Abstract:
A first separator to which a resin film is joined beforehand is set in a cavity formed between a lower die and an upper die of an injection molding machine. At the time of die locking by moving the upper die toward the lower die, in the case where the total thickness of the resin film and the first separator is larger than a predetermined dimension, the resin film is pressed by the lower die or the upper die, and thus, the resin film is deformed by compression within its elastic deformation range.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application is based upon and claims the benefit of priority from Patent Application No. 2009-026745 filed on Feb. 6, 2009, in the Japan Patent Office, of which the contents are incorporated herein by reference. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a fuel cell formed by sandwiching a membrane electrode assembly between a pair of separators. The membrane electrode assembly includes an anode, a cathode, and an electrolyte membrane interposed between the anode and the cathode. Further, the present invention relates to a method of producing the fuel cell. 
     2. Description of the Related Art 
     A solid polymer electrolyte fuel cell as one type of fuel cell employs a solid polymer electrolyte membrane. The solid polymer electrolyte membrane is a polymer ion exchange membrane. In the solid polymer electrolyte fuel cell of this type, an anode and a cathode each having an electrolyte catalyst layer and a gas diffusion layer are formed on surfaces of the solid polymer electrolyte membrane to form a membrane electrode assembly. The membrane electrode assembly is sandwiched between a pair of separators (bipolar plates) to form a unit cell for generating electricity. In use, typically, a predetermined number of unit cells are stacked together to form a fuel cell stack. 
     In the fuel cell, a fuel gas flow field for supplying a fuel gas (e.g., hydrogen) is formed on a separator surface facing the anode, and an oxygen-containing gas flow field for supplying an oxygen-containing gas (e.g., air) is formed on a separator surface facing the cathode. Hereinafter, the fuel gas and the oxygen-containing gas may be referred to as a reactant gas. Further, a coolant flow field is formed between the separators for supplying a coolant along the surfaces of the separators for each unit cell, or for every predetermined number of unit cells. 
     As is known in the art, in operating the fuel cell, the reactant gases and the coolant flow into the flow fields of the fuel cell stack. For this purpose, seals are formed at the edges of both surfaces the separator and near the flow fields of the separator. The seals prevent leakage of the reactant gases and the coolant to the outside of the fuel cell stack. 
     Additionally, the seals function as insulating coating for preventing corrosion of the separator. That is, the seal is made of insulating material. 
     As the material for the seal, silicone rubber is used widely. The seal of the silicone rubber of this type may be provided by forming a seal member beforehand, and then, attaching the seal member to the separator. Preferably, as disclosed in Japanese Laid-Open Patent Publication No. 11-309746, the seal is formed by injection molding. In this manner, seals can be provided accurately at predetermined positions of the separator. Stated otherwise, the seals can be positioned with a high degree of accuracy advantageously. 
     At the time of carrying out the injection molding, as shown in  FIG. 8 , firstly, a separator  1  is provided at a predetermined position of one molding die  2 . In this state, the remaining molding die  3  moves closer to the molding die  2 , and thus, so called die locking is carried out. As a result, a cavity  4  is formed. Then, a rubber  5  having fluidity (e.g., melted or liquid substance) is supplied into the cavity  4 . When the rubber  5  is hardened, seals are formed on both surfaces at the edges of the separator  1 . 
     In this case, when the separator  1  is thick due to dimensional variation, since the separator  1  blocks the molding die  3 , die locking may not be carried out sufficiently. Under the circumstances, as shown in  FIG. 8 , a very small gap  6  is formed between the molding dies  2 ,  3 . In this state, when the rubber  5  is supplied into the cavity  4 , the rubber  5  is filled in the gap  6 . The rubber  5  hardened in the gap  6  forms so called burrs  7 . When die opening is carried out, the remaining burrs  7  are present in the molding die  2  or the molding die  3 . As can be seen from the above, in the case of forming the rubber seals by injection molding, the molding dies  2 ,  3  may be tainted by the remaining burrs  7  disadvantageously. For this reason, operation of the injection molding machine needs to be stopped each time the stains in the die due to the burrs  7  are removed. Accordingly, the production efficiency is lowered disadvantageously. 
