JP2017043857A - Method for producing porous sheet, apparatus for producing porous sheet, fuel cell including porous sheet, and vehicle with fuel cell - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method and apparatus for producing a porous sheet which can provide openings having a uniform shape through uniform arrangement of linear materials, can facilitate continuous production, and can reduce production time.SOLUTION: In a method for producing a porous sheet, a thick yarn group 10 (a first linear material group) is swept by a first movable reed 51 (a fist reed) to arrange thick yarns 11 (first linear materials) in order. A thin yarn group 20 (a second linear material group) is swept by a second movable reed 81 (a second reed) to arrange thin yarns 21 (second linear materials) in order. Then, the thick yarn group arranged in order and the thin yarn group arranged in order are joined by thermal fusion, and whereby a porous sheet 30 is obtained. In the porous sheet, the thick yarns intersect the thin yarns in a plan view. All of the thick yarns in the thick yarn group are present on only one surface side of both surfaces of the thin yarn group and are joined to the thin yarns.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a porous sheet manufacturing method, a porous sheet manufacturing apparatus, a fuel cell including the porous sheet, and a vehicle including the fuel cell. More specifically, the present invention relates to a porous sheet manufacturing method capable of simplifying manufacturing, a porous sheet manufacturing apparatus, a fuel cell including the porous sheet, and a vehicle including the fuel cell.

  As a base material for forming a filter or a gas diffusion layer of a fuel cell, for example, a porous sheet formed from a plurality of wires is used. Patent Document 1 describes a carbon cloth produced by knitting weft and warp as a porous sheet used for a base material of a gas diffusion layer.

JP 2003-173789 A

  However, when creating a porous sheet, if a plurality of wires are arranged on a plane, it is difficult to regulate or maintain the spacing between the wires to an appropriate size due to the action of intermolecular force or static electricity. . If a porous sheet with unevenness in the distribution of the wire is used as the base material of the gas diffusion layer, for example, power density is concentrated, and the durability and output stability of the fuel cell are hindered.

  When creating a porous sheet by knitting one wire group and the other wire group, there is a problem that continuous production is difficult and production time is long because a knitting operation is required.

  Accordingly, an object of the present invention is to produce a porous sheet that can be provided with openings having a uniform shape through uniform arrangement of wire rods, can easily achieve continuous production, and can reduce production time. It is to provide a method and an apparatus for producing a porous sheet. It is another object of the present invention to provide a fuel cell including the porous sheet and a vehicle including the fuel cell.

  In the method for producing a porous sheet according to the present invention that achieves the above object, first, a first group of first wires consisting of a set of first wires arranged side by side is prepared, and a first set of the arranged first arranged A second wire group consisting of two wires is prepared. The second wire is formed from a resin fiber having a core-sheath structure, and the sheath layer has a lower melting point than the core layer.

  The first wire group is pulled out and fixed through at least one first drawing. The first wire group is scanned at least once by the first scissors.

  The second wire group is pulled out through at least one second rod and fixed without being brought into contact with the first wire group. The second wire group is scanned at least once by the second scissors.

  An area scanned by the first ridge in the first wire group and an area scanned by the second ridge in the second wire group are the first wire and the second wire. Are brought into contact with each other so as to intersect with each other in plan view.

  The first wire group and the second wire group are joined by cooling and solidifying the sheath layer of the second wire after heating and melting.

  Then, at least one of the first wire group and the second wire group is cut at a non-joined portion where the first wire group and the second wire group are not joined.

  By this procedure, the first wire rod and the second wire rod intersect in plan view, but all the first wire rods in the first wire rod group are one of both surfaces of the second wire rod group. The porous sheet which exists only in the surface side and is joined to the said 2nd wire is obtained.

