Patent Description:
Fuel cells have attracted attention as driving power sources for automobiles, mobiles phones, etc. Fuel cells are power generation systems of generating power using electrochemical reaction between hydrogen (H<NUM>) contained in fuel and oxygen (O<NUM>) in the air. Fuel cells have an advantage of achieving higher power generation efficiency and placing lower load on environment than other types of batteries.

There are some types of fuel cells responsive to electrolytes to be used. One of such fuel cells is a polymer electrolyte fuel cell (PEFC) using an ion-exchange membrane as an electrolyte (electrolyte membrane). The polymer electrolyte fuel cell achieves operation at ordinary temperatures and reduction in size and weight, so that it is expected to be applied to automobiles or portable devices.

The polymer electrolyte fuel cell generally has a configuration with a stack of a plurality of cells. One of the cells is formed by holding a membrane electrode assembly (MEA) between separators in a pair from opposite sides. The membrane electrode assembly includes an electrolyte membrane and electrode layers in a pair formed on opposite surfaces of the electrolyte membrane. One of the electrode layers in a pair is an anode electrode, and the other is a cathode electrode. As fuel gas containing hydrogen contacts the anode electrode and air contacts the cathode electrode, electrochemical reaction is caused to generate power.

For manufacture of such a membrane electrode assembly, Patent Literature <NUM> discloses an electrode manufacturing device including a rotary die cutter that includes a die roll with a blade, and an anvil roll. According to the disclosure of this electrode manufacturing device, an electrode material is caught between the die roll and the anvil roll and the die roll with the blade is rotated, thereby providing cut-out portions continuously in the electrode material.

According to the conventional technique, however, the position of the die roll with the blade is fixed relative to the electrode material. This makes it hard to adjust the position of the blade relative to the electrode material. Hence, the occurrence of positional deviation of the blade causes a risk that a cut-out portion will be formed at an inappropriate position.

It is an object of the present invention to provide a technique of providing a cut-out portion at an appropriate position of an electrode layer base material.

To solve the above-described problem, a first aspect is intended for a manufacturing device for a membrane electrode assembly comprising: a suction stage that sucks an electrode layer base material from an elongated strip-shaped first backsheet, the electrode layer base material including the first backsheet, an electrolyte membrane, and a first catalyst layer provided on a part of a surface of the electrolyte membrane arranged in the order named; a cylindrical rotary die cutter with a blade used for forming a cut-out portion in the electrode layer base material along a cutting target line around the first catalyst layer; a rotary drive part that rotates the rotary die cutter about a rotary shaft; and a movement drive part that moves the rotary die cutter relative to the suction stage to a half-cut position where the blade reaches an intermediate portion of the first backsheet in a thickness direction at the electrode layer base material sucked by the suction stage when the rotary die cutter rotates.

According to a second aspect, in the manufacturing device for the membrane electrode assembly according to the first aspect, the electrode layer base material further includes a second catalyst layer provided on a part of a surface of the electrolyte membrane adjacent to the first backsheet and overlapping the first catalyst layer in a thickness direction.

According to a third aspect, in the manufacturing device for the membrane electrode assembly according to the first or second aspect, the rotary shaft is arranged in a width direction orthogonal to a longitudinal direction of the electrode layer base material sucked by the suction stage.

According to a fourth aspect, the manufacturing device for the membrane electrode assembly according to any one of the first to third aspects further comprises a position determination part that determines the position of the first catalyst layer, wherein the movement drive part moves the rotary die cutter to the half-cut position responsive to the position of the first catalyst layer determined by the position determination part.

According to a fifth aspect, the manufacturing device for the membrane electrode assembly according to the fourth aspect further comprises an imaging part that captures an image of the first catalyst layer of the electrode layer base material, wherein the position determination part determines the position of the first catalyst layer on the basis of an image acquired by the imaging part.

According to a sixth aspect, in the manufacturing device for the membrane electrode assembly according to any one of the first to fifth aspects, the suction stage includes: a suction groove provided at a surface of the suction stage for suction of the electrode layer base material; and a suction hole provided inside the suction groove and used for suction of atmosphere.

According to a seventh aspect, in the manufacturing device for the membrane electrode assembly according to the sixth aspect, the suction groove includes a recess extending in a direction intersecting the cutting target line.

According to an eighth aspect, the manufacturing device for the membrane electrode assembly according to the seventh aspect further comprises a transport mechanism that transports the electrode layer base material while moving and stopping the electrode layer base material alternately on the suction stage, wherein while the transport mechanism stops the electrode layer base material, the movement drive part moves the rotary die cutter to the half-cut position.

A ninth aspect is intended for a manufacturing method for a membrane electrode assembly comprising: (a) a step of preparing an electrode layer base material including an elongated strip-shaped first backsheet, an elongated strip-shaped electrolyte membrane provided on one side of the first backsheet, and a first catalyst layer provided on a part of a surface of the electrolyte membrane on one side; (b) a step of sucking the electrode layer base material from a side with the first backsheet to a suction stage; (c) a step of moving a cylindrical rotary die cutter with a blade relative to the suction stage to a half-cut position, the blade having a shape responsive to a cutting target line defined around the first catalyst layer; and (d) a step of forming a cut-out portion in the electrode layer base material along the cutting target line by rotating the rotary die cutter at the half-cut position about a rotary shaft to cause the blade to reach an intermediate portion of the first backsheet in a thickness direction from one side of the first catalyst layer.

The manufacturing device for the membrane electrode assembly according to the first aspect allows movement of the rotary die cutter relative to the suction stage. This allows movement of the blade of the rotary die cutter relative to the electrode layer base material. Thus, it becomes possible to form the cut-out portion at an appropriate position of the electrode layer base material.

The manufacturing device for the membrane electrode assembly according to the second aspect allows formation of the cut-out portion at an appropriate position of the electrode layer base material with the second catalyst layer.

The manufacturing device for the membrane electrode assembly according to the third aspect makes it possible to form the cut-out portion in the electrode layer base material efficiently by moving the rotary die cutter in the longitudinal direction relative to the suction stage using the movement drive part, while rotating the rotary die cutter using the rotary drive part.

In the manufacturing device for the membrane electrode assembly according to the fourth aspect, as the position of the first catalyst layer is determined, it becomes possible to improve the accuracy of a position where the cut-out portion is to be formed.

The manufacturing device for the membrane electrode assembly according to the fifth aspect allows the position of the first catalyst layer to be determined on the basis of an image acquired by the imaging part.

In the manufacturing device for the membrane electrode assembly according to the sixth aspect, as the electrode layer base material is sucked along the suction groove, it becomes possible to alleviate deviation of the position of the electrode layer base material during formation of the cut-out portion.

In the manufacturing device for the membrane electrode assembly according to the seventh aspect, as the suction groove extends in a direction intersecting the cutting target line in the electrode layer base material, it becomes possible to suck opposite portions of the electrode layer base material across the cutting target line into the suction groove. Thus, a portion of the electrode layer base material in abutting contact with the blade is held fixedly to allow the cut-out portion to be formed accurately in the electrode layer base material.

In the manufacturing device for the membrane electrode assembly according to the eighth aspect, the rotary die cutter is moved to the half-cut position while transport of the electrode layer base material is stopped. This makes it possible to improve the accuracy of a position where the cut-out portion is to be formed.

The manufacturing method for the membrane electrode assembly according to the ninth aspect allows movement of the rotary die cutter relative to the suction stage. This allows movement of the blade of the rotary die cutter relative to the electrode layer base material. Thus, it becomes possible to form the cut-out portion at an appropriate position of the electrode layer base material.

An embodiment of the present invention will be described below by referring to the drawings. Constituting elements in the embodiment are described merely as examples, and the scope of the present invention is not to be limited only to these elements. To facilitate understanding, the size of each part or the number of such parts in the drawings may be illustrated in an exaggerated or simplified manner, if appropriate.

<FIG> shows the configuration of a gasket applicator <NUM> according to the embodiment. The gasket applicator <NUM> is a device to manufacture a membrane electrode assembly with subgasket by applying a subgasket base material <NUM> with a subgasket film <NUM> to an electrode layer base material <NUM> with a membrane electrode assembly layer <NUM>.

The gasket applicator <NUM> includes a first transport mechanism <NUM>, a second transport mechanism <NUM>, a first half-cut part <NUM>, a second half-cut part <NUM>, a bonding mechanism <NUM>, a sheet collection roller <NUM>, and a controller <NUM>.

The first transport mechanism <NUM> transports an elongated strip-shaped electrode layer base material <NUM> (see <FIG>) toward the bonding mechanism <NUM> along a fixed transport path 8TR while supporting the electrode layer base material <NUM> with a plurality of rollers. The first transport mechanism <NUM> includes a first supply roller <NUM>, a first feed roller <NUM>, and a first dancer roller <NUM>. The first transport mechanism <NUM> includes an electrolyte membrane collection roller <NUM> that collects a portion (a non-adopted region 8A2 of an electrolyte membrane <NUM> described later) by winding detached from the electrode layer base material <NUM> along the transport path 8TR.

