roll 65 may wind up the electrolyte membrane 92 to which the second support film 96 is not attached.
Further, the detailed structure of the manufacturing apparatus 1 may be different from each drawing of the present invention. In addition, the respective elements described in the above embodiments and modifications may be appropriately combined within a range not inconsistent with each other.
Description of the reference numerals
1. 1a manufacturing apparatus
2 maintenance site
3 operator
9a first electrode layer
9b second electrode layer
10 adsorption roller
20 porous substrate conveying part
30 electrolyte membrane supply part
40 material supply part
63 laminating roller
64 delivery roll for joined body
65 conjugant recovery roller
70 inspection part
71 first inspection part
72 second inspection part
73. 73a, 73b appearance inspection part
74a total load amount inspection unit
74b first load amount inspection part
79 marking part
80 control part
91 porous substrate
92 electrolyte membrane
93 first supporting film
94 laminated base material
95 Membrane-electrode layer Assembly
96 second support film

Claims (16)

1. An apparatus for manufacturing a membrane-electrode layer assembly having a first electrode layer on a back surface of an electrolyte membrane and a second electrode layer on a front surface of the electrolyte membrane, comprising:
a plurality of conveying rollers for conveying the long strip-shaped electrolyte membrane in a conveying direction which is a longitudinal direction of the electrolyte membrane, wherein the first electrode layer formed in advance on the back surface of the electrolyte membrane in an apparatus different from the manufacturing apparatus contains first catalyst particles;
an adsorption roller that adsorbs and holds the back surface of the electrolyte membrane conveyed by the plurality of conveying rollers by a part of the outer peripheral surface of the adsorption roller, and that rotates around the axis of the adsorption roller;
a material supply unit configured to supply an electrode material containing second catalyst particles to a surface of the electrolyte membrane that moves while being held by the suction roller, thereby forming a second electrode layer; and
one or more inspection units for inspecting defects in the first electrode layer caused by the electrolyte membrane being adsorbed to the adsorption roller after the electrolyte membrane is separated from the adsorption roller,
the inspection unit includes:
a total loading amount inspection unit that inspects a loading amount of the first catalyst particles contained in the first electrode layer and a loading amount of the second catalyst particles contained in the second electrode layer after the electrolyte membrane is separated from the adsorption roller; and
a calculation unit that calculates a loading amount of the second catalyst particles by subtracting a first loading amount of the first catalyst particles contained in the first electrode layer, which is acquired in advance, from the total loading amount obtained by the total loading amount inspection unit,
the calculation unit calculates a second loading amount of the second catalyst particles based on the total loading amount and the first loading amount,
the inspection unit inspects the first electrode layer based on whether the second amount of load is an abnormal value.
2. The manufacturing apparatus according to claim 1,
the inspection unit has an appearance inspection unit for inspecting the appearance of the first electrode layer.
3. The manufacturing apparatus according to claim 1,
the inspection unit further includes a first loading amount inspection unit that inspects the first loading amount of the first catalyst particles contained in the first electrode layer on the back surface of the electrolyte membrane before the electrolyte membrane reaches the adsorption roller.
4. The manufacturing apparatus according to claim 1,
the manufacturing apparatus further includes a porous base material conveying unit that conveys the long strip-shaped porous base material while interposing the porous base material between the adsorption roller and the electrolyte membrane.
5. The manufacturing apparatus according to claim 1,
among the plurality of conveying rollers, a conveying roller on the downstream side in the conveying direction from the inspection unit is disposed on the surface side of the electrolyte membrane.
6. The manufacturing apparatus according to claim 1,
the manufacturing apparatus further includes a marking unit that marks the vicinity of the first electrode layer determined to have a defect based on an inspection result of the inspection unit.
7. The manufacturing apparatus according to claim 1,
the back surface of the electrolyte membrane and the first electrode layer are held by the suction roller in an exposed state.
