Separator for fuel cell, method of fabricating the same, and fuel cell electrode assembly

Abstract

Provided are a separator for a fuel cell, a method of manufacturing the same, and a fuel cell electrode assembly, The fuel cell separator includes: a first support formed by accumulating a polymer fiber and having a plurality of first pores; a first ion exchange resin filled in the plurality of first pores of the first support by droplets of the first ion exchange resin obtained by electrospraying the first ion exchange resin on the first support; a second support formed by accumulating a polymer fiber on the first support and having a plurality of second pores; and a second ion exchange resin filled in the plurality of second pores of the second support by droplets of the second ion exchange resin obtained by electrospraying the second ion exchange resin on the second support.

What is claimed is: 
     
         1 . A fuel cell separator comprising:
 a first support having a plurality of first pores;   a first ion exchange resin filled in the plurality of first pores of the first support;   a second support stacked on the first support and having a plurality of second pores; and   a second ion exchange resin filled in the plurality of second pores of the second support.   
     
     
         2 . The fuel cell separator of  claim 1 , wherein the first support and the second support comprise nanofiber membranes having pores of a three-dimensional network structure and formed by accumulating electrospun polymer fibers, respectively. 
     
     
         3 . The fuel cell separator of  claim 1 , wherein the sizes of the first and second pores are in a range of 0.2 μm to 1.5 μm. 
     
     
         4 . The fuel cell separator of  claim 1 , wherein the thicknesses of the first and second supports are each be in a range of 1 μm to 3 μm. 
     
     
         5 . The fuel cell separator of  claim 2 , wherein the polymer fibers are elastic polymer fibers. 
     
     
         6 . The fuel cell separator of  claim 2 , wherein the polymer fibers comprise 20 wt % to 50 wt % of a fiber-forming polymer and 50 wt % to 80 wt % of a heat-resistant polymer. 
     
     
         7 . An electrode assembly for a fuel cell comprising:
 a cathode; an anode; and   a fuel cell separator according to  claim 1 , which is interposed between the cathode and the anode.   
     
     
         8 . A method of manufacturing a separator for a fuel cell comprising the steps of:
 accumulating fibers obtained by electrospinning a spinning solution in which a polymer and a solvent are mixed to obtain a first support having a plurality of first pores in a three-dimensional network structure;   electrospraying a spraying solution in which a first ion exchange resin and a solvent are mixed to thereby spray droplets of the first ion exchange resin on the first support body and fill the droplets of the first ion exchange resin in the plurality of first pores of the first support;   accumulating fibers obtained by electrospinning a spinning solution in which a polymer and a solvent are mixed on the first support to thus form a second support having a plurality of second pores in a three-dimensional network structure; and   electrospraying a spraying solution in which a second ion exchange resin and a solvent are mixed to thereby spray droplets of the second ion exchange resin on the second support body and fill the droplets of the second ion exchange resin in the plurality of second pores of the second support.   
     
     
         9 . The method of  claim 8 , wherein after filling the plurality of second pores of the second support with the droplets of the second ion exchange resin, heat processing or thermal calendering of the first and second supports is further performed. 
     
     
         10 . The method of  claim 8 , wherein a spraying amount of the spraying solution for forming droplets of the ion exchange resin is twice to three times a spinning amount of the spinning solution for forming the first and second supports. 
     
     
         11 . The method of  claim 8 , wherein the sizes of the first and second pores are in a range of 0.2 μm to 1.5 μm. 
     
     
         12 . The method of  claim 8 , wherein the fibers constituting the first and second supports comprise 20 wt % to 50 wt % of a fiber-forming polymer and 50 wt % to 80 wt % of a heat-resistant polymer.