In the present embodiment, a movement direction in which the electrode layer base material <NUM> is moved by the first transport mechanism <NUM> toward the bonding mechanism <NUM> will be called a transport direction DR1, and a direction orthogonal to the transport direction DR1 and parallel to a main surface (a surface of the largest area) of the electrode layer base material <NUM> will be called a width direction DR2. A side along the transport path 8TR closer to the first supply roller <NUM> is defined as an upstream side of the transport direction DR1, and a side along the transport path 8TR closer to the bonding mechanism <NUM> is defined as a downstream side of the transport direction DR1. The transport direction DR1 agrees with the longitudinal direction of the electrode layer base material <NUM>.

<FIG> is a longitudinal sectional view and a plan view schematically showing the electrode layer base material <NUM> sent from the first supply roller <NUM>. As shown in <FIG>, the electrode layer base material <NUM> includes an elongated strip-shaped first backsheet <NUM>, and an elongated strip-shaped electrolyte membrane <NUM> provided on the upper surface (one side surface) of the first backsheet <NUM>. The electrolyte membrane <NUM> has an upper surface on which rectangular first catalyst layers <NUM> are formed at regular intervals, and a lower surface (other side surface) on which a plurality of second catalyst layers <NUM> is formed to overlap the respective first catalyst layers <NUM> in a thickness direction. In the electrode layer base material <NUM>, the second catalyst layer <NUM> is caught between the electrolyte membrane <NUM> and the first backsheet <NUM>. The electrode layer base material <NUM> is manufactured in advance by an external device not shown in the drawings, and is prepared in a state of being wound in a roll shape on the first supply roller <NUM>. The electrolyte membrane <NUM>, a plurality of the first catalyst layers <NUM>, and a plurality of the second catalyst layers <NUM> form the membrane electrode assembly layer <NUM>. The first backsheet <NUM> and the electrolyte membrane <NUM> are attached to each other.

For example, a fluorine-based or hydrocarbon-based polyelectrolyte membrane is used as the electrolyte membrane <NUM>. Specific examples of the electrolyte membrane <NUM> include polyelectrolyte membranes containing perfluorocarbon sulfonic acid (for example, Nafion (registered trademark) available from DuPont US), Flemion (registered trademark) available from AGC Inc. , Aciplex (registered trademark) available from AGC Inc. , and Goreselect (registered trademark) available from W. Gore & Associates). The electrolyte membrane <NUM> has a thickness from <NUM> to <NUM>, for example. While the electrolyte membrane <NUM> swells with moisture in the air, it contracts with reduction in the moisture. Namely, the electrolyte membrane <NUM> has a property of being deformed easily in response to the moisture in the air.

The first backsheet <NUM> is a film for suppressing the deformation of the electrolyte membrane <NUM>. As a material of the first backsheet <NUM>, resin higher in mechanical strength and more excellent in shape retaining function than the electrolyte membrane <NUM> is used. For example, polyethylene naphthalate (PEN) or polyethylene terephthalate (PET) is used preferably as a material of the first backsheet <NUM>. The first backsheet <NUM> has a thickness from <NUM> to <NUM>, for example.

As shown in <FIG>, the first backsheet <NUM> has a width slightly greater than the width of the electrolyte membrane <NUM>. The electrolyte membrane <NUM> is formed at the center of the first backsheet <NUM> in the width direction. The first catalyst layer <NUM> has a width less than the width of the electrolyte membrane <NUM>. The first and second catalyst layers <NUM> and <NUM> are formed at the center of the upper surface and the center of the lower surface respectively of the electrolyte membrane <NUM> in the width direction.

A material to cause fuel cell reaction at an anode or a cathode of a polymer electrolyte fuel cell is used as a material of the first and second catalyst layers <NUM> and <NUM>. For example, catalyst particles of platinum (Pt), a platinum alloy, or a platinum compound are used as a material of the first and second catalyst layers <NUM> and <NUM>. For example, the platinum alloy may be an alloy of at least one type of metals selected from a group constituting of ruthenium (Ru), palladium (Pd), nickel (Ni), molybdenum (Mo), iridium (Ir), and Iron (Fe), and platinum. Generally, platinum is used as a material of a catalyst layer for a cathode, and a platinum alloy is used as a catalyst layer for an anode.

As shown in <FIG>, the first feed roller <NUM> includes two roller bodies arranged in such a manner as to contact each other. In the first feed roller <NUM>, while the electrode layer base material <NUM> is caught between these two roller bodies, the two roller bodies rotate to pull out the electrode layer base material <NUM> from the first supply roller <NUM>. The first feed roller <NUM> is configured to be capable of rotating actively in response to a control signal from the controller <NUM>. When the rotation of the first feed roller <NUM> is stopped, sending of the electrode layer base material <NUM> from the first supply roller <NUM> is stopped to stop transport of the electrode layer base material <NUM> into the first half-cut part <NUM> and transport of the electrode layer base material <NUM> out of the first half-cut part <NUM>.

<FIG> is a longitudinal sectional view and a plan view schematically showing the electrode layer base material <NUM> with a cut-out portion 8C. The first half-cut part <NUM> is arranged downstream from the first feed roller <NUM>. As shown in <FIG>, the first half-cut part <NUM> is a processing part that performs a process of cutting the membrane electrode assembly layer <NUM> of the electrode layer base material <NUM> sent from the first supply roller <NUM> into an adopted region 8A1 and a non-adopted region 8A2 (first half-cut process). The configuration of the first half-cut part <NUM> will be described later.

As shown in <FIG>, the cut-out portion 8C is formed by cutting the electrolyte membrane <NUM> into a rectangular shape surrounding a single first catalyst layer <NUM> and a single second catalyst layer <NUM> on the back side of this first catalyst layer <NUM>. The cut-out portion 8C is defined by a cutting plane penetrating the electrolyte membrane <NUM> from the upper surface to the lower surface thereof. The cut-out portion 8C does not penetrate the first backsheet <NUM> but is defined by a cutting plane extending from the upper surface to an intermediate portion of the first backsheet <NUM> in the thickness direction. Namely, the cut-out portion 8C does not reach the lower surface of the first backsheet <NUM>.

In order to apply constant tension on the electrode layer base material <NUM>, the first dancer roller <NUM> moves up and down (in a direction orthogonal to the main surface of the electrode layer base material <NUM>) in response to tension on the electrode layer base material <NUM>. By the upward and downward movement of the first dancer roller <NUM>, abrupt variation in the tension on the electrode layer base material <NUM> is absorbed.

The electrolyte membrane collection roller <NUM> collects by winding up a portion of the electrode layer base material <NUM> that in the non-adopted area 8A2 of the membrane electrode junction layer <NUM>. The non-adopted region 8A2 is a portion of the elongated strip-shaped electrolyte membrane <NUM> other than the adopted region 8A1. The non-adopted region 8A2 of the electrolyte membrane <NUM> is detached from the electrode layer base material <NUM> at a position downstream from the first half-cut part <NUM>, and is then wound on the electrolyte membrane collection roller <NUM>.

<FIG> is a longitudinal sectional view and a plan view schematically showing the electrode layer base material <NUM> from which a portion of the membrane electrode assembly layer <NUM> in the non-adopted region 8A2 is separated As shown in <FIG>, by collecting the non-adopted region 8A2 of the electrolyte membrane <NUM> from the electrode layer base material <NUM> using the electrolyte membrane collection roller <NUM>, a single membrane electrode assembly <NUM> is left on the upper surface of the first backsheet <NUM> that is composed of a portion of the electrolyte membrane <NUM> in the adopted region 8A1, and a single first catalyst layer <NUM> and a single second catalyst layer <NUM> formed on the upper surface and the lower surface respectively of this portion of the electrolyte membrane <NUM>. The membrane electrode assembly <NUM> is transported together with the first backsheet <NUM> toward the bonding mechanism <NUM>.

The second transport mechanism <NUM> transports the elongated strip-shaped subgasket base material <NUM> (see <FIG>) toward the bonding mechanism <NUM> along a fixed transport path 9TR while supporting the subgasket base material <NUM> with a plurality of rollers. The second transport mechanism <NUM> includes a second supply roller <NUM> and a second dancer roller <NUM>. The second transport mechanism <NUM> further includes a cover film collection roller <NUM> that collects an unnecessary portion by winding detached from the subgasket base material <NUM> on the transport path 9TR.

