Cartridge and method for handling thin film membranes
A cartridge and a method for handling thin film membranes using a cartridge are disclosed. The cartridge may be used to handle any thin-film material, but is particularly useful in handling the thin membrane materials used in fabricating Membrane Electrode Assemblies (MEA) for fuel cells. In one aspect, the cartridge includes cavities positioned at opposite ends of a frame. The cavities and associated mounting arrangements are adapted to accept spools for dispensing membrane material and drawing it across the frame. The cartridge also includes a removable cover having an aperture through which the membrane material may be accessed and, for example, cut to a desired shape. Aspects also include methods and apparatus for advancing the membrane in the cartridge. Aspects of the present invention provide improved methods and devices that facilitate the handling and assembly of thin film membranes into membrane-containing devices, such as, fuel cells.
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This application contains subject matter that is related to the subject matter of the following applications, each of which is assigned to the same assignee as this application. Each of the below listed applications is hereby incorporated herein by reference in its entirety:
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- U.S. patent application Ser. 10/232,424 filed on 30 Aug. 2002, entitled “METHOD AND APPARATUS FOR TRANSFERRING THIN FILMS FROM A SOURCE POSITION TO A TARGET POSITION”, and published as U.S. application US 20040042789 A1 on 4 Mar. 2004 (Attrny. Ref. 2036.001); and
- PCT application PCT/EP2003/00920 filed on 20 Aug. 2003, entitled “FIXTURES AND METHODS FOR FACILITATING THE FABRICATION OF DEVICES HAVING THIN FILM MATERIALS,” and published as PCT publication WO 2004/021489 A2 on 11 Mar. 2004 (Attrny. Ref. 2036.002).
This invention relates generally to methods and devices used for handling thin films, for example, thin-film membranes. Specifically, the present invention provides methods and devices employing cartridge-type enclosures for handling membranes used in the fabrication of membrane electrode assemblies for fuel cells.
BACKGROUND OF THE INVENTIONThin film-like materials are handled in many different types of industries, for example, in photographic and x-ray film manufacture and processing, membrane manufacture and processing, packaging, printing, and electronics, among others. The thin, flexible, and often fragile nature of film-like materials typically requires special considerations when handling these materials, for example, to prevent tearing, distortion, and breakage, and to ensure proper orientation and alignment during assembly.
One field in which the handling of thin film-like materials is often problematic is the field of fuel cells, for example, during the handling and assembly of electrodes mounted on thin-film gaskets found in Membrane Electrode Assemblies (or MEAs). MEAs typically consist of several layers of thin materials (that is, materials having a thickness of about 0.001 inches) which are assembled with layer-to-layer registration or alignment tolerances of a few thousandths of an inch. In some types of MEAs, the MEA typically includes two layers of gasket material, two electrodes, and one membrane, for example, a proton exchange membrane (PEM). These components are typically cut to appropriate size and assembled with dimensional tolerances of a few thousandths of an inch. Typically, prior art MEA assembly processes consist of several diverse operations that must be performed in a prescribed sequence, typically requiring the materials to be transported between assembly stations during processing. The handling of the components of the MEA, for example, the thin gaskets, the thin electrodes, and the thin membrane is typically hampered by the flexibility and fragility that characterizes these thin materials.
According to the prior art, membranes and the assembly of these membranes into, for example, MEAs, is typically assembled by hand, one at a time. In order for fuel cells to become economically viable it is preferred that the fabrication and assembly of the components of MEAs and the MEAs themselves be automated. However, the transport and registration (that is, alignment) of multiple layers of thin film materials presents a particularly difficult challenge for prior art fabrication methods. Aspects of the inventions shown in published applications US 20040042789 A1 and WO 2004/021489 A2 provide devices and methods for automating the assembly of MEAs. However, the prior art methods and devices for providing membranes, for example, providing membranes to an automated system as disclosed in these applications, limit the effectiveness and ease with which membranes, for example, can be introduced to an automated system.