     In the example shown in  FIG. 8 , the total amount of the rubber corresponding to the volume of the cavity  4  is supplied by one time injection to form the seals on both surfaces of the separator  1 . In this case, the separator  1  may be deformed by the pressure of the rubber having fluidity. In this regard, in another known method, after a seal is formed on one surface of the separator  1  by injection molding, a seal is formed on the other surface of the separator  1  by the second injection molding. However, in this method, though it is possible to suppress deformation of the separator  1 , since injection molding needs to be carried out twice, the production efficiency is lowered disadvantageously. 
     Additionally, the rubber such as a silicone rubber used for the seal is expensive. Therefore, it is desirable to reduce the amount of the rubber used for the seal as much as possible. 
     SUMMARY OF THE INVENTION 
     A general object of the present invention is to provide a fuel cell that can be produced efficiently. 
     A main object of the present invention is to provide a method of producing a fuel cell which makes it possible to form a rubber seal easily. 
     According to an aspect of the present invention, a fuel cell formed by sandwiching a membrane electrode assembly between a pair of separators is provided. The membrane electrode assembly includes an anode, a cathode, and an electrolyte membrane interposed between the anode and the cathode. 
     Each of the separators includes a metal plate having a flow field for supplying a gas to the anode or the cathode. 
     A resin film that is deformable elastically and functions as a seal is provided on one surface of the metal plate, and a rubber seal is provided on the other surface of the metal plate. 
     The “rubber” of the rubber seal means material having good insulating characteristics and elasticity required as the seal. 
     Conventionally, rubber seals are formed on both surfaces of the metal plate to form the separator. In this regard, according to the careful study of the inventors of the present application, sealing is achieved by providing a rubber seal on one surface of the separator, and providing a resin film on the other surface of the separator. That is, in the present invention, the rubber seal is formed only on one surface of the metal plate. In this manner, the amount of rubber required for the rubber seal is reduced, and the separator can be produced at low cost. 
     Further, the resin film can be joined to the metal plate simply by heat welding or using adhesive. Therefore, the separator can be fabricated easily. 
     According to another aspect of the present invention, a method of producing a fuel cell formed by sandwiching a membrane electrode assembly between a pair of separators is provided. The membrane electrode assembly includes an anode, a cathode, and an electrolyte membrane interposed between the anode and the cathode. 
     Each of the separators includes a metal plate having a flow field for supplying a gas to the anode or the cathode. The method includes the steps of providing a resin film that is deformable elastically on one surface of the metal plate, and inserting the metal plate having the resin film provided on the one surface into a molding die to provide a rubber seal on the other surface of the metal plate by injection molding. 
     In the case of the conventional technique of forming rubber seals on both surfaces of the metal plate by injection molding, a rubber seal is formed on each surface. In the technique, as described above, injection molding needs to be carried out twice in order to suppress deformation of the separator. In contrast, according to the present invention, the rubber seal can be formed only by one time injection molding. Therefore, the time required for fabricating the separator is reduced significantly. Thus, improvement in the efficiency of producing the separator, and thus, the fuel cell is achieved. 
     That is, in the present invention, a resin film is provided on one surface of the metal plate. Therefore, the amount of rubber required for the rubber seal is reduced, and cost reduction is achieved. Further, injection molding for forming the rubber seal needs to be carried out only once without causing deformation of the metal plate (separator). For this reason, it is possible to produce the separator, and thus, the fuel cell efficiently. 
     Preferably, at the time of the injection molding, the resin film is pressed by the molding die after die locking. 
     For example, in the case where the total thickness of the resin film and the separator is larger than a design value due to dimensional variation, die locking generates a reaction force against the molding die, since the resin film is pressed by the molding die. By the reaction force, die locking is sufficiently carried out between the resin film and the molding die or between the resin film and the separator. 
     Thus, no gap is formed between the molding dies. Therefore, at the time of injection molding for forming the rubber seal, the rubber is not filled in the gap, and no burrs are produced. 