In the present embodiment, a movement direction in which the subgasket base material <NUM> is moved by the second transport mechanism <NUM> toward the bonding mechanism <NUM> will be called a transport direction DR3. A side along the transport path 9TR closer to the first supply roller <NUM> is defined as an upstream side of the transport direction DR3, and a side along the transport path 9TR closer to the bonding mechanism <NUM> is defined as a downstream side of the transport direction DR3. The transport direction DR3 agrees with the longitudinal direction of the subgasket base material <NUM>. A direction orthogonal to the transport direction DR3 and parallel to a main surface (a surface of the largest area) of the subgasket base material <NUM> agrees with the width direction DR2.

<FIG> is a longitudinal sectional view and a plan view schematically showing the subgasket base material <NUM>. The subgasket base material <NUM> shown in <FIG> is provided with a cut-out portion 9C. The cut-out portion 9C is to be formed by the second half-cut part <NUM> described later and does not exist immediately after sending from the second supply roller <NUM>.

As shown in <FIG>, the subgasket base material <NUM> includes an elongated strip-shaped second backsheet <NUM>, the elongated strip-shaped subgasket film <NUM> formed on the upper surface (one side surface) of the second backsheet <NUM>, and an elongated strip-shaped cover film <NUM> formed on the upper surface (one side surface) of the subgasket film <NUM>. The subgasket base material <NUM> is manufactured in advance by an external device not shown in the drawings, and is prepared in a state of being wound in a roll shape on the second supply roller <NUM>.

As a material of the subgasket film <NUM>, resin higher in mechanical strength and more excellent in shape retaining function than the electrolyte membrane <NUM> is used preferably. Polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polyphenylene sulfide (PPS), or polystyrene (PS) is used preferably as a material of the subgasket film <NUM>. The subgasket film <NUM> has a thickness from <NUM> to <NUM>, for example.

In the subgasket base material <NUM>, the upper surface (one side surface) of the second backsheet <NUM> is an adhesive surface in which a layer of an adhesive is formed. The adhesive is a pressure-sensitive adhesive, for example. The pressure-sensitive adhesive may be replaced with a thermosetting adhesive, a thermoplastic adhesive, or a UV-curable adhesive. This adhesive surface on the second backsheet <NUM> is covered with the subgasket film <NUM>. Polyethylene naphthalate (PEN) or polyethylene terephthalate (PET) is used preferably as a material of the second backsheet <NUM>. The second backsheet <NUM> has a thickness from <NUM> to <NUM>, for example.

In the subgasket base material <NUM>, the upper surface (one side surface) of the subgasket film <NUM> is an adhesive surface in which a layer of an adhesive is formed. This adhesive surface on the subgasket film <NUM> is covered with the cover film <NUM>. The cover film <NUM> is adhesively bonded under adhesive force of a degree allowing the cover film <NUM> to be detached easily from the subgasket film <NUM>. While a material of the cover film <NUM> is not particularly limited, it is preferably polyethylene terephthalate (PET), for example.

In order to apply constant tension on the subgasket base material <NUM>, the second dancer roller <NUM> moves from side to side (in a direction orthogonal to the main surface of the subgasket base material <NUM>) in response to tension on the electrode layer base material <NUM>. By the side-to-side movement of the second dancer roller <NUM>, abrupt variation in the tension on the subgasket base material <NUM> is absorbed.

The second half-cut part <NUM> is provided between the second supply roller <NUM> and the second dancer roller <NUM>. The second half-cut part <NUM> is a processing part that performs a process of cutting the cover film <NUM> and the subgasket film <NUM> of the subgasket base material <NUM> supplied from the second supply roller <NUM> into a corresponding region 9A1 and a non-corresponding region 9A2 (second half-cut process).

As shown in <FIG>, the second half-cut process is to form the cut-out portion 9C in the subgasket base material <NUM>. The cut-out portion 9C is formed along a boundary line (cutting target line 9T) between the rectangular corresponding region 9A1 and the non-corresponding region 9A2 other than the corresponding region 9A1. The corresponding region 9A1 has a similar shape and has a substantially equal size to the first catalyst layer <NUM>, for example. The corresponding region 9A1 may be dissimilar in shape to the first catalyst layer <NUM>. The corresponding region 9A1 may be larger than the first catalyst layer <NUM>.

In this example, the second half-cut part <NUM> includes two upper and lower rollers <NUM> and <NUM> facing each other, and the subgasket base material <NUM> is passed between these two rollers <NUM> and <NUM>. A pinnacle blade is provided on the outer peripheral surface of the roller <NUM> facing the cover film <NUM> of the subgasket base material <NUM>. This pinnacle blade has a shape responsive to the shape (rectangular shape) of the corresponding region 9A1.

In the second half-cut part <NUM>, the subgasket base material <NUM> is caught between the two rollers <NUM> and <NUM>. Each of the rollers <NUM> and <NUM> rotates synchronously with a speed at which the subgasket base material <NUM> moves in the transport direction DR3. As the pinnacle blade on the outer peripheral surface of the roller <NUM> abuts on the subgasket base material <NUM>, the cut-out portion 9C is formed in the subgasket base material <NUM>. In this way, the subgasket base material <NUM> is cut into the corresponding region 9A1 and the non-corresponding region 9A2. The roller <NUM> has an outer periphery agreeing with an interval between the cut-out portions 9C (in other words, an interval between the corresponding regions 9A1) formed in the subgasket base material <NUM>. For this reason, by the rotations of the rollers <NUM> and <NUM> synchronous with the movement of the subgasket base material <NUM>, the cut-out portions 9C are formed at a constant pitch in the subgasket base material <NUM>. Each of the rollers <NUM> and <NUM> is not always required to rotate at a speed synchronous with a movement speed of the subgasket base material <NUM>. For example, when the pinnacle blade abuts on the subgasket base material <NUM>, the roller <NUM> is rotated at a speed synchronous with a movement speed of the subgasket base material <NUM>. When the pinnacle blade does not contact the subgasket base material <NUM>, the roller <NUM> may be rotated at a higher speed than the movement speed of the subgasket base material <NUM>. This makes it possible to shorten an interval between the cut-out portions 9C formed in the subgasket base material <NUM> to allow loss reduction in the subgasket base material <NUM>.

The rollers <NUM> and <NUM> may be driven to rotate by frictional resistance generated by friction with the subgasket base material <NUM>. In this case, the rollers <NUM> and <NUM> rotate synchronously with a movement speed of the subgasket base material <NUM> to eliminate the need for synchronous control by the controller <NUM>. At least one of the rollers <NUM> and <NUM> may have a configuration of rotating actively in response to driving by a motor. In this case, the controller <NUM> may control the rotations of the rollers <NUM> and <NUM> to conform to a speed at which the subgasket base material <NUM> is moved by the second transport mechanism <NUM>.

As shown in <FIG>, the cut-out portion 9C is defined by a cutting plane penetrating the cover film <NUM> and the subgasket film <NUM>. The cut-out portion 9C does not penetrate the second backsheet <NUM> but is defined by a cutting plane extending from the upper surface (one side surface) to an intermediate portion of the second backsheet <NUM> in the thickness direction. Namely, the cut-out portion 9C does not reach the lower surface (other side surface) of the second backsheet <NUM>.

The cover film collection roller <NUM> collects a portion of the subgasket base material <NUM> provided with the cut-out portion 9C by winding. This portion is a portion of the cover film <NUM> in the non-corresponding region 9A2. The non-corresponding region 9A2 of the cover film <NUM> is detached from the subgasket base material <NUM> at a position between the second dancer roller <NUM> and the bonding mechanism <NUM> along the transport path 9TR, and is then collected on the cover film collection roller <NUM>. The cover film collection roller <NUM> is an example of a detachment part.

<FIG> is a longitudinal sectional view and a plan view schematically showing the subgasket base material <NUM> from which a portion of the cover film <NUM> in the non-corresponding region 9A2 is separated. As shown in <FIG>, as a result of separation of the portion of the cover film <NUM> in the non-corresponding region 9A2, a rectangular portion that is the corresponding region 9A1 of the cover film <NUM> is left on the upper surface of the subgasket film <NUM>. This rectangular portion is transported together with the second backsheet <NUM> and the subgasket film <NUM> to the bonding mechanism <NUM>.

<FIG> is a longitudinal sectional view schematically showing the electrode layer base material <NUM> and the subgasket base material <NUM> to be bonded to each other by the bonding mechanism <NUM>. As shown in <FIG>, the bonding mechanism <NUM> is for bonding between the electrode layer base material <NUM> from which a portion of the electrolyte membrane <NUM> in the non-adopted region 8A2 is separated (see <FIG>) and the subgasket base material <NUM> from which a portion of the cover film <NUM> in the non-corresponding region 9A2 is separated. In this case, the electrode layer base material <NUM> and the subgasket base material <NUM> are bonded to each other in such a manner as to align the upper surface of the first catalyst layer <NUM> of the membrane electrode assembly <NUM> at the electrode layer base material <NUM> with the upper surface of the cover film <NUM> of the subgasket base material <NUM>. The electrolyte membrane <NUM> forming a part of the membrane electrode assembly <NUM> at the electrode layer base material <NUM> and existing in the periphery of the first catalyst layer <NUM> is adhesively bonded to a surface (adhesive surface) of the subgasket film <NUM> existing in the periphery of the cover film <NUM> at the subgasket base material <NUM>.