According to the prior art, membranes are typically provided in an acidic solution in sealed bags, for example, as shown in above-referenced U.S. application 20040042789 A1. Also shown in application US 20040042789 A1, according to the existing art, these bags must typically be opened, for example, by cutting, and the membrane extracted from the bag before the electrode can be handled and assembled to provide an MEA. This extraction of the membrane from the bag is typically cumbersome and detracts from the desire to automate the handling and assembly of, among other things, MEAs. Aspects of the present invention address these and other disadvantages of the prior art by providing methods and devices for providing and handling thin films, for example, membranes. Aspects of the present invention are particularly conducive to the automated assembly of devices having membranes, for example, to the automated assembly of MEAs for use in fuel cells.
SUMMARY OF THE INVENTIONOne aspect of the invention relates to a cartridge for handling a thin film membrane, the cartridge including a frame having a first end and a second end; a first cavity positioned adjacent the first end of the frame comprising a source of the thin film membrane; and a cover mounted above the frame, the cover having an aperture for providing access to the thin film membrane. In one aspect of the invention, the cartridge further comprises a second cavity positioned adjacent the second end of the frame comprising a depository for the thin film membrane.
Another aspect of the invention relates to a method for handling thin film membranes using a cartridge, the cartridge including a frame having a first end and a second end; a first cavity positioned at the first end of the frame comprising a source of the thin film membrane; and a cover mounted above the frame, the cover having an aperture for providing access to the thin film membrane, the method including providing a thin film membrane in the first cavity; extracting the thin film membrane from the first cavity and positioning the thin film membrane beneath the aperture in the cover; and handling the thin film membrane via the aperture in the cover. In one aspect of the invention, extracting the thin film from the first cavity comprises drawing the thin film from a spool mounted in the first cavity. In another aspect of the invention, the cartridge comprises a second cavity positioned adjacent the second end of the frame, and the method further comprises, after handling, forwarding the thin film membrane to the second cavity.
The cartridge may include a frame having a first end and a second end; a first cavity positioned adjacent the first end of the frame; a second cavity positioned adjacent the second end of the frame; a first spool mounted for rotation in the first cavity, the first spool having a thin-film membrane mounted thereon; a second spool mounted for rotation in the second cavity, the second spool adapted to receive the thin-film membrane; and a cover mounted above the frame, the cover having an aperture for providing access to the thin film membrane. In one aspect of the invention, the cartridge further comprises means for conveying the thin film membrane from the first cavity to the second cavity.
These and other embodiments and aspects of the present invention will become more apparent upon review of the attached drawings, description below, and attached claims.
BRIEF DESCRIPTION OF THE DRAWINGSThe subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, both as to organization and method of practice, together with further objects and advantages thereof, may best be understood by reference to the following detailed descriptions of the preferred embodiments and the accompanying drawings in which:
The details and scope of the aspects of the present invention can best be understood upon review of the attached figures and their following descriptions.
The illustration of the various aspects of the present invention shown in the figures is intended to illustrate the aspects of the present invention as clearly as possible. Since some of the structures are relatively thin in cross-section, for example, membrane assembly 15, for the sake of clarity, the dimensions (most notably the thickness) of these structures may be exaggerated, that is, not drawn to scale. The text of this specification provides ranges of dimensions for most structures that should be relied upon when the depictions in the figures are not to scale. Membrane assembly 15 may have a broad range of thickness, according to the present invention, depending upon the type of thin film being handled by cartridge assembly 10. In one aspect of the invention, thin-film membrane 12 may have a thickness that ranges from about 1 micrometer (about 0.00004 inches) to about 500 micrometers (about 0.020 inches), and may typically have a thickness that ranges from about 25 micrometers (about 0.001 inches) to about 200 micrometers (about 0.008 inches).