     As described above, at the time of injection molding for forming the rubber seal, the resin film is pressed by the molding die after die locking, and die locking is sufficiently carried out between the resin film and the molding die or between the resin film and the metal plate, and thus, no burrs are produced. Therefore, no remaining burrs are present in the molding die, and it is not necessary to stop operation of the injection molding machine for removal of burrs. Accordingly, further improvement in the efficiency of producing the fuel cell is achieved. 
     The above and other objects, features and advantages of the present invention will become more apparent from the following description when taken in conjunction with the accompanying drawings in which preferred embodiments of the present invention are shown by way of illustrative example. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an exploded perspective view showing a unit cell of a fuel cell according to an embodiment of the present invention; 
         FIG. 2  is a front view showing a first separator of the unit cell; 
         FIG. 3  is a cross sectional view taken along a line in  FIG. 1 ; 
         FIG. 4  is a cross sectional view taken along a line IV-IV in  FIG. 1 ; 
         FIG. 5  is a cross sectional view taken along a line V-V in  FIG. 1 ; 
         FIG. 6  is a longitudinal sectional view showing main components of an injection molding machine, for illustrating an example of a process of producing the first separator shown in  FIG. 2 ; 
         FIG. 7  is a longitudinal sectional view showing main components of an injection molding machine, for illustrating another example of the process of producing the first separator; and 
         FIG. 8  is a longitudinal cross sectional view showing main components of an injection molding machine for producing a conventional separator. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Hereinafter, a fuel cell and a method of producing the fuel cell according to preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. 
       FIG. 1  is an exploded perspective view showing a unit cell  12  of a fuel cell  10  according to an embodiment of the present invention. The fuel cell  10  is formed by stacking a plurality of the unit cells  12  in a direction indicated by an arrow A. Each of the unit cells  12  is formed by sandwiching a membrane electrode assembly (electrolyte electrode assembly)  14  between a first separator  16  and a second separator  18 . 
     The membrane electrode assembly  14  includes a cathode  22 , an anode  24 , and a solid polymer electrolyte membrane (electrolyte)  20  interposed between the cathode  22  and the anode  24 . The solid polymer electrolyte membrane  20  is formed by impregnating a thin membrane of perfluorosulfonic acid with water, for example. 
     Each of the cathode  22  and the anode  24  has a gas diffusion layer (not shown) such as a carbon paper, and an electrode catalyst layer (not shown) of platinum alloy supported on porous carbon particles. The carbon particles are deposited uniformly on the surface of the gas diffusion layer. Since the cathode  22  and the anode  24  have structure known in the art, such structure of the cathode  22  and the anode  24  is not shown in the drawings, and detailed descriptions thereof are omitted. It should be noted that the surface area of the anode  24  is smaller than the surface area of the cathode  22  and the surface area of the solid polymer electrolyte membrane  20 . 
     At one end of the first separator  16  and the second separator  18  in the direction indicated by the arrow B, an oxygen-containing gas supply passage  26   a  for supplying an oxygen-containing gas, a coolant supply passage  28   a  for supplying a coolant, and a fuel gas discharge passage  30   b  for discharging a fuel gas are arranged in a vertical direction indicated by an arrow C. The oxygen-containing gas supply passage  26   a , the coolant supply passage  28   a , and the fuel gas discharge passage  30   b  extend through the first separator  16  and the second separator  18  in the stacking direction indicated by the arrow A. 
     At the other end of the first separator  16  and the second separator  18  in the direction indicated by the arrow B, a fuel gas supply passage  30   a  for supplying the fuel gas, a coolant discharge passage  28   b  for discharging the coolant, and an oxygen-containing gas discharge passage  26   b  for discharging the oxygen-containing gas are arranged in the direction indicated by the arrow C. The fuel gas supply passage  30   a , the coolant discharge passage  28   b , and the oxygen-containing gas discharge passage  26   b  extend through the first separator  16  and the second separator  18  in the direction indicated by the arrow A. 
     As shown in  FIG. 2 , an oxygen-containing gas flow field  32  is formed on a surface  16   a  of the first separator  16  facing the membrane electrode assembly  14 . The oxygen-containing gas flow field  32  is formed in a straight pattern in the direction indicated by the arrow B, by providing ridges  32   a  and grooves  32   b  extending in the direction indicated by the arrow B. The ridges  32   a  protrude from the surface  16   a . The ridges  32   a  and the grooves  32   b  are formed alternately in the direction indicated by the arrow C. Bosses  32   c  are formed at both ends of the oxygen-containing gas flow field  32 . 