In the present embodiment, the subgasket base material <NUM> has the cut-out portion 9C formed in the corresponding region 9A1 corresponding to the first catalyst layer <NUM> while extending to an intermediate portion of the second backsheet <NUM> in the thickness direction, and the subgasket base material <NUM> is bonded to the electrode layer base material <NUM>. Namely, the subgasket base material <NUM> is bonded to the electrode layer base material <NUM> while the corresponding region 9A1 is not cut out from the subgasket base material <NUM>. This makes it possible to maintain high rigidity of the subgasket film <NUM> before the bonding to reduce the occurrence of creases in the subgasket film <NUM>.

A first backsheet collection roller <NUM> collects the first backsheet <NUM> by winding detached from the electrode layer base material <NUM> after the electrode layer base material <NUM> is bonded to the subgasket base material <NUM> by the bonding mechanism <NUM>. The first backsheet <NUM> is detached from the electrode layer base material <NUM> at a position between the bonding mechanism <NUM> and the sheet collection roller <NUM>. As a result, an assembly sheet with subgasket <NUM> (see <FIG>) is formed.

<FIG> is a longitudinal sectional view and a plan view showing the assembly sheet with subgasket <NUM> and a membrane electrode assembly with subgasket <NUM>. The assembly sheet with subgasket <NUM> has a configuration in which the subgasket base material <NUM> is attached to one side of the membrane electrode assembly <NUM>. In the assembly sheet with subgasket <NUM>, a portion of the subgasket film <NUM> in the corresponding region 9A1, and additionally, a portion of the cover film <NUM> in the corresponding region 9A1 are applied to the first catalyst layer <NUM>, as well as to the periphery of the first catalyst layer <NUM> of the membrane electrode assembly <NUM>. This achieves higher rigidity of the electrolyte membrane <NUM> and that of the first catalyst layer <NUM> (also that of the second catalyst layer <NUM>). As a result, it becomes possible to reduce the occurrence of deformation such as creases at the above-described portions.

The assembly sheet with subgasket <NUM> is collected by being wound in a roll shape on the sheet collection roller <NUM>. The assembly sheet with subgasket <NUM> is wound on the sheet collection roller <NUM> with a surface thereof closer to the second backsheet <NUM> facing the outer peripheral surface of the sheet collection roller <NUM>. This allows reduction in the occurrence of direct contact of the second catalyst layer <NUM> of the assembly sheet with subgasket <NUM> with the outer peripheral surface of the sheet collection roller <NUM>.

As shown in <FIG>, the sheet collection roller <NUM> collects the assembly sheet with subgasket <NUM> by winding. A motor not shown in the drawings is connected to a rotary shaft of the sheet collection roller <NUM> and the sheet collection roller <NUM> rotate sunder control by the controller <NUM>.

As shown in <FIG>, in detaching the second backsheet <NUM> from the assembly sheet with subgasket <NUM>, it becomes possible to detach an unnecessary portion of the subgasket film <NUM> inside the cut-out portion 9C (a portion thereof in the corresponding region 9A1) and the cover film <NUM> together with detachment of the second backsheet <NUM>. This makes it possible to provide the membrane electrode assembly with subgasket <NUM> with a portion of the subgasket film <NUM> in the non-corresponding region 9A2 as a frame body added to an edge of the membrane electrode assembly <NUM>. Regarding the membrane electrode assembly with subgasket <NUM>, by cutting the subgasket film <NUM> at a position of a break line 85C of a rectangular shape slightly greater than the membrane electrode assembly <NUM> as shown in <FIG>, for example, it becomes possible to obtain a membrane electrode assembly with subgasket with a subgasket film like a frame added to one membrane electrode assembly <NUM>.

<FIG> is a block diagram showing electrical connection between the controller <NUM> and each unit in the gasket applicator <NUM>. The controller <NUM> controls the operation of each unit in the gasket applicator <NUM>. As conceptually shown in <FIG>, the controller <NUM> is configured using a computer including a processor <NUM> such as a CPU, a memory <NUM> such as a RAM, and a storage unit <NUM> such as a hard disk drive. The storage unit <NUM> stores a computer program P installed for controlling the operation of the gasket applicator <NUM>.

The configuration of the first half-cut part <NUM> will be described by referring to <FIG>. For the convenience of description, arrows indicating an X direction, a Y direction, and a Z direction orthogonal to each other are given in <FIG>. In the following description, a direction in which the tip of each arrow is pointed is defined as a + direction (positive direction), and a direction opposite to the former direction is defined as a - direction (negative direction). The X direction is parallel to the transport direction DR1, the Y direction is parallel to the width direction DR2, and the Z direction is vertical to the upper surface of the electrode layer base material <NUM>. In this example, the X direction and the Y direction are parallel to a horizontal plane, and the Z direction is parallel to the vertical direction.

<FIG> schematically shows the first half-cut part <NUM> on the +X side. <FIG> schematically shows the first half-cut part <NUM> on the +X side. <FIG> schematically shows the first half-cut part <NUM> on the -Y side. <FIG> schematically shows an X direction drive section <NUM> of the first half-cut part <NUM>.

The first half-cut part <NUM> is a device that performs the first half-cut process of forming the rectangular cut-out portion 8C (see <FIG>) in the electrode layer base material <NUM> moving in the transport direction DR1. The first half-cut part <NUM> includes a suction stage <NUM>, a rotary die cutter <NUM>, a rotary drive part <NUM>, and a movement drive part <NUM>.

The suction stage <NUM> holds the electrode layer base material <NUM> under suction from the first backsheet <NUM>. A suction surface (+Z side surface) of the suction stage <NUM> has a rectangular shape extending long in the X direction and extending short in the Y direction.

The rotary die cutter <NUM> is a cylindrical member to rotate about a rotary shaft 31A extending in the Y direction. The rotary die cutter <NUM> has an outer peripheral surface where a pinnacle blade <NUM> is provided. The pinnacle blade <NUM> is used for forming the cut-out portion 8C in the electrode layer base material <NUM> along a cutting target line 8T (see <FIG>) around the first catalyst layer <NUM> of the electrode layer base material <NUM>. In this example, the cut-out portion 8C has a square shape. In response to this, the pinnacle blade <NUM> is defined by two width direction portions <NUM> extending parallel to each other in the Y direction (width direction DR2), and two peripheral direction portions <NUM> extending parallel to each other in the peripheral direction of the rotary die cutter <NUM>.

The movement drive part <NUM> includes a bridge-like body <NUM> holding the rotary die cutter <NUM>, the X direction drive section <NUM> that moves the bridge-like body <NUM> in the X direction, a Y direction drive section <NUM> that moves the bridge-like body <NUM> in the Y direction, and a Z direction drive section <NUM> that moves the rotary die cutter <NUM> in the Z direction.

The bridge-like body <NUM> includes two columns <NUM> extending in the Z direction and arranged on the +Y side and the -Y side of the suction stage <NUM>, and a beam <NUM> coupling the respective ends on the +Z side of the two columns <NUM>. The rotary die cutter <NUM> is arranged between the two columns <NUM>.

The movement drive part <NUM> moves the rotary die cutter <NUM> at least to a separated position L11 (see <FIG>) and to a half-cut position L12 (see <FIG>). As shown in <FIG>, the rotary die cutter <NUM> at the separated position L11 is separated upward (+Z side) from the electrode layer base material <NUM> passing along the transport path 8TR above the suction stage <NUM>. As shown in <FIG>, with the rotary die cutter <NUM> at the half-cut position L12, by the rotation of the rotary die cutter <NUM>, the pinnacle blade <NUM> abuts on the upper surface of the electrode layer base material <NUM> sucked on the suction stage <NUM>, and the cut-out portion 8C becomes ready to be formed.

The Z direction drive section <NUM> includes one Z direction guide <NUM>, one lifting plate <NUM>, one spring <NUM>, and one eccentric cam <NUM> provided on each of the +Y side and the -Y side of the rotary die cutter <NUM>. The Z direction drive section <NUM> includes a rotary shaft <NUM> extending in the Y direction, and a Z direction motor <NUM> to rotate the rotary shaft <NUM>. The two eccentric cams <NUM> are attached to the rotary shaft <NUM>.