According to this aspect of the invention, base 14 and cover 16 provide a convenient cartridge assembly 10 for handling membrane assembly 15. For example, when introducing a thin-film membrane 12 to an assembly process, membrane assembly 15 may be provided on spool 26 mounted in first cavity 18. Similar to the handling of photographic film, membrane assembly 15 may be drawn across base 14 and attached to spool 28. Spool 28 may then be rotated to draw membrane assembly 15 from spool 26 across base 14 onto spool 28. After membrane assembly 15 is drawn across base 14, aperture 30 in cover 16 permits access to membrane 12, for example, for processing and removal. For example, in one aspect of the invention, aperture 30 may provide access to a cutting device, for instance, a die-type cutting device, for cutting membrane 12 to a desired size, for example, as indicated by cut membrane section 34. After cutting, cut membrane section 34 may be removed from backing 13 and handled as desired, for example, transported for further processing or installation into an assembly, for example, into an MEA.
In one aspect of the invention, the membrane 12 may be provided in an aqueous medium, for example, an acidic or caustic aqueous medium, for instance, to maintain a desired pH for membrane 12. In this aspect of the invention, base 14, cover 16, spools 26 and 28, and cavities 18 and 22 are made from a corrosion-resistant material, for example, from a corrosion-resistant, such as polyvinylchloride (PVC) plastic or a corrosion-resistant stainless steel, such as, AISI 316 stainless steel. In one aspect of the invention, at least cavity 18 may be provided with a level 17 of aqueous medium, for example, to provide a reservoir of aqueous medium to maintain membrane 12 at the desired acidity or causticity. In one aspect of the invention, membrane 12 may be maintained in an acid medium, for example, a phosphoric acid medium, for instance, a phosphoric acid medium at about a 75% acid concentration.
As shown in
According to one aspect of the invention, base 14 and cover 16 may be metallic or non-metallic. For example, base 14 and cover 16 may be fabricated from one or more of the following metals: iron, steel, stainless steel, aluminum, titanium, nickel, magnesium, or any other structural metal; or base 14 and cover 16 may be fabricated from one or more of the following plastics: nylon, polyethylene (PE), polypropylene (PP), polyester (PE), polytetraflouroethylene (PTFE), acrylonitrile butadiene styrene (ABS), or polyvinylchloride (PVC), among other plastics. In one aspect of the invention, base 14 and cover 16 are made from PVC plastic. In one aspect of the invention, base 14 and cover 16 may be about the same size. For example, in one aspect, base 14 and cover 16 may each have a length of between about 6 inches and about 20 feet, but are typically between about 1 foot and about 5 feet in length. In one aspect, base 14 and cover 16 may each have a width of between about 3 inches and about 10 feet, but are typically between about 1 foot and about 3 feet in width. In one aspect base 14 and cover 16 may each have a thickness of between about 0.125 inches and about 1 foot, but are typically between about 0.25 inches and about 1 inch in thickness.
First cavity 18 and second cavity 22 may comprise any cavity adapted to retain a thin-film membrane. In the aspect of the invention shown in
As shown in FIGS. 2 ands 4, spools 26 and 28 may be mounted, for example, rotatably mounted, in cavities 18 and 22, respectively, by means of spool mounting gussets 46, 48, 50, and 52, respectively. Gussets 46, 48, 50, and 52, may be mounted to base 14 by conventional means, for example, by means of mechanical fasteners or welding. The details of the mounting of spools 26 and 28 are shown and described with respect to
As shown in
Cartridge assembly 10 may also include one or more latches 57. Latches 57 may be used to secure cover 16 to base 14 of cartridge assembly 10. In one aspect of the invention, latches 57 may comprise latches similar to latches 56 above, for example, draw latches having a part number 97-30-163-12 provided by Southco, or its equivalent. As shown in
As shown in
In one aspect of the invention, roller 61 may be a machined shaft. As shown in
As shown in
According to this aspect of the invention endplates 76 and 78 include some means for mounting to base 14, for example, some means for rotatably mounting to base 14. In the aspect of the inventions shown in
As shown in
According to this aspect of the invention, spool-mounting disk 82 is operationally connected to a means for rotating spool mounting disk 82 and thus rotating spool 28. In the aspect shown in
Miscellaneous other hardware may be provided as appropriate to support shaft 86 and disk 82 and to provide uniform operation and minimize leakage. For example, in the aspect shown in
Assembly 75 may also include a spacer ring 93 mounted to gusset 50. Spacer ring 93 may be made from one or more of the materials referenced above with respect to base 14 and cover 16. In one aspect of the invention, spacer ring 93 may be made from PTFE-containing material, for example, Dupont Teflon® PTFE , or its equivalent.
