Manufacturing method of gas diffusion layer

Abstract

A gas diffusion layer, a manufacturing apparatus and a manufacturing method thereof are provided. The gas diffusion layer having different hydrophilic/hydrophobic structure and channel therein can be manufactured quickly and easily by using a coating mask. The gas diffusion layer is used in various fuel cells to enhance the ability of water management and to solve the problem of flooding at the cathode, the problem of water deficit at the anode, and the problem of gas transfer. The gas diffusion layer includes a gas diffusion medium having a first property and a micro porous layer having a second property. The micro porous layer is formed on one surface of the gas diffusion medium. The micro porous layer has a plurality of channel layers penetrating the gas diffusion medium. One of the first property and the second property is hydrophilic, and the other is hydrophobic.

1 . A manufacturing method of a gas diffusion layer, comprising:
 providing a coating mask having a plurality of through holes therein;   disposing a gas diffusion medium on the coating mask;   forming a first micro porous layer slurry on the gas diffusion medium;   performing a penetrating step to penetrate the first micro porous layer slurry into the gas diffusion medium, and to run through the gas diffusion medium, wherein the part of the gas diffusion medium where the first micro porous layer slurry penetrates through is corresponding to the through holes of the coating mask; and   performing a first heating and sintering step to remove a solution in the first micro porous layer slurry, so as to form a first micro porous layer having a plurality of channel layers.   
     
     
         2 . The manufacturing method of the gas diffusion layer as claimed in  claim 1 , further comprising forming a second micro porous layer on the gas diffusion medium, before the step of forming the first micro porous layer slurry on the gas diffusion medium. 
     
     
         3 . The manufacturing method of the gas diffusion layer as claimed in  claim 1 , wherein the step of forming the second micro porous layer on the gas diffusion medium comprises:
 forming a second micro porous layer slurry on the gas diffusion medium; and   performing a second heating and sintering step, to remove the solution in the second micro porous layer slurry, so as to form the second micro porous layer.   
     
     
         4 . The manufacturing method of the gas diffusion layer as claimed in  claim 1 , wherein the first micro porous layer slurry and the second micro porous layer slurry comprise a carbon material having a high conductivity, a dispersing agent, a solution and hydrophile/hydrophobicizer. 
     
     
         5 . The manufacturing method of the gas diffusion layer as claimed in  claim 1 , wherein the through holes of the coating mask are arranged regularly or irregularly. 
     
     
         6 . The manufacturing method of the gas diffusion layer as claimed in  claim 1 , wherein the material of the gas diffusion medium comprises a porous material. 
     
     
         7 . The manufacturing method of the gas diffusion layer as claimed in  claim 1 , wherein a pattern constituted by the channel layers depends upon a pattern constituted by the through holes. 
     
     
         8 . The manufacturing method of the gas diffusion layer as claimed in  claim 1 , wherein the penetrating step comprises fixing the gas diffusion medium and making the micro porous layer slurry be penetrated into the gas diffusion medium under the effect of a suction. 
     
     
         9 . The manufacturing method of the gas diffusion layer as claimed in  claim 8 , wherein the coating mask is disposed on an opening of a vacuum chamber body; and
 in the penetrating step, a vacuum pump is used to produce the suction in the vacuum chamber body.