The spring <NUM> is arranged between the lifting plate <NUM> and a Y direction guide <NUM> arranged closer to the -Z side than the lifting plate <NUM>. The spring <NUM> is coupled to an end of the lifting plate <NUM> on the -Z side and biases the lifting plate <NUM> toward the +Z side. An end of the lifting plate <NUM> on the +Z side abuts on an end of the outer peripheral surface (cam surface) of the eccentric cam <NUM> on the -Z side. As the eccentric cam <NUM> rotates together with the rotary shaft <NUM>, an end of the eccentric cam <NUM> on the -Z side is displaced in the Z direction. This further changes the position of the lifting plate <NUM> pressed with the eccentric cam <NUM> in the Z direction. The lifting plate <NUM> is coupled to the Z direction guide <NUM> extending in the Z direction and is displaced parallel to the vertical direction by the Z direction guide <NUM>.

The opposite ends of the rotary shaft 31A of the rotary die cutter <NUM> are supported by the lifting plate <NUM> via a bearing 32B. Thus, the rotary die cutter <NUM> is moved in the Z direction together with the lifting plate <NUM>.

The Y direction drive section <NUM> includes a Y direction motor <NUM> that is a servo motor, a ball screw <NUM> extending in the Y direction, and four Y direction guides <NUM> extending in the Y direction (see <FIG>). A portion of the bridge-like body <NUM> on the - Z side is coupled to each of the Y direction guides <NUM>. The ball screw <NUM> is coupled to a nut member provided to a surface of the bridge-like body <NUM> on the -Y side (see <FIG> and <FIG>). As the Y direction motor <NUM> rotates the ball screw <NUM>, the bridge-like body <NUM> moves in the Y direction along the Y direction guides <NUM>. This moves the rotary die cutter <NUM> in the Y direction.

The X direction drive section <NUM> includes an X direction motor <NUM> that is a servo motor, a ball screw <NUM> extending in the X direction, and two X direction guides <NUM> extending parallel to the X direction. The ball screw <NUM> is coupled to a surface of the bridge-like body <NUM> on the +X side. As the X direction motor <NUM> rotates the ball screw <NUM>, the bridge-like body <NUM> moves in the X direction along the X direction guide <NUM>. This moves the rotary die cutter <NUM> in the X direction.

The rotary drive part <NUM> rotates the rotary die cutter <NUM> by rotating the rotary shaft 31A. The rotary drive part <NUM> includes a rotary motor <NUM> and a clutch <NUM>.

The rotary motor <NUM> is coupled to an end of the rotary shaft 31A on the -Y side. As the rotary motor <NUM> rotates the rotary shaft 31A, the rotary die cutter <NUM> rotates about the rotary shaft 31A. The opposite portions of the rotary shaft 31A are supported by the lifting plates <NUM> on the +Y side and on the -Y side via the bearing 32B.

The clutch <NUM> is provided on the rotary shaft 31A between the rotary motor <NUM> and the rotary die cutter <NUM>. The rotary shaft 31A is divided by the clutch <NUM> into a drive shaft (a shaft section closer to the rotary motor <NUM> than the clutch <NUM>) and a driven shaft (a shaft section closer to the rotary die cutter <NUM> than the clutch <NUM>). Connecting and disconnecting the drive shaft and the driven shaft using the clutch <NUM> allows switching between transmission and non-transmission of rotary drive power from the rotary motor <NUM> to the rotary die cutter <NUM>. The clutch <NUM> is not an absolute necessity but is omissible.

The column <NUM> of the bridge-like body <NUM> on the -Y side has a through hole (not shown in the drawings) penetrating the column <NUM> in the Y direction and where the rotary shaft 31A is passed. This through hole has a shape allowing lifting movement of the rotary shaft 31A such as an oval shape extending long in the Z direction.

<FIG> is a plan view showing a suction surface <NUM> of the suction stage <NUM>. <FIG> is a plan view showing the electrode layer base material <NUM> sucked on the suction surface <NUM> of the suction stage <NUM>. The suction surface <NUM> (surface on the +Z side) of the suction stage <NUM> for suction of the electrode layer base material <NUM> is provided with a suction groove <NUM>. A plurality of suction holes <NUM> for suction of atmosphere is provided inside the suction groove <NUM>.

The suction groove <NUM> includes a plurality of first recesses <NUM> extending in the +Y direction toward the +X direction, and a plurality of second recesses <NUM> extending in the -Y direction toward the +X direction. These first recesses <NUM> and second recesses <NUM> intersect at a plurality of intersections <NUM> and are coupled to each other at the intersections <NUM>. In the present embodiment, some of these intersections <NUM> are given the suction holes <NUM>. Forming two or more suction holes <NUM> is not an absolute necessity but there may be one suction hole <NUM>.

The suction hole <NUM> is connected via a suction pipe not shown in the drawings to a suction unit 30P (see <FIG>) including a vacuum pump, etc. By the action of the suction unit 30P, surrounding atmosphere is sucked through the suction hole <NUM>. The controller <NUM> controls a valve (not shown in the drawings) provided to the suction pipe to control start and stop of suction of atmosphere through the suction hole <NUM>. When the controller <NUM> starts suction of atmosphere through the suction hole <NUM>, the electrode layer base material <NUM> is sucked on the suction surface <NUM> of the suction stage <NUM>. When the controller <NUM> stops suction of atmosphere through the suction hole <NUM>, the electrode layer base material <NUM> is released from the suction to be separated upward (+Z side) from the suction stage <NUM>.

The cutting target line 8T corresponding to the cut-out portion 8C formed in the electrode layer base material <NUM> by the first half-cut part <NUM> has a rectangular shape with portions parallel to the X direction and portions parallel to the Y direction. The suction groove <NUM> includes the first recesses <NUM> and the second recesses <NUM> intersecting the portions parallel to the X direction and the portions parallel to the Y direction of the cutting target line 8T.

As the electrode layer base material <NUM> can be sucked on the suction stage <NUM> along the suction groove <NUM>, deviation of the electrode layer base material <NUM> is alleviated during implementation of the first half-cut process. Furthermore, the suction groove <NUM> includes a plurality of the first recesses <NUM> and a plurality of the second recesses <NUM> extending in directions intersecting the cutting target line 8T. This allows the electrode layer base material <NUM> to be held along the suction groove <NUM> crossing each portion of the cutting target line 8T in the electrode layer base material <NUM>. Thus, even with the pinnacle blade <NUM> abutting on the electrode layer base material <NUM>, a corresponding abutting portion of the electrode layer base material <NUM> can still be held fixedly on the suction stage <NUM>. This allows the cut-out portion 8C to be formed accurately along the cutting target line 8T in the electrode layer base material <NUM>.

As shown in <FIG>, the first half-cut part <NUM> includes an imaging part <NUM>. The imaging part <NUM> is arranged closer to the +Z side than the suction surface <NUM> of the suction stage <NUM>. The imaging part <NUM> includes one, or two or more cameras with image sensors. The imaging part <NUM> captures an image of the first catalyst layer <NUM> at the electrode layer base material <NUM> sucked on the suction stage <NUM>. The imaging part <NUM> is electrically connected to the controller <NUM>, and transmits an image signal resulting from imaging to the controller <NUM>.

As shown in <FIG>, the controller <NUM> functions as a position determination part <NUM>. The position determination part <NUM> is a function realized as software by causing the processor <NUM> to execute the computer program P. The position determination part <NUM> may be a hardware configuration such as an application-specific integrated circuit. The position determination part <NUM> determines the position of the first catalyst layer <NUM> (a barycenter position, for example) in an image acquired by the imaging part <NUM>. Furthermore, the controller <NUM> sets the cutting target line 8T on the basis of the determined position of the first catalyst layer <NUM> and operates the movement drive part <NUM> in response to the set cutting target line 8T, thereby moving the rotary die cutter <NUM>.

As shown in <FIG>, for example, the position determination part <NUM> may determine four corners <NUM>, <NUM>, <NUM>, and <NUM> of the first catalyst layer <NUM>, and determine the barycenter position of the first catalyst layer <NUM> on the basis of the determined corner positions. In this case, the imaging part <NUM> may capture images of the corners <NUM> to <NUM> using a plurality of cameras. The imaging part <NUM> may capture images of the corners <NUM> to <NUM> simultaneously using one camera, or may acquire these images separately by imaging performed several times by moving this camera.

The position determination part <NUM> is not always required to determine the position of the first catalyst layer <NUM> on the basis of the positions of the corners <NUM> to <NUM>. For example, the position determination part <NUM> may determine the positions of the four sides of the first catalyst layer <NUM>, and may determine the position of the first catalyst layer <NUM> on the basis of the determined side positions.

The position determination part <NUM> may determine the position of the second catalyst layer <NUM>. If the first backsheet <NUM> has transparency, for example, the imaging part <NUM> may be arranged adjacent to the first backsheet <NUM> of the electrode layer base material <NUM> and an image of the second catalyst layer <NUM> may be captured using the imaging part <NUM>. In this case, the controller <NUM> can set the cutting target line 8T properly on the basis of the position of the second catalyst layer <NUM>.