     As shown in  FIG. 1 , a fuel gas flow field  34  is formed on a surface  18   a  of the second separator  18  facing the membrane electrode assembly  14 . The fuel gas flow field  34  is formed in a straight pattern in the direction indicated by the arrow B, by providing ridges  34   a  and grooves  34   b  extending in the direction indicated by the arrow B. The ridges  34   a  protrude from the surface  18   a . The ridges  34   a  and the grooves  32   b  are formed alternately in the direction indicated by the arrow C. Bosses  34   c  are formed at both ends of the fuel gas flow field  34 . 
     A coolant flow field  36  is formed between a surface  16   b  of the first separator  16  and a surface  18   b  of the second separator  18 , i.e., on the back surfaces of the corrugated surfaces of the oxygen-containing gas flow field  32  and the fuel gas flow field  34 . 
     As shown in  FIGS. 2 and 3 , the first separator  16  includes a metal plate  38  formed to have a predetermined shape. A resin film  40  covering the end of the metal plate  38  is provided on one surface (surface  16   a  side) of the metal plate  38 , and a rubber seal  42  is provided on the other surface (surface  16   b  side) of the metal plate  38 . 
     The resin film  40  is made of soft material having sufficient elasticity, and preferably, has good heat resistance, acid resistance, and steam resistance. As preferable examples of such resin, fluorine resin such as polytetrafluoroethylene (PTFE), engineering plastic such as polyamide (PA), polycarbonate (PC), polyethylene terephthalate (PET), polybutylene terephthalate (PBT), or super engineering plastic such as polyamide-imide (PAI), polyphenylene sulfide (PPS), polyether-imide (PEI), polyethylene naphthalate (PEN), polyetheretherketone (PEEK), or liquid crystal polymer (LCP) may be used. In some cases, general-purpose plastic such as polyethylene (PE) and polypropylene (PP) may be used. 
     The resin film  40  is joined to one surface  16   a  of the metal plate  38  (e.g., by heat welding). Thus, the resin film  40  is formed integrally with the metal plate  38 . The resin film  40  is made of soft material having sufficient elasticity. 
     For example, the rubber seal  42  is made of silicone rubber. Other rubbers such as ethylene propylene rubber (EPDM), natural rubber (NBR), fluoro rubber, fluorosilicone rubber, butyl rubber, styrene rubber, chloroprene rubber or acrylic rubber may be used. 
     As shown in  FIG. 2 , the resin film  40  is provided on the surface  16   a  of the first separator  16  around the oxygen-containing gas flow field  32 . An inlet channel  44   a  and an outlet channel  44   b  pass through the resin film  40 , and extend toward the oxygen-containing gas supply passage  26   a  and the oxygen-containing gas discharge passage  26   b , respectively. 
     As shown in  FIG. 1 , the rubber seal  42  includes a ridge seal  46  formed around the oxygen-containing gas supply passage  26   a , the oxygen-containing gas discharge passage  26   b , the fuel gas supply passage  30   a , and the fuel gas discharge passage  30   b , while allowing the coolant supply passage  28   a  and the coolant discharge passage  28   b  to be connected to the coolant flow field  36 . 
     In the first separator  16 , the oxygen-containing gas supply passage  26   a , the coolant supply passage  28   a , the fuel gas discharge passage  30   b , the fuel gas supply passage  30   a , the coolant discharge passage  28   b , and the oxygen-containing gas discharge passage  26   b  extend through the metal plate  38 , the resin film  40 , and the rubber seal  42 . In this respect, the second separator  18  as described later has the same structure. 
     The second separator  18  has a metal plate  48  formed to have a predetermined shape. A resin film  50  is formed on one surface  18   b  of the metal plate  48 . A rubber seal  52  is formed on the other surface  18   a  of the metal plate  48  (see  FIGS. 1 and 3 ). The resin film  50  and the resin film  40  have the same structure, and the rubber seal  52  and the rubber seal  42  have the same structure. 