As also shown in
According to one aspect of the invention, disk 82, shaft 86, spacer ring 93, seal housing 95, and bushing 90 may be made of one or more of the materials referenced above with respect to base 14 and cover 16. However, in one aspect of the invention, disk 82 may made from AISI 316 stainless steel; shaft 86 may be made from AISI 316 stainless steel or a surface-hardened mild steel, for example, an Armalite-plated mild steel; spacer ring 93 may be made from a PTFE-containing material, for example, Dupont Teflon® PTFE , or its equivalent; seal housing 95 mat be made from AISI 316 stainless steel; and bushing 90 may be made from AISI 316 stainless steel. Again, one or more of these parts may be specially designed by PMD.
As shown in
According to this aspect of the invention, spool-mounting disk 182 is operationally connected to a means for rotating spool mounting disk 182 and thus rotating spools 26 and 28. In the aspect shown in
Miscellaneous other hardware may be provided as appropriate to support shaft 186 and disk 182 and to provide uniform operation and minimize leakage. For example, in the aspect shown in
As also shown in
In one aspect of the invention, assembly 72 may be spring loaded to permit deflection of spool-mounting disk 182 so that spool-mounting disk 182 may disengage spool 26 or 28 whereby spools 26 and 28 may be removed, for example, for replacement or servicing. According to this aspect of the invention, assembly 72 also includes a spring 197, for example, a coil spring, mounted between spool mounting disk 182 and seal housing 190. In one aspect of the invention, seal hosing 190 may include a recess to aid in positioning or capturing spring 197. According to this aspect of the invention, handle 187 may be used to translate shaft 186 and spool-mounting disk 182 in the direction of arrow 200 whereby disk 182 disengages spool 26 or 28 (not shown). When not deflected, spring 197 biases the position of disk 182 against spool 26 or 28 to ensure engagement between disk 182 and spool 26 or 28. In one aspect of the invention, spring 197 may be a coil spring provided by Lee Spring Company of Brooklyn, N.Y. having a part number LC-063L-5-S, or its equivalent.
According to another aspect of the invention, load handle assembly 72 may also include means for retaining spool-mounting disk 182 in the deflected position, for example, to assist the operator in removing or mounting spool 26 or 28 onto load handle assembly 72. According to one aspect of this invention, assembly 72 includes at lest one pin 201 mounted in gusset 48 or 52, for example, press fit or welded to gusset 48 or 52. In addition, disk 182 may also include at least one aperture or through hole 202 adapted to engage pin 201. For example, in one aspect of the invention, the diameter of through hole 202 on disk 182 may be larger than the maximum diameter of pin 201, and pin 201 may include at least one shoulder or recess 203 having an external dimension less than the maximum diameter of pin 201. According to this aspect of the invention, when disk 182 is compressed against spring 197, pin 201 may be inserted into through hole 202 whereby pin 201 may penetrate through hole 202 and an edge of the shoulder 203 on pin 201 may engage a keyhole of hole 202 whereby disk 182 is retained in the deflected position. With disk 182 retained, the operator may replace or mount a spool 26 or 28 and then, for example, when mounted, the operator may disengage hole 202 from pin 201 whereby disk 182 may engage spool 26 or 28.