The position determination part <NUM> may determine the respective positions of the first and second catalyst layers <NUM> and <NUM>, and the controller <NUM> may set the cutting target line 8T on the basis of the determined positions. In this case, the controller <NUM> may set the cutting target line 8T using a midpoint between the barycenter position of the first catalyst layer <NUM> and the barycenter position of the second catalyst layer <NUM> as a reference, for example.

If the first or second catalyst layer <NUM> or <NUM> in the electrode layer base material <NUM> has a defect such as malformation, the controller <NUM> may exclude such a defective item from the first half-cut process by the first half-cut part <NUM> and may skip this item. In this case, an interval between implementations of the first half-cut process on the electrode layer base material <NUM> is inevitably not limited to an equal pitch.

The first or second catalyst layer <NUM> or <NUM> may be subjected to a non-defective inspection when the first or second catalyst layer <NUM> or <NUM> is formed on the electrolyte membrane <NUM>, for example. In this case, management data indicating non-defective/defective of each first catalyst layer <NUM> or each second catalyst layer <NUM> is prepared preferably on the basis of a result of this non-defective inspection. Then, in the gasket applicator <NUM>, the controller <NUM> may refer to this management data to perform the first half-cut process at the first half-cut part <NUM> only on a region including the first or second catalyst layer <NUM> or <NUM> determined to be "non-defective. " This makes it possible to reduce the formation of an unnecessary cut-out portion 8C in the electrode layer base material <NUM> to allow the gasket applicator <NUM> to manufacture the assembly sheet with subgasket <NUM> efficiently. This further reduces the occurrence of bonding of the first catalyst layer <NUM> not to be adopted to the subgasket base material <NUM>, thereby suppressing wasteful consumption of the subgasket base material <NUM>.

The non-defective inspection on the first or second catalyst layer <NUM> or <NUM> may be conducted at the gasket applicator <NUM>. In this case, a camera for capturing an image of the first or second catalyst layer <NUM> or <NUM> may be provided at a position between the first supply roller <NUM> and the first half-cut part <NUM>. Then, the controller <NUM> may conduct non-defective inspection on the first or second catalyst layer <NUM> or <NUM> by applying an inspection technique such as pattern matching to an image acquired by the camera.

The first half-cut process performed in the gasket applicator <NUM> will be described. First, the first transport mechanism <NUM> transports the adopted region 8A1 including the first catalyst layer <NUM> determined to be non-defective at the electrode layer base material <NUM> to a fixed position on the suction stage <NUM>. Then, the controller <NUM> controls the first transport mechanism <NUM> to stop movement of the electrode layer base material <NUM> in the transport direction DR1 (in the +X direction). Whether the adopted region 8A1 has reached the fixed position may be determined by causing a photosensor arranged at a predetermined position on the transport path 8TR to detect the passage of the intended first catalyst layer <NUM>.

After the movement of the electrode layer base material <NUM> is stopped, the controller <NUM> starts suction of atmosphere through the suction hole <NUM> in the suction stage <NUM>. By doing so, the electrode layer base material <NUM> is sucked on the suction surface <NUM> through the suction groove <NUM>.

Next, the imaging part <NUM> captures an image of the first catalyst layer <NUM>, and the position determination part <NUM> determines the position of the first catalyst layer <NUM> in the captured image. Then, the controller <NUM> sets the cutting target line 8T on the basis of the determined position of the first catalyst layer <NUM>.

Next, the controller <NUM> moves the rotary die cutter <NUM> from the separated position L11 (see <FIG>) to the half-cut position L12 (see <FIG>). The half-cut position L12 is the position of the rotary die cutter <NUM> for forming the cut-out portion 8C in the electrode layer base material <NUM> using the pinnacle blade <NUM> of the rotary die cutter <NUM>. As described above, the cutting target line 8T differs in response to the position of the first catalyst layer <NUM> (or second catalyst layer <NUM>) determined by the position determination part <NUM>. For this reason, the half-cut position L12 of the rotary die cutter <NUM> can change in response to the position of the first catalyst layer <NUM>.

Before the rotary die cutter <NUM> moves to the half-cut position L12, the controller <NUM> controls the rotary drive part <NUM> so that the rotary die cutter <NUM> rotates until the pinnacle blade <NUM> of the rotary die cutter <NUM> is placed at an initial position.

As shown in <FIG>, for example, the initial position of the pinnacle blade <NUM> may be a position where a blade portion (here, the width direction portion <NUM>) of the pinnacle blade <NUM> to abut on a most upstream portion 8T1 of the cutting target line 8T (see <FIG>) comes to the bottom of the rotary die cutter <NUM>. In this case, by moving down the rotary die cutter <NUM> toward the -Z side and placing the rotary die cutter <NUM> at the half-cut position L12, the cut-out portion 8C can be formed at the most upstream portion 8T1 of the electrode layer base material <NUM> with the pinnacle blade <NUM>.

When the rotary die cutter <NUM> comes to the half-cut position L12, the outer peripheral surface of the rotary die cutter <NUM> comes into contact with the upper surface of the electrode layer base material <NUM> (the first catalyst layer <NUM> or the electrolyte membrane <NUM>) sucked on the suction stage <NUM>. Preferably, the outer peripheral surface of the rotary die cutter <NUM> and the suction surface <NUM> of the suction stage <NUM> are pressed against each other with the intervention of the electrode layer base material <NUM> therebetween. In this state, the controller <NUM> causes the rotary drive part <NUM> and the movement drive part <NUM> to rotate the rotary die cutter <NUM> synchronously with the movement of the rotary die cutter <NUM> toward the upstream side (-Y side). Then, the pinnacle blade <NUM> is rotated by a fixed angle from the initial position to an end position to form the cut-out portion 8C in the electrode layer base material <NUM> along the cutting target line 8T.

The rotary die cutter <NUM> may be driven to rotate by frictional resistance generated between the electrode layer base material <NUM> and the rotary die cutter <NUM>. In this case, after moving the pinnacle blade <NUM> to the initial position, the controller <NUM> may control the clutch <NUM> to cut the connection between the drive shaft and the driven shaft of the rotary shaft 31A, for example. As described above, the clutch <NUM> may be omitted if the rotary die cutter <NUM> is to rotate actively at the half-cut position L12.

When the pinnacle blade <NUM> rotates to the end position, the controller <NUM> moves up the rotary die cutter <NUM> toward the +Z side and moves the rotary die cutter <NUM> to the separated position L11 using the movement drive part <NUM>. Next, the controller <NUM> releases the electrode layer base material <NUM> from the suction by the suction stage <NUM>. Then, the controller <NUM> causes the first transport mechanism <NUM> to move the electrode layer base material <NUM> again in the transport direction DR1.

At the first half-cut part <NUM>, the position of the rotary die cutter <NUM> is movable relative to the suction stage <NUM>. This allows the blade of the rotary die cutter <NUM> to move relative to the electrode layer base material <NUM> sucked on the suction stage <NUM>. In this way, the cut-out portion 8C can be formed at an appropriate position of the electrode layer base material <NUM>.

In particular, in the present embodiment, the rotary die cutter <NUM> is movable in the X direction (transport direction DR1) and in the Y direction (width direction DR2). This allows adjustment of a position where the cut-out portion 8C is to be formed in a direction parallel to the surface of the electrode layer base material <NUM>. In the present embodiment, the rotary die cutter <NUM> is movable in the Z direction (the thickness direction of the electrode layer base material <NUM>). This allows adjustment of the depth of the cut-out portion 8C to be formed in the electrode layer base material <NUM>.

The first half-cut part <NUM> cuts the electrolyte membrane <NUM> while leaving the first backsheet <NUM> unremoved at the electrode layer base material <NUM>. Thus, during bonding to the subgasket base material <NUM> at the bonding mechanism <NUM>, the membrane electrode assembly <NUM> formed by the first half-cut process by the first half-cut part <NUM> can be left on the first backsheet <NUM>. As a result, it becomes possible to reduce the occurrence of creases at the membrane electrode assembly <NUM> including the first and second catalyst layers <NUM> and <NUM>.

At the first half-cut part <NUM>, the rotary shaft 31A of the rotary die cutter <NUM> is arranged in the width direction DR2 orthogonal to the longitudinal direction of the electrode layer base material <NUM>. In this arrangement, moving the rotary die cutter <NUM> in the longitudinal direction of the electrode layer base material <NUM> while rotating the rotary die cutter <NUM> about the rotary shaft 31A allows efficient formation of the cut-out portion 8C in the electrode layer base material <NUM>.

At the first half-cut part <NUM>, the cutting target line 8T is decided on the basis of the position of the first catalyst layer <NUM> determined by the position determination part <NUM>, and the half-cut position L12 of the rotary die cutter <NUM> is set to conform to the decided cutting target line 8T. This allows formation of the cut-out portion 8C accurately to conform to the position of the first catalyst layer <NUM>.