8. An apparatus for manufacturing a membrane-electrode layer assembly having a first electrode layer on a back surface of an electrolyte membrane and a second electrode layer on a front surface of the electrolyte membrane, comprising:
a plurality of conveying rollers for conveying the long strip-shaped electrolyte membrane in a conveying direction which is a longitudinal direction of the electrolyte membrane, wherein the first electrode layer formed in advance on the back surface of the electrolyte membrane in an apparatus different from the manufacturing apparatus contains first catalyst particles;
an adsorption roller that adsorbs and holds the back surface of the electrolyte membrane conveyed by the plurality of conveying rollers by a part of the outer peripheral surface of the adsorption roller, and that rotates around the axis of the adsorption roller;
a material supply unit configured to supply an electrode material containing second catalyst particles to a surface of the electrolyte membrane that moves while being held by the suction roller, thereby forming a second electrode layer; and
one or more inspection units that inspect for defects in the first electrode layer caused by the electrolyte membrane being adsorbed to the adsorption roller after the electrolyte membrane has been separated from the adsorption roller,
the inspection unit includes:
a total loading amount inspection unit that inspects a loading amount of the first catalyst particles contained in the first electrode layer and a loading amount of the second catalyst particles contained in the second electrode layer after the electrolyte membrane is separated from the adsorption roller; and
a calculation unit for obtaining the amount of the first catalyst particles by subtracting the amount of the second catalyst particles assumed to be constant from the total amount of the second catalyst particles obtained by the total amount of the first catalyst particles,
the inspection unit inspects the first electrode layer by comparing the amount of the first catalyst particles obtained in advance with the amount of the first catalyst particles calculated by the calculation unit.
9. A method for producing a membrane-electrode layer assembly produced by a production apparatus, the membrane-electrode layer assembly having an electrolyte membrane with a first electrode layer on a back surface thereof and a second electrode layer on a surface thereof, the production method comprising:
a conveying step a) of conveying the electrolyte membrane while holding the back surface of the long strip-shaped electrolyte membrane by suction with a part of the outer peripheral surface of a suction roller and rotating the suction roller around the axis of the suction roller, wherein the first electrode layer formed on the back surface of the electrolyte membrane in advance contains first catalyst particles in an apparatus different from the manufacturing apparatus;
a step b) of forming the second electrode layer by supplying an electrode material containing second catalyst particles to the surface of the electrolyte membrane that moves while being held by the suction roll; and
a step c) of inspecting a defect of the first electrode layer due to the adsorption roller after the electrolyte membrane is separated from the adsorption roller,
the step c) includes:
a step e) of checking a loading amount of the first catalyst particles contained in the first electrode layer and a loading amount of the second catalyst particles contained in the second electrode layer; and
a step f) of obtaining a second loading amount of the second catalyst particles by subtracting a loading amount of the first catalyst particles contained in the first electrode layer obtained in advance from the total loading amount obtained in the step e),
in the step c), the first electrode layer is inspected based on whether or not the second supporting amount is an abnormal value.
10. The manufacturing method according to claim 9,
the step c) includes a step d) of inspecting an appearance of the first electrode layer.
11. The manufacturing method according to claim 9,
the manufacturing method further includes: a step of inspecting a first supporting amount of the first catalyst particles contained in the first electrode layer on the back surface of the electrolyte membrane before the electrolyte membrane reaches the adsorption roll,
in the step f), the second loading amount of the second catalyst particles is determined by subtracting the first loading amount from the total loading amount.
12. The manufacturing method according to claim 9,
in the step a), the porous substrate is conveyed while interposing the long strip-shaped porous substrate between the adsorption roll and the electrolyte membrane.
13. The manufacturing method according to claim 9,
after the step c), the electrolyte membrane is conveyed by a plurality of conveying rollers disposed on the front surface side of the electrolyte membrane.
14. The manufacturing method according to claim 9,
the manufacturing method further includes a step g) of marking a vicinity of the first electrode layer determined to have a defect based on the inspection result of the step c).
15. The manufacturing method according to claim 9,
in the step a), the back surface of the electrolyte membrane and the first electrode layer are sucked and held by the suction roller in an exposed state.
16. A method for producing a membrane-electrode layer assembly produced by a production apparatus, the membrane-electrode layer assembly having an electrolyte membrane with a first electrode layer on a back surface thereof and a second electrode layer on a surface thereof, the production method comprising:
a conveying step a) of conveying the electrolyte membrane while holding the back surface of the long strip-shaped electrolyte membrane by suction with a part of the outer peripheral surface of a suction roller and rotating the suction roller around the axis of the suction roller, wherein the first electrode layer formed on the back surface of the electrolyte membrane in advance contains first catalyst particles in an apparatus different from the manufacturing apparatus;
a step b) of forming the second electrode layer by supplying an electrode material containing second catalyst particles to the surface of the electrolyte membrane that moves while being held by the suction roll; and
a step c) of inspecting a defect of the first electrode layer due to the adsorption roller after the electrolyte membrane is separated from the adsorption roller,
the step c) includes:
a step e) of checking the amount of the first catalyst particles contained in the first electrode layer and the amount of the second catalyst particles contained in the second electrode layer; and
a step f) of obtaining a loading amount of the first catalyst particles by subtracting a loading amount of the second catalyst particles assumed to be constant from the total loading amount obtained in the step e),
in the step c), the first electrode layer is inspected by comparing the amount of the first catalyst particles obtained in advance with the amount of the first catalyst particles calculated in the step f).
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