According to one aspect of the invention, disk 182, shaft 186, handle 187, bearing housing 189 and seal housing 190 may be made of one or more of the materials referenced above with respect to base 14 and cover 16. However, in one aspect of the invention, disk 182, shaft 186, handle 187, bearing housing 189, and seal housing 190 may be made from AISI 316 stainless steel. Again, one or more of these parts may be designed by PMD.
As shown in
According to this aspect of the invention, spool-mounting disk 282 is operationally connected to a means for limiting the rotation spool-mounting disk 282 and thus limiting the rotation of spool 26. In the aspect shown in
Miscellaneous other hardware may be provided in assembly 70 as appropriate to support shaft 286 and disk 282 and to provide uniform operation. For example, in the aspect shown in
According to this aspect of the invention, assembly 70 may include a piston housing 290 mounted to gusset 46, for example, mounted by means of a plurality of threaded fasteners 291. According to this aspect of the invention, piston housing 290 may include at least one recess 292, typically a plurality of circular recesses 292, for holding at least one piston 293 and at least one spring 294. In one aspect of the invention, at least three pistons 293 and springs 294 are provided. Piston 293 may simply be a cup-type device adapted to mount and translate in recess 292. Spring 294 may be a coil spring, for example, a coil spring sold by Lee Spring Company having the part number LC-035E-6-S, or its equivalent. According to this aspect of the invention, spring 294 compresses piston 293 against the surface of disk 288 to provide at least some friction between piston 293 and disk 288 to provide at least some retarding of the rotation of disk 288. In other words, in this aspect of the invention, payout tensioner assembly 70 provides a disk-brake-like apparatus for limiting the rotation of disk 288, and thus limiting the rotation of shaft 286, disk 282, and the associated spool 26. As a result, according to one aspect of the invention, payout tensioner assembly 70 allows the operator to maintain or control the tension of the membrane assembly 15 dispensed from spool 26.
In addition, according to this aspect, assembly 70 may also include at least one reaction member 295 mounted in gusset 46 to oppose the normal force applied by spring 294 and, if desired, provide one or more additional friction-inducing surfaces on disk 288. In the aspect shown in
According to one aspect of the invention, the compression of spring 294 against disk 288 provides sufficient frictional resistance to the rotation of disk 282 to provide sufficient tension to the membrane assembly 15 mounted in cartridge assembly 10. In one aspect, the desired tension in membrane assembly 15 may be regulated by replacing coil spring 294 with a spring having a higher or lower stiffness. According to another aspect of the invention, the tension in membrane assembly 15 may also be regulated by adjusting the compression applied by spring 294. For example, in one aspect, compression provided by spring 294 may be varied by means of an adjustment screw mounted in housing 290 adapted to vary the compression of spring 294. In another aspect of the invention, the normal force applied by piston 293 may be replaced or supplemented by a pneumatic or hydraulic pressure, for example, applied behind piston 293.
According to one aspect of the invention, disk 282, shaft 286, plate 288, housing 290, piston 293, plate 296, and reaction member 295 may be made of one or more of the materials referenced above with respect to base 14 and cover 16. However, in one aspect of the invention, disk 282 may be made from AISI 316 stainless steel ; shaft 286 may be made from AISI 316 stainless steel; plate 288 may be made from stainless steel, for example, AISI 304; housing 290 may be made from PVC plastic; piston 293 may be made from a PTFE-containing material, such as, Dupont Teflon® PTFE or Saint-Gobain Rulon® PTFE, or their equivalents; plate 296 may be made from PVC plastic; and reaction member 295 may comprise a material having a low coefficient of friction and resistance to corrosion, for example, a plastic material. In one aspect, reaction member 295 may comprise a Rulon-641 flanged bearing provided by McMaster-Carr having a part number 7560K18, or its equivalent.
Vacuum table assembly 300 includes a vacuum surface 302 having a plurality of perforations or holes 304. Holes 304 may have a diameter of between about 0.001 inches and about 0.50 inches and be uniformly or non-uniformly spaced about vacuum surface 302. As is typical, holes 304 are in fluid communication with a source of vacuum (not shown) that may be used to draw and retain a thin film, such as, membrane assembly 15. The source of vacuum may typically provide an under-pressure of about 1 psi to about 2.5 psi below the prevailing atmospheric pressure.