In the gasket applicator <NUM>, the first transport mechanism <NUM> transports the electrode layer base material <NUM> in the transport direction DR1 while moving and stopping the electrode layer base material <NUM> alternately on the suction stage <NUM>. Then, while the gasket applicator <NUM> stops the electrode layer base material <NUM>, the movement drive part <NUM> moves the rotary die cutter <NUM> to the half-cut position L12. This provides increased positional accuracy of the cut-out portion 8C formed in the electrode layer base material <NUM>.

The configuration of the bonding mechanism <NUM> will be described by referring to <FIG> and <FIG>. For the convenience of description, arrows indicating an X direction, a Y direction, and a Z direction orthogonal to each other are given in <FIG> and <FIG>. The +X direction agrees with the transport direction DR1, and the -X direction agrees with the transport direction DR3. The Y direction is parallel to the width direction DR2.

<FIG> and <FIG> are side views each schematically showing the bonding mechanism <NUM>. As described by referring to <FIG>, the bonding mechanism <NUM> is a device for bonding between the electrode layer base material <NUM> from which a portion of the electrolyte membrane <NUM> in the non-adopted region 8A2 is separated and the subgasket base material <NUM> from which a portion of the cover film <NUM> in the non-corresponding region 9A2 is separated. The bonding mechanism <NUM> performs a positioning process described later to align the first catalyst layer <NUM> and the cut-out portion 9C (corresponding region 9A1) with each other. In this state, the bonding mechanism <NUM> bonds the electrode layer base material <NUM> and the subgasket base material <NUM> to each other. The bonding mechanism <NUM> includes a first bonding roller <NUM>, a second bonding roller <NUM>, a suction mechanism <NUM>, a bonding roller movement drive part <NUM>, a first imaging part <NUM>, and a second imaging part <NUM>.

The first bonding roller <NUM> is a cylindrical member having an outer peripheral surface on which the electrode layer base material <NUM> is to be held. The first bonding roller <NUM> rotates about a rotary shaft 51A extending in the width direction DR2. The first bonding roller <NUM> holds the electrode layer base material <NUM> from the first backsheet <NUM>. The outer peripheral surface of the first bonding roller <NUM> may be made of rubber, for example.

The second bonding roller <NUM> is a cylindrical member having an outer peripheral surface on which the subgasket base material <NUM> is to be held. The second bonding roller <NUM> rotates about a rotary shaft 52A extending in the width direction DR2. The second bonding roller <NUM> holds the subgasket base material <NUM> from the second backsheet <NUM>. The first and second bonding rollers <NUM> and <NUM> may be driven rollers to be rotated passively by frictional resistances applied from the electrode layer base material <NUM> and the subgasket base material <NUM> respectively. The first and second bonding rollers <NUM> and <NUM> may rotate actively. Namely, the first and second bonding rollers <NUM> and <NUM> may be rotated by connecting a servo motor not shown in the drawings to the rotary shafts 51A and 52A, and causing the controller <NUM> to control this servo motor.

The second bonding roller <NUM> is arranged parallel to the first bonding roller <NUM>. The suction mechanism <NUM> is a mechanism to suck the subgasket base material <NUM> as a target of holding by the second bonding roller <NUM> on the outer peripheral surface of the second bonding roller <NUM>.

The suction mechanism <NUM> includes a porous member <NUM> formed on the outer peripheral surface of the second bonding roller <NUM>, and a suction unit <NUM> connected to the porous member <NUM>. The porous member <NUM> has many tiny holes and is made of a porous material such as porous carbon or porous ceramic, for example. The porous ceramic is a sintered compact of alumina (Al<NUM>O<NUM>) or silicon carbide (SiC), for example. The porous member <NUM> has a pore diameter of equal to or less than <NUM>, for example, and porosity from <NUM> to <NUM>%, for example.

The porous member <NUM> may be replaced with a metallic member that may be stainless steel such as SUS or iron. In this case, the outer surface of the metallic member is preferably given tiny suction holes by machining. To reduce the occurrence of a suction mark, the diameters of the suction holes are set at equal to or less than <NUM>, for example.

The suction unit <NUM> is configured using a vacuum pump, for example, and is coupled to the porous member <NUM> via a suction pipe. As the suction unit <NUM> is driven, atmosphere in the vicinity of the outer surface of the porous member <NUM> is sucked into the many holes. By doing so, the subgasket base material <NUM> is sucked on the outer peripheral surface of the second bonding roller <NUM> (the outer surface of the porous member <NUM>). Here, the second bonding roller <NUM> holds the subgasket base material <NUM> under suction from the second backsheet <NUM>. In this way, in the present embodiment, the second bonding roller <NUM> is configured as a suction roller.

The bonding roller movement drive part <NUM> moves the second bonding roller <NUM>. The bonding roller movement drive part <NUM> includes an approaching/separating direction drive part 54X and an axis direction drive part 54Y. As shown in <FIG> and <FIG>, the approaching/separating direction drive part 54X moves the second bonding roller <NUM> in a direction of moving closer to the first bonding roller <NUM> (-X direction) and in a direction of moving farther from the first bonding roller <NUM> (+X direction).

The approaching/separating direction drive part 54X includes an X axis table <NUM>, a linear drive mechanism (a linear motor mechanism or a ball screw mechanism, for example) for moving the X axis table <NUM> in the X direction, a guide part for guiding the X axis table in the X direction, etc. The linear drive mechanism of the approaching/separating direction drive part 54X is electrically connected to the controller <NUM> and operates in response to a control signal from the controller <NUM>.

The axis direction drive part 54Y moves the second bonding roller <NUM> in the Y direction parallel to the width direction DR2 (axis direction) in which the rotary shaft 52A of the second bonding roller <NUM> extends. The axis direction drive part 54Y includes a Y axis table <NUM>, a linear drive mechanism (a linear motor mechanism or a ball screw mechanism, for example) for moving the Y axis table <NUM> in the Y direction, a guide part for guiding the Y axis table in the Y direction, etc. The linear drive mechanism of the axis direction drive part 54Y is electrically connected to the controller <NUM> and operates in response to a control signal from the controller <NUM>. The axis direction drive part 54Y is placed on the X axis table <NUM> and moves in the X direction together with the X axis table <NUM>.

The rotary shaft 52A of the second bonding roller <NUM> is coupled to the Y axis table <NUM> of the axis direction drive part 54Y via a coupling member <NUM>. Thus, as the Y axis table <NUM> moves in the Y direction, the second bonding roller <NUM> moves in the Y direction. Furthermore, as the X axis table <NUM> moves in the X direction, the second bonding roller <NUM> moves in the width direction DR2.

The first imaging part <NUM> is arranged in such a manner as to face a surface of the electrode layer base material <NUM> on the +Z side (a surface at the first catalyst layer <NUM>) held on the first bonding roller <NUM>. The second imaging part <NUM> is arranged in such a manner as to face a surface of the subgasket base material <NUM> on the +Z side (a surface at the cover film <NUM>) held on the second bonding roller <NUM>. The first and second imaging parts <NUM> and <NUM> is each configured using one, or two or more cameras with image sensors. The first and second imaging parts <NUM> and <NUM> are electrically connected to the controller <NUM>, and transmit image signals detected by the image sensors to the controller <NUM>.

The first imaging part <NUM> captures an image of the surface of the electrode layer base material <NUM> on the +Z side (namely, the surface at the first catalyst layer <NUM>) held on the first bonding roller <NUM>. The second imaging part <NUM> captures an image of the surface of the subgasket base material <NUM> on the +Z side (namely, the surface at the cover film <NUM>) held on the second bonding roller <NUM>.

The bonding mechanism <NUM> includes a photosensor <NUM> arranged upstream of the transport direction DR1 from the first imaging part <NUM>. The photosensor <NUM> is of a reflective type, for example, and detects light reflected on the first catalyst layer <NUM> of the electrode layer base material <NUM>. The photosensor <NUM> may be of a transmission type, for example. The photosensor <NUM> is electrically connected to the controller <NUM> and outputs a detection signal. On the basis of the detection signal from the photosensor <NUM>, the controller <NUM> determines that the first catalyst layer <NUM> has reached a point of measurement by the photosensor <NUM>. The controller <NUM> can measure the length dimension of the first catalyst layer <NUM> in the X direction (transport direction DR1) on the basis of a distance the electrode layer base material <NUM> has traveled from the start of detection of the first catalyst layer <NUM> to the end of the detection by the photosensor <NUM>.

As shown in <FIG>, the controller <NUM> functions as a first position measuring part <NUM> and a second position measuring part <NUM>. The first and second position measuring parts <NUM> and <NUM> are functions realized as software by causing the processor <NUM> to execute the computer program P. The first and second position measuring parts <NUM> and <NUM> may be hardware configurations such as application-specific integrated circuits.