     As shown in  FIG. 1 , the rubber seal  52  includes a first ridge seal  54   a  formed around the fuel gas flow field  34  for allowing the fuel gas flow field  34  to be connected to the fuel gas supply passage  30   a  and the fuel gas discharge passage  30   b , and a second ridge seal  54   b  formed around the oxygen-containing gas supply passage  26   a , the oxygen-containing gas discharge passage  26   b , the coolant supply passage  28   a , and the coolant discharge passage  28   b  for preventing leakage. 
     An inlet channel  56   a  is formed between the fuel gas supply passage  30   a  and the fuel gas flow field  34 , and an outlet channel  56   b  is formed between the fuel gas discharge passage  30   b  and the fuel gas flow field  34 . 
     A method of producing the fuel cell  10  having the above structure will be described below. 
       FIG. 6  is a longitudinal sectional view showing main components of an injection molding machine  70 . The injection molding machine  70  includes a lower die  72  and an upper die  74 . A cavity  76  is formed between the lower die  72  and the upper die  74 . 
     The lower die  72  and the upper die  74  have a gate (not shown) for filling a start material (e.g., melted substance or liquid substance)  78  to be formed into the rubber seal  42 , the gate communicating with the cavity  76 . It is a matter of course that a runner (not shown) is provided near the gate for injecting the start material  78 . 
     In the injection molding machine  70  having the above structure, firstly, the metal plate  38  and the resin film  40  are set in the cavity  76 . The resin film  40  is joined to one surface  16   a  of the metal plate  38  beforehand, e.g., by heat welding. The end of the resin film  40  extends from the cavity  76  toward the outer side of the lower die  72  and the upper die  74  such that the upper die  74  is received by the end of the resin film  40 . 
     Then, die locking is carried out as shown in  FIG. 6 . At the time of die locking, if the metal plate  38  and the resin film  40  become thick due to dimensional variation, the end of the flexible resin film  40  is pressed from the upper die  74 , and a reaction force to the upper die  74  is generated. Therefore, die locking is effected between the upper die  74  and the end of the resin film  40 , and no gap is formed between the upper die  74  and the end of the resin film  40 . 
     That is, in this case, since die locking is carried out by pressing the resin film  40  from the upper die  74 , no gap is formed between the lower die  72  and the upper die  74 . Therefore, it is possible to carry out die locking sufficiently. In the case where the resin film  40  is pressed by the upper die  74 , plastic deformation may occur when deformation is beyond the elastic deformation range of resin. Even in this case, die locking is carried out sufficiently. 
     Then, the start material  78  to be formed into the rubber seal  52  is supplied. The start material  78  is injected into the cavity  76  through the runner and the gate. Preferably, the injection molding should be performed at the injection molding die temperature of 373 to 473 K (100 to 200° C.) and the start material  78  should be injected at the injection pressure of 15 to 100 MPa (150 to 1000 kg/cm 2 ). 
     After the start material  78  is solidified (hardened), the lower die  72  is moved away from the upper die  74 . That is, die opening is carried out. In this manner, the resin film  40  is formed on one surface of the metal plate  38 , the rubber seal  42  is formed on the other surface of the metal plate  38 , and the first separator  16  is exposed. Thereafter, ends of the resin film  40  exposed from the rubber seal  42  are cut away to form a predetermined shape corresponding to the first separator  16 . 
       FIG. 7  shows pressing in another embodiment. Specifically, in the embodiment shown in  FIG. 6 , the end of the resin film  40  extends outwardly to receive the upper die  74 . However, in the embodiment shown in  FIG. 7 , the resin film  40  extends from the cavity  76  toward the inner side of the lower die  72  and the upper die  74 . In this case, when the metal plate  38  and the resin film  40  become thick due to dimensional variation, the inner end of the upper die  74  presses the extended portion of the resin film  40  through the metal plate  38 . That is, the extended portion of the resin film  40  is compressed to become thin, and die locking is carried out. Therefore, also in this case, die locking is performed without any gap between the lower die  72  and the upper die  74 . 