As shown in
According to one aspect of the invention support surface 307 may also include a sealing element 314 and a channel 316 for retaining sealing element 314. Seal element 314 and channel 316 may typically encircle the entire vacuum surface 302. Sealing element 314 may be used to limit or prevent the leakage of liquids, for example, corrosive liquids, which may be present in cartridge assembly 10, for instance, the corrosive liquids used to condition membrane assembly 15. In one aspect of the invention, sealing element 314 comprises an elastomeric sealing element that is corrosion resistant. In one aspect of the invention, sealing element 314 may be a high-temperature Viton rubber tubing provided by McMaster-Carr having a part number 5119K33, or its equivalent.
In another aspect of the invention, support surface 306 may also include a trough 318 positioned between sealing element 314 and raised vacuum surface 302 to collect any fluids that may leak from cartridge assembly 10. Trough 318 may also encircle vacuum surface 302 and may include a collection drain (not shown) through which the fluids may pass for collection, treatment, or disposal.
According to one aspect of the invention, vacuum surface 302, support plate 306, pins 308, support structure 310, base plate 312 may be made of one or more of the materials referenced above with respect to base 14 and cover 16. However, in one aspect of the invention, vacuum surface 302, support plate 306, and pins 308 may be made from AISI 316 stainless steel; support structure 310 may be made from aluminum, for example, nickel-plated 6061 aluminum, or its equivalent; and base plate 312 may be made from AISI 316 stainless steel. Again, one or more of these parts may be designed by PMD.
Membrane cutting station 404 includes a press 410, for example, a hydraulic or pneumatic press, that may be used to cut membrane material to size. As shown most clearly in
In one aspect of the invention, membrane-cutting station 404 may include a convey or for translating the cartridge assembly 10 and vacuum table 300. In one aspect of the invention, cutting station 404 includes one or more screw conveyors 414. In one aspect of the invention, vacuum table 300 may be adapted to engage screw conveyor 414 whereby screw conveyor 414 may translate vacuum table 300 and cartridge assembly 10.
Membrane removal station 406 typically includes at least one robotic arm 416 having arm-end tooling 418. According to one aspect of the invention, arm-end tooling 418 may comprise some means for grasping thin film membranes so that the membrane may be transported to further treatment or handling. In one aspect of the invention, arm-end tooling 418 includes at least one vacuum surface, for example, a vacuum table adapted to remove one or more sections of membrane 12 from cartridge assembly 10. As shown in
According to one aspect of the invention, cartridge assembly 10 and vacuum table 300 may be used in the following manner. First, with reference to
Prior to or after mounting cartridge assembly 10 on vacuum table 300, vacuum table 300 may be engaged with screw conveyor 414. Screw conveyor may then be activated, for example, automatedly or manually, to convey vacuum table 300 and cartridge assembly 10 into membrane cutting station 404. Cartridge assembly 10 may be positioned as desired within station 404 by means of mechanical stops, by means of visual inspection by the operator, by means of positioning sensors, or by means of an automated vision system, among other positioning means. When positioned as desired, press 410 may be activated to apply cutting blade 412 to membrane assembly 15 to cut membrane 12 to the desired dimensions to produce one or more membrane sections, such as, section 34 shown in
After membrane assembly 15 is cut as desired, vacuum table 300 and cartridge assembly 10 may be translated by screw conveyor 414 to membrane removal station 406. When positioned in membrane removal station 406, one or more membrane sections may be removed from cartridge assembly 10 by means of arm-end tooling 418, for example, by means of vacuum. Robotic arm 416 may then transport the one or more membrane sections to further treatment or processing, for example, to assembly into a Membrane Electrode Assembly (MEA), for instance, for a fuel cell. According to one aspect of the invention, arm-end tooling 418 may remove one or more sections of membrane 12 alone from cartridge assembly 10, for example, when die press 410 performs a kiss cut, or one or more sections of membrane 12 may be removed with backing material 13. In one aspect of the invention, arm-end tooling 418 may be adapted to remove only the membrane 12 while leaving backing 13 on vacuum table 300. For example, in one aspect of the invention, during removal of a membrane section in station 406 from cartridge assembly 10, a vacuum may be applied to vacuum table 300 to minimize or prevent the removal of backing 13 from vacuum table 300.