  In the porous sheet manufacturing apparatus according to the present invention, with respect to the first wire group, the first supply unit that supplies the first wire group, the first fixing unit, and at least one first Has a bag. The second wire group includes a second supply unit that supplies the second wire group, a second fixing unit, and at least one second rod. The first wire rod group is composed of a set of first wire rods arranged side by side. The first fixing portion is configured to be able to pull out and fix the first wire group. At least one first rod is passed through the first wire group fixed to the first fixing portion so as to be freely scanned. The second wire group consists of a set of second wires arranged side by side. The second wire has a core-sheath structure, and the sheath layer has a lower melting point than the core layer. The second fixing portion is configured to be fixed without pulling out the second wire group and bringing it into contact with the first wire group. At least one second rod is passed through the second wire rod group fixed to the second fixing portion so as to be freely scanned. The manufacturing apparatus further includes a joining portion and a cutting portion. The bonding portion includes a region scanned by the first ridge in the first wire group, and a region scanned by the second ridge in the second wire group, and the first wire and the The second wire rods are overlapped and brought into contact with each other in plan view, and the sheath layer of the second wire rod is heated and melted to join the first wire rod group and the second wire rod group. . The cutting section cuts at least one of the first wire group and the second wire group at a non-joined portion where the first wire group and the second wire group are not joined. And the manufacturing apparatus of a porous sheet WHEREIN: Although the said 1st wire and the said 2nd wire cross in planar view, all the said 1st wire in the said 1st wire group is the said 2nd wire. A porous sheet that is present only on one side of the two surfaces of the group and is bonded to the second wire is obtained.

  A fuel cell according to the present invention that achieves the above object includes the porous sheet described above.

  A vehicle according to the present invention that achieves the above object includes the fuel cell described above.

  According to the method for manufacturing a porous sheet and the apparatus for manufacturing a porous sheet according to the present invention, the first wire group is scanned with the first scissors to reduce the action of intermolecular force, static electricity and the like. The first wire can be knitted, and the second wire can be knitted by scanning the second group of wires with the second scissors to reduce the action of intermolecular force, static electricity, and the like. Thereafter, the first wire group that has been knitted and the second group of wire that has been knitted are joined by thermal fusion to obtain a porous sheet. In the porous sheet, the first wire rod and the second wire rod intersect in plan view, but all the first wire rods in the first wire rod group are on one surface side of both surfaces of the second wire rod group. Only present and bonded to the second wire. As a result of reducing the effects of intermolecular force, static electricity, and the like and arranging the first wire and the second wire uniformly, a porous sheet having a uniform opening can be obtained. Furthermore, since the first wire and the second wire are not knitted, the operation of knitting is unnecessary, continuous production is facilitated, and the manufacturing time can be shortened.

  Since the fuel cell according to the present invention includes the porous sheet manufactured as described above, the performance of the parts to which the porous sheet is applied can be improved, and the cost of the entire fuel cell can be reduced through the reduction of the parts cost. Can be reduced.

  Since the vehicle according to the present invention includes the fuel cell including the porous sheet manufactured as described above, the vehicle is excellent in in-vehicle performance, productivity, and cost.

FIG. 1A is a perspective view showing a porous sheet formed from a first wire and a second wire, and FIG. 1B shows a second wire formed from resin fibers having a core-sheath structure. FIG. 1C, which is a cross-sectional view, is an enlarged cross-sectional view illustrating a bonding state between the first wire and the second wire. FIG. 2 is a perspective view showing a schematic configuration of a porous sheet manufacturing apparatus. FIG. 3 is a configuration diagram showing a first processing line for processing the first wire group in the porous sheet manufacturing apparatus. FIG. 4 is a configuration diagram illustrating a second processing line for processing the second wire group in the porous sheet manufacturing apparatus. 5A and 5B are perspective views schematically showing a state in which the wire can be uniformly arranged by scanning the wire group with a scissors. FIG. 6 is a flowchart showing an outline of a procedure for producing a porous sheet. FIG. 7 is a diagram showing a processing procedure for the first wire group in the manufacturing procedure of the porous sheet. FIG. 8 is a diagram illustrating a processing procedure for the first wire group subsequent to FIG. 7. FIG. 9 is a diagram showing a processing procedure for the first wire group subsequent to FIG. 8. FIG. 10 is a diagram illustrating a processing procedure for the first wire group subsequent to FIG. 9. FIG. 11 is a diagram illustrating a processing procedure for the first wire group following FIG. 10. FIG. 12 is a diagram illustrating a processing procedure for the first wire group subsequent to FIG. 11. FIG. 13: is a figure which shows the process sequence with respect to a 2nd wire rod group among the manufacture procedures of a porous sheet. FIG. 14 is a diagram illustrating a processing procedure for the second wire group subsequent to FIG. 13. FIG. 15 is a diagram illustrating a processing procedure for the second wire group subsequent to FIG. 14. FIG. 16 is a diagram illustrating a processing procedure for the second wire group subsequent to FIG. 15. 17A and 17B are a schematic cross-sectional view and an exploded perspective view showing the basic structure of the fuel cell. 18A and 18B are diagrams showing an example of a vehicle equipped with a fuel cell.

  Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings. However, the technical scope of the present invention should be determined based on the description of the scope of claims, and is not limited to the following embodiments. In the description of the drawings, the same elements are denoted by the same reference numerals, and redundant description is omitted. In addition, the dimensional ratios in the drawings are exaggerated for convenience of explanation, and may be different from the actual ratios.

[Porous sheet 30]
The porous sheet 30 of this embodiment will be described.

  1A and 1C, a porous sheet 30 is formed from a first wire group 10 made of a first wire 11 and a second wire group 20 made of a second wire 21. Has been. Both the first wire 11 and the second wire 21 are formed from resin fibers. In the illustrated embodiment, the first wire 11 is thicker than the second wire 21. The pitch of the adjacent first wire 11 is wider than the pitch of the adjacent second wire 21.

  Referring to FIGS. 1B and 1C, the second wire rod 21 is formed from a resin fiber having a core-sheath structure. The sheath layer 22 has a lower melting point than the core layer 23. The melting point of the first wire 11 is higher than that of the sheath layer 22. The resin fiber forming the second wire rod 21 can be formed from, for example, polyester, polyamide, or polyolefin. Since these materials are inexpensive and excellent in mechanical properties, they are used in various fields as various materials, and the porous sheet 30 can be manufactured at low cost, and desired mechanical properties can be imparted to the porous sheet 30. it can. However, the 2nd wire 21 is not limited to the material mentioned above. The sheath layer 22 and the core layer 23 in the second wire 21 may be formed from different resin materials, but are preferably formed from the same type of resin materials having different melting points. It is because there is little peeling of the layer and the stable second wire 21 can be obtained. Although the 1st wire 11 and the 2nd wire 21 may be formed from a different resin material, it is preferable to form from the same kind of resin material. It is because there is little peeling in the interface which joins the 1st wire 11 and the 2nd wire 21, and a stable joined state can be maintained.

  The diameter of the 1st wire 11, the diameter of the 2nd wire 21, and melting | fusing point are not specifically limited, A desired size and melting | fusing point can be selected. For example, the diameter of the first wire 11 is about 100 to 150 μm, the diameter of the sheath layer 22 in the second wire 21 is about 50 μm, and the diameter of the core layer 23 is about 10 μm. The melting point of the first wire 11, the melting point of the core layer 23 in the second wire 21 is about 190 ° C., and the melting point of the sheath layer 22 is about 160 ° C. However, the diameter and melting point of the wire are not limited to the above-described dimensions and temperature.

  Referring to FIG. 1C, the first wire 11 and the second wire 21 are joined by cooling and solidifying the sheath layer 22 of the second wire 21 after heating and melting. The first wire 11 is slightly crushed in size at the portion that comes into contact with the second wire 21. The melted resin of the sheath layer 22 rises and solidifies by capillary action at the interface between the first wire 11 and the second wire 21 and at the side of the first wire 11 as indicated by reference numeral 24. Thereby, the 1st wire 11 and the 2nd wire 21 are joined.

  In the porous sheet 30, as shown in FIGS. 1A and 1C, the first wire 11 and the second wire 21 intersect each other in plan view. That is, the first wire 11 and the second wire 21 are orthogonal (90 degrees) on the XY plane viewed from the Z axis in FIG. In the porous sheet 30, all the first wire rods 11 in the first wire rod group 10 exist only on one surface side of both surfaces of the second wire rod group 20 and are joined to the second wire rod 21. . That is, on the YZ plane viewed from the X axis in FIGS. 1A and 1C, all the first wire rods 11 exist only on the upper surface side of the upper and lower surfaces of the second wire rod group 20, and the second It is joined to the wire 21.

  In the present specification, the term “intersection” is used to indicate that the first wire 11 and the second wire 21 are not arranged in parallel and are in a crossed state in plan view. The intersecting angle is not limited to being orthogonal (90 degrees). Therefore, the opening defined by the first wire 11 and the second wire 21 is not limited to a rectangular shape, and may be a rhombus shape. Further, “all the first wire rods 11 in the first wire rod group 10 are present