     As described above, in the embodiments of the present invention, the gap is not formed between the lower die  72  and the upper die  74  easily. Therefore, the start material  78  is not filled in the clearance, and for this reason, no remaining burrs are present. Thus, it is not necessary to stop operation of the injection molding machine  70  for deburring. Accordingly, improvement in the efficiency of operating the injection molding machine  70  is achieved, and improvement in the efficiency of producing the first separator  16 , and the fuel cell  10  is achieved. 
     Further, in the case where rubber seals are provided on both surfaces of the metal plate by injection molding, in order to suppress deformation of the metal plate, it is necessary to carry out the first injection molding for providing a rubber seal on one surface of the metal plate, and then carry out the second injection molding for providing a rubber seal on the remaining other surface of the metal plate. However, in the embodiments of the present invention, at the time of producing the first separator  16 , the rubber seal  42  is formed only on one surface of the metal plate  38 . Therefore, for this reason, it is sufficient to carry out injection molding only once. 
     Further, in the embodiments of the present invention, the amount of rubber seal is reduced. For this reason, the fuel cell can be produced at low cost. 
     As described above, since no remaining burrs are present, improvement in the efficiency of operating the injection molding machine  70  is achieved, and the number of times of injection molding is reduced. Therefore, it becomes possible to produce the first separator  16 , and the fuel cell  10  efficiently. Further, since the amount of the rubber seal is reduced, the fuel cell can be produced at low cost. 
     It is a matter of course that the second separator  18  can be obtained in the same manner. 
     The fuel cell  10  obtained as described above can be operated in the following manner. 
     As shown in  FIG. 1 , an oxygen-containing gas such as the air is supplied into the oxygen-containing gas supply passage  26   a , and a fuel gas such as hydrogen is supplied into the fuel gas supply passage  30   a . Further, a coolant such as pure water or ethylene glycol is supplied to the coolant supply passage  28   a.    
     As shown in  FIG. 3 , the oxygen-containing gas supplied to the oxygen-containing gas supply passage  26   a  flows through the inlet channel  44   a  provided in the first separator  16 , and then, the oxygen-containing gas is supplied to the oxygen-containing gas flow field  32 . After the oxygen-containing gas flows along the oxygen-containing gas flow field  32  in the direction indicated by the arrow B, the oxygen-containing gas is discharged from the outlet channel  44   b  to the oxygen-containing gas discharge passage  26   b  (see  FIG. 1 ). 
     As shown in  FIG. 4 , the fuel gas supplied to the fuel gas supply passage  30   a  flows through the inlet channel  56   a  provided in the second separator  18 , and the fuel gas is supplied to the fuel gas flow field  34 . The fuel gas flows along the fuel gas flow field  34  in the direction indicated by the arrow B, and then, the fuel gas is discharged from the outlet channel  56   b  to the fuel gas discharge passage  30   b  (see  FIG. 1 ). 
     Thus, in the membrane electrode assembly  14 , the oxygen-containing gas supplied to the cathode  22  and the fuel gas supplied to the anode  24  are consumed in the electrochemical reactions at the catalyst layers of the cathode  22  and the anode  24  for generating electricity. 
     Further, the coolant supplied to the coolant supply passage  28   a  flows into the coolant flow field  36  between the first separator  16  and the second separator  18  (see  FIG. 5 ). In the structure, the coolant moves in the direction indicated by the arrow B to cool the membrane electrode assembly  14 , and then, the coolant is discharged into the coolant discharge passage  28   b  (see  FIG. 1 ). 
     In the embodiments described above, the resin film  40  is formed on the surface  16   a  of the first separator  16 , and the resin film  50  is formed on the surface  18   b  of the second separator  18 . Alternatively, the resin film  40  may be formed on the surface  16   b  of the first separator  16 , and the resin film  50  may be formed on the surface  18   a  of the second separator  18 . Further, the resin films  40 ,  50  may be formed on the surfaces  16   a ,  18   a  of the first separator  16  and the second separator  18 , respectively, and the resin films  40 ,  50  may be formed on the surfaces  16   b ,  18   b  of the first separator  16  and the second separator  18 , respectively. 
     While the invention has been particularly shown and described with reference to the preferred embodiments, it will be understood that variations and modifications can be effected thereto by those skilled in the art without departing from the spirit of the invention as defined by the appended claims.