After removal of the one or more membrane sections in membrane removal station 406, screw conveyor 414 may translate cartridge assembly 10 and vacuum table 300 back to cutting station 404, for example, to cut one or more further membrane sections to size. However, according to one aspect of the invention, prior to further cutting, membrane assembly 15 may be advanced in cartridge assembly 10 to expose a new uncut section of membrane assembly 15 to aperture 30. In one aspect of the invention, membrane assembly 15 may be advanced manually, for example, by a human attendant, by rotating load handle assembly 72 or 73. In another aspect of the invention, membrane assembly 15 may be advanced automatedly, for example, by a robotic manipulator or a motor, for example, a stepper motor.
In the aspect of the invention shown in
Drive motor 424 may be any motor capable of transmitting the desired torque in the desired response time. In one aspect of the invention, motor 424 may be a servomotor, for example, a high-performance, low-ripple brushless servomotor provide by KollMorgen, which is a division of Danaher Corporation of Washington, D.C., having a model number MT302a1-R1C1, or its equivalent. Gearbox 426 may be any gear configuration capable of transmitting the desired torque. In one aspect of the invention, gear box 426 may be a right-angled gearbox, for example, a Dyna-Lite Series hypoid gearbox provided by GAM Corporate of Harwood Heights, Ill. having part number DL-N34-050, or its equivalent. Actuator 428 may be any actuator configured to deflect coupling 430, for example, a solenoid actuator, a pneumatic actuator, or a hydraulic actuator. In one aspect of the invention, actuator 428 may be guided-cylinder actuator, for example, a guided-cylinder actuator provided by SMC Corporation of Indianapolis, Indiana having part number MXQ25-30BS, or its equivalent.
According to one aspect of the invention the positioning of cartridge assembly 10 whereby spline 87 of driven spline take-up assembly 75 may be aligned with extendable drive coupling 428 by various means. For example, the position of cartridge assembly 10 may be controlled by means of mechanical stops, by means of visual inspection by the operator, by means of positioning sensors, or by means of an automated vision system, among other positioning means.
Handling system 400 may include appropriate monitoring and control devices that are not disclosed in FIGS. 30 trough 32. For example, though in one aspect of the invention stations 404 and 406 may be visually monitored and manually manipulated by a human attendant, in one aspect of the invention, at least some of the monitoring and manipulation performed by handling system 400 may be automated and controlled by one or more electronic controllers, for example, a PC-based controller or a distributed control system. Preferred methods and devices for monitoring and controlling the operation of handling system 400 will be apparent to those of ordinary skill in the automation field.
The present invention provides device and methods for handling thin film materials. Aspects of the present invention provide for the handling of thin film materials when introducing thin films to fabrication or assembly processes, for example, the assembly of Membrane Electrode Assemblies, for instance, for the fabrication of fuel cells. The present invention is especially useful when automating the assembly of such devices, which according to prior art methods, can typically only be processed individually by hand. The present invention facilitates the manufacture of such membrane-containing devices wherein such devices can be produced more quickly and more economically than when using prior art devices or methods. Thus, by employing aspects of the present invention, such devices can be made commercially available at reasonable cost where otherwise such devices would be too expensive to commercially produce. Though aspects of the invention were described as they apply to the handling of thin-film membrane materials, such as, fuel cell membranes, it will be readily apparent to those of skill in the art that aspects of the invention may be applied any thin film-like materials.
