Apparatus for manufacturing membrane-electrode assembly for fuel cell and membrane-electrode assembly manufactured using the same

Abstract

An apparatus for manufacturing a membrane-electrode assembly for a fuel cell is provided. The apparatus includes a sub-gasket feeding unit that forms first electrode windows, unrolls a first sub-gasket sheet, and supplies the sheet to a transfer line. An electrode membrane loading unit installed over the transfer line forms electrode catalyst layers on both faces of an electrolyte membrane, collects the electrode membrane sheet cut, and loads the sheets onto first electrode windows. A sub-gasket loading unit installed over the transfer line forms second electrode windows, collects a second sub-gasket sheet, and loads the sheets on the electrode membrane sheet. MEA bonding units installed on the transfer line bond the first sub-gasket sheet, the electrode membrane sheet, and the second sub-gasket sheet mutually stacked while passing the first sub-gasket sheet, the electrode membrane sheet, and the second sub-gasket sheet between a pair of hot rollers along the transfer line.

1 - 15 . (canceled) 
     
     
         16 . A membrane-electrode assembly for a fuel cell manufactured by an apparatus for manufacturing a membrane-electrode assembly according to claim  1  using a roll-to-roll and a sheet loading method, wherein
 electrode catalyst layers are formed on both faces of an electrolyte membrane and sub-gaskets are respectively formed on edge sides of the electrode catalyst layers, and 
 an end of the electrolyte membrane protrudes into a partial region between the sub-gaskets. 
 
     
     
         17 . The membrane-electrode assembly of  claim 16 , wherein a bonding unit configured to fix the electrolyte membrane and the electrode catalyst layers is formed in remaining regions between the sub-gaskets. 
     
     
         18 . The membrane-electrode assembly of  claim 16 , wherein the end of the electrolyte membrane protrudes into a partial region that belongs to an entire region between the sub-gaskets and is about 33% of the entire region. 
     
     
         19 . A membrane-electrode assembly for a fuel cell manufactured by an apparatus for manufacturing a membrane-electrode assembly using a roll-to-roll and a sheet loading method, wherein
 electrode catalyst layers are formed on both faces of an electrolyte membrane and sub-gaskets are respectively formed on edge sides of the electrode catalyst layers, and   an end of the electrolyte membrane protrudes into a partial region between the sub-gaskets.   
     
     
         20 . The membrane-electrode assembly of  claim 19 , wherein a bonding unit configured to fix the electrolyte membrane and the electrode catalyst layers is formed in remaining regions between the sub-gaskets. 
     
     
         21 . The membrane-electrode assembly of  claim 19 , wherein the end of the electrolyte membrane protrudes into a partial region that belongs to an entire region between the sub-gaskets and is about 33% of the entire region. 
     
     
         22 . The membrane-electrode assembly of  claim 16  wherein the apparatus for manufacturing a membrane-electrode assembly for a fuel cell comprises:
 a sub-gasket feeding unit configured to consecutively form first electrode windows to space the first windows apart from each other at particular intervals, unroll a first sub-gasket sheet wound in a roll form, and supply the first sub-gasket sheet to a transfer line; 
 an electrode membrane loading unit installed over the transfer line and configured to form electrode catalyst layers on both faces of an electrolyte membrane, collect the electrode membrane sheet cut in a unit form, and load the electrode membrane sheets onto the first electrode windows of the first sub-gasket sheet; 
 a sub-gasket loading unit installed over the transfer line and configured to form second electrode windows, collect a second sub-gasket sheet cut in a unit form, and load the second sub-gasket sheets on the electrode membrane sheet; and 
 membrane-electrode assembly (MEA) bonding units installed on upper and lower sides of the transfer line and configured to bond together the first sub-gasket sheet, the electrode membrane sheet, and the second sub-gasket sheet mutually stacked while passing the first sub-gasket sheet, the electrode membrane sheet, and the second sub-gasket sheet between a pair of hot rollers along the transfer line. 
 
     
     
         23 . The membrane-electrode assembly of  claim 22  wherein the apparatus for manufacturing a membrane-electrode assembly further comprises an MEA rewinder installed in a rear of the MEA bonding units and configured to wind an MEA sheet to which the electrode membrane sheet and the second sub-gasket sheet are bonded on the first sub-gasket sheet by the MEA bonding units in a roll form. 
     
     
         24 . The membrane-electrode assembly of  claim 23  wherein the apparatus for manufacturing a membrane-electrode assembly further comprises a film rewinder installed on a part of the sub-gasket feeding unit and configured to recover a protection film of the first sub-gasket sheet and wind the protection film in a roll form; and
 a film unwinder installed on a part of the MEA rewinder and configured to unroll the protection film of a roll form and supply the unrolled protection film to the MEA sheet. 
 
     
     
         25 . The membrane-electrode assembly of  claim 22  wherein the apparatus for manufacturing a membrane-electrode assembly further comprises an electrostatic generator installed over the transfer line and configured to generate static electricity in the first sub-gasket sheet to attach the second sub-gasket sheet loaded onto the electrode membrane sheet to the first sub-gasket sheet using the static electricity. 
     
     
         26 . The membrane-electrode assembly of  claim 19  wherein the apparatus for manufacturing a membrane-electrode assembly for a fuel cell comprises:
 a first sub-gasket feeding unit configured to unroll a first sub-gasket sheet wound in a roll form and supply the first sub-gasket sheet to a transfer line; 
 a first cutting unit installed on a part of the first sub-gasket feeding unit and configured to consecutively form first electrode windows in the first sub-gasket sheet fed through the first sub-gasket feeding unit to space the first electrode windows apart from each other at particular intervals; 
 an electrode membrane loading unit installed over the transfer line and configured to form electrode catalyst layers on both faces of an electrolyte membrane, collect an electrode membrane sheet cut in a unit form, and load the electrode membrane sheets onto the first electrode windows of the first sub-gasket sheet; 
 a second sub-gasket feeding unit installed extraneous to the transfer line and configured to unroll a second sub-gasket sheet wound in a roll form and supply the second sub-gasket sheet to the electrode membrane sheet; 
 a second cutting unit installed on a part of the second sub-gasket feeding unit and configured to consecutively form second electrode windows in the second sub-gasket sheet fed through the second sub-gasket feeding unit to space the second electrode windows apart from each other at particular intervals; and 
 membrane-electrode assembly (MEA) bonding units installed extraneous to the transfer line and configured to bond together the first sub-gasket sheet, the electrode membrane sheet, and the second sub-gasket sheet mutually stacked while passing the first sub-gasket sheet, the electrode membrane sheet, and the second sub-gasket sheet between a pair of hot rollers. 
 
     
     
         27 . The membrane-electrode assembly of  claim 26  wherein the apparatus for manufacturing a membrane-electrode assembly further comprises:
 an MEA rewinder installed in a rear of the MEA bonding units and configured to wind an MEA sheet to which the electrode membrane sheet and the second sub-gasket sheet are bonded on the first sub-gasket sheet by the MEA bonding units in a roll form. 
 
     
     
         28 . The membrane-electrode assembly of  claim 27  wherein the apparatus for manufacturing a membrane-electrode assembly further comprises:
 a film rewinder installed on the part of the first sub-gasket feeding unit and configured to recover a protection film of the first sub-gasket sheet and wind the protection film in a roll form; 
 a second film rewinder installed on the part of the second sub-gasket feeding unit and configured to recover a protection film of the second sub-gasket sheet and wind the protection film in a roll form; and 
 
       a film unwinder installed on a part of the MEA rewinder and configured to unroll the protection film of a roll form and supply the unrolled protection film to the MEA sheet.