<FIG> is a plan view schematically showing the membrane electrode assembly <NUM> on the electrode layer base material <NUM>. The first position measuring part <NUM> determines the position of the electrode layer base material <NUM> on the basis of an image acquired by the first imaging part <NUM>. More specifically, the first position measuring part <NUM> determines the position of the first catalyst layer <NUM> (a position in the transport direction DR1 and a position in the width direction DR2) in the image acquired by the first imaging part <NUM>. As shown in <FIG>, for example, the first position measuring part <NUM> measures the position of a crossing CL1 and the position of a crossing CL2 of a center line LX1 of the first catalyst layer <NUM> in the transport direction DR1 with a side LS1 and a side LS2 respectively of the first catalyst layer <NUM> parallel to the X direction. The position of the center line LX1 may be determined on the basis of the length dimension of the first catalyst layer <NUM> in the X direction, for example. The sides LS1 and LS2 are preferably detected by performing publicly-known image processing such as binarization or edge extraction on the image captured by the first imaging part <NUM>, for example. The first position measuring part <NUM> may determine the center of the positions of the crossings CL1 and CL2 as the position of the first catalyst layer <NUM>.

The first position measuring part <NUM> may detect the four corners <NUM> to <NUM> (see <FIG>) or the four sides of the first catalyst layer <NUM>, and determine the position of the first catalyst layer <NUM> on the basis of the positions of these portions.

The second position measuring part <NUM> determines the position of the subgasket base material <NUM> on the basis of an image acquired by the second imaging part <NUM>. More specifically, the second position measuring part <NUM> detects the cut-out portion 9C formed in the subgasket base material <NUM> in the image acquired by the second imaging part <NUM>. Then, on the basis of the detected position, the second position measuring part <NUM> determines the position of the cut-out portion 9C (a position in the transport direction DR1 and a position in the width direction DR2).

As shown in <FIG>, while bonding is not performed between the first and second bonding rollers <NUM> and <NUM>, the first and second bonding rollers <NUM> and <NUM> are separated from each other in the X direction. In this state, the electrode layer base material <NUM> and the subgasket base material <NUM> are aligned with each other. As shown in <FIG>, for implementation of bonding between the first and second bonding rollers <NUM> and <NUM>, the first and second bonding rollers <NUM> and <NUM> are moved closer to each other. At a bonding position LA1 where the first and second bonding rollers <NUM> and <NUM> are at positions closest to each other, the electrode layer base material <NUM> and the subgasket base material <NUM> are bonded to each other to form a bonded body. In the gasket applicator <NUM>, immediately after the bonded body is formed at the bonding position LA1, the first backsheet <NUM> is detached from the electrode layer base material <NUM>. By doing so, the assembly sheet with subgasket <NUM> is obtained including the membrane electrode assemblies <NUM> at regular intervals (shown in <FIG>). The assembly sheet with subgasket <NUM> is carried in a transport direction DR4 and collected on the sheet collection roller <NUM>.

<FIG> shows a flow of the bonding process performed by the bonding mechanism <NUM>. First, the first transport mechanism <NUM> transports the electrode layer base material <NUM> in the +X direction. By doing so, the first catalyst layer <NUM> as a bonding target (namely, the adopted region 8A1) is detected by the photosensor <NUM>. The controller <NUM> stores start time of the detection into the memory <NUM>. The controller <NUM> may store a movement amount of the electrode layer base material <NUM> into the memory <NUM> as the length dimension of the first catalyst layer <NUM> in the X direction by which the electrode layer base material <NUM> has moved from the start time of the detection to finish time of the detection when detection of the first catalyst layer <NUM> is finished.

When the first catalyst layer <NUM> reaches a position of imaging by the first imaging part <NUM>, the controller <NUM> stops transport of the electrode layer base material <NUM> by the first transport mechanism <NUM> (step S21). Then, the first position measuring part <NUM> of the controller <NUM> determines the position of the first catalyst layer <NUM> on the basis of an image acquired by the first imaging part <NUM> (step S22).

When the cut-out portion 9C reaches a position of imaging by the second imaging part <NUM>, the controller <NUM> stops transport of the subgasket base material <NUM> by the second transport mechanism <NUM> (step S23). Then, the second position measuring part <NUM> of the controller <NUM> determines the position of the cut-out portion 9C (corresponding region 9A1) on the basis of an image acquired by the second imaging part <NUM> (step S24).

The controller <NUM> performs the processes in step S23 and step S24 in parallel with the processes in step S21 and step S22.

Next, the controller <NUM> performs the positioning process (step S25). Specifically, to compensate for positional deviation between the first catalyst layer <NUM> and the cut-out portion 9C in the width direction DR2 (axis direction), the controller <NUM> controls the axis direction drive part 54Y to move the second bonding roller <NUM> in the width direction DR2 (axis direction).

To compensate for positional deviation between the first catalyst layer <NUM> and the cut-out portion 9C in each of the transport directions DR1 and DR3, the controller <NUM> controls the first or second transport mechanism <NUM> or <NUM>. As a result, one of the electrode layer base material <NUM> and the subgasket base material <NUM> is transported. By doing so, the first catalyst layer <NUM> and the cut-out portion 9C can be aligned with each other at the bonding position LA1 (contact position) in the bonding mechanism <NUM>.

When the positioning process in step S25 is finished, the controller <NUM> moves the second bonding roller <NUM> closer to the first bonding roller <NUM> (step S26). By doing so, the electrode layer base material <NUM> and the subgasket base material <NUM> are brought into contact with each other at the bonding position LA1 between the first and second bonding rollers <NUM> and <NUM>.

Next, the controller <NUM> restarts to transport the electrode layer base material <NUM> and the subgasket base material <NUM> using the first and second transport mechanisms <NUM> and <NUM>. As a result, bonding between the electrode layer base material <NUM> and the subgasket base material <NUM> is started at the bonding mechanism <NUM>. As a result of the positioning process in step S25, this bonding proceeds while the first catalyst layer <NUM> (adopted region 8A1) and the cut-out portion 9C (corresponding region 9A1) are aligned with each other.

In the gasket applicator <NUM> of the present embodiment, the subgasket base material <NUM> can be held fixedly under suction by the second bonding roller <NUM> moving in the width direction DR2 (axis direction). This makes it possible to reduce the occurrence of positional deviation of the subgasket base material <NUM> on the second bonding roller <NUM> to be caused when the second bonding roller <NUM> is moved in the width direction DR2. As a result, it becomes possible to align the electrode layer base material <NUM> and the subgasket base material <NUM> with each other with higher accuracy in the width direction DR2, thereby allowing the subgasket base material <NUM> to be applied favorably to the electrode layer base material <NUM>.

The second bonding roller <NUM> for holding the subgasket base material <NUM> under suction is moved in the approaching/separating direction relative to the first bonding roller <NUM>. This makes it possible to reduce the occurrence of positional deviation of the subgasket base material <NUM> on the second bonding roller <NUM> to be caused when the second bonding roller <NUM> is moved in the approaching/separating direction.

In the present embodiment, the suction mechanism <NUM> is provided for the second bonding roller <NUM> to hold the subgasket base material <NUM>. However, this is not an absolute necessity. Specifically, the porous member <NUM> may be formed on the outer peripheral surface of the first bonding roller <NUM> to hold the electrode layer base material <NUM>, and the electrode layer base material <NUM> may be held under suction on the first bonding roller <NUM>. In another case, the bonding roller movement drive part <NUM> may be coupled to the first bonding roller <NUM> to move the first bonding roller <NUM> in the axis direction (width direction DR2) and in the approaching/separating direction (X direction).

Claim 1:
A manufacturing device (<NUM>) for a membrane electrode assembly (<NUM>) comprising:
a suction stage (<NUM>) that sucks an electrode layer base material (<NUM>) from an elongated strip-shaped first backsheet (<NUM>), said electrode layer base material (<NUM>) including said first backsheet (<NUM>), an electrolyte membrane (<NUM>), and a first catalyst layer (<NUM>) provided on a part of a surface of said electrolyte membrane (<NUM>) arranged in the order named;
a cylindrical rotary die cutter (<NUM>) with a blade (<NUM>) used for forming a cut-out portion (8C) in said electrode layer base material (<NUM>) along a cutting target line (8T) around said first catalyst layer (<NUM>);
a rotary drive part (<NUM>) that rotates said rotary die cutter (<NUM>) about a rotary shaft (31A); and
a movement drive part (<NUM>) that moves said rotary die cutter (<NUM>) relative to said suction stage (<NUM>) to a half-cut position (L12) where said blade (<NUM>) reaches an intermediate portion of said first backsheet (<NUM>) in a thickness direction at said electrode layer base material (<NUM>) sucked by said suction stage (<NUM>) when said rotary die cutter (<NUM>) rotates.