While the invention has been particularly shown and described with reference to preferred embodiment, it will be understood by those skilled in the art that various changes in form and details may be made to the invention without departing from the spirit and scope of the invention described in the following claims.
Claims
1. A cartridge for handling a thin film membrane, the cartridge comprising:
- a frame having a first end and a second end;
- a first cavity positioned adjacent the first end of the frame comprising a source of the thin film membrane; and
- a cover mounted above the frame, the cover having an aperture for providing access to the thin film membrane.
2. The cartridge as recited in claim 1, wherein the cartridge further comprises a second cavity positioned adjacent the second end of the frame comprising a depository for the thin film membrane.
3. The cartridge as recited in claim 1, wherein the cartridge further comprises a first spool mounted in the first cavity, the first spool adapted to provide the thin film membrane thereon.
4. The cartridge as recited in claim 2, wherein the cartridge further comprises a second spool mounted in the second cavity, the second spool adapted to accept the thin film membrane.
5. The cartridge as recited in claim 1, wherein the frame further comprises an aperture positioned opposite the aperture in the cover.
6. The cartridge as recited in claim 5, wherein the frame aperture is adapted to engage a vacuum table.
7. The cartridge as recited in claim 1, further comprising at least one guide roller positioned between the first end and the second end.
8. The cartridge as recited in claim 1, further comprising at least one wiper assembly positioned between the first end and the second end.
9. The cartridge as recited in claim 1, wherein the thin film membrane comprises a thin film membrane in an acidic solution.
10. The cartridge as recited in claim 1, wherein the cover is pivotally mounted to the frame.
11. A method for handling thin film membranes using a cartridge, the cartridge comprising:
- a frame having a first end and a second end;
- a first cavity positioned at the first end of the frame comprising a source of the thin film membrane; and
- a cover mounted above the frame, the cover having an aperture for providing access to the thin film membrane;
- the method comprising:
- providing a thin film membrane in the first cavity;
- extracting the thin film membrane from the first cavity and positioning the thin film membrane beneath the aperture in the cover; and
- handling the thin film membrane via the aperture in the cover.
12. The method as recited in claim 11, wherein providing a thin film membrane comprises providing a thin film membrane on a spool mounted in the first cavity.
13. The method as recited in claim 12, wherein extracting the thin film from the first cavity comprises drawing the thin film from the spool mounted in the first cavity.
14. The method as recited in claim 11, wherein the cartridge comprises a second cavity positioned adjacent the second end of the frame, and wherein the method further comprises, after handling, forwarding the thin film membrane to the second cavity.
15. The method as recited in claim 11, wherein handling comprises cutting the thin film membrane.
16. The method as recited in claim 15, wherein cutting comprises one of die cutting, laser cutting, and water jet cutting.
17. The method as recited in claim 11, wherein the thin film membrane comprises a thin film membrane mounted on a backing, and wherein handling comprises removing at least some of the thin film membrane from the backing.
18. A cartridge for handling thin-film membranes, the cartridge comprising:
- a frame having a first end and a second end;
- a first cavity positioned adjacent the first end of the frame;
- a second cavity positioned adjacent the second end of the frame;
- a first spool mounted for rotation in the first cavity, the first spool having a thin-film membrane mounted thereon;
- a second spool mounted for rotation in the second cavity, the second spool adapted to receive the thin-film membrane; and
- a cover mounted above the frame, the cover having an aperture for providing access to the thin film membrane.
19. The cartridge as recited in claim 18, further comprising means for conveying the thin film membrane from the first cavity to the second cavity.
20. The cartridge as recited in claim 19, wherein the means for conveying the thin-film membrane comprises automated means for rotating the second spool.
Type: Application
Filed: Jul 30, 2004
Publication Date: Feb 2, 2006
Applicant: Pemeas GmbH (Frankfurt am Main)
Inventor: Raymond Puffer (Watervliet, NY)
Application Number: 10/903,109
International Classification: B65H 18/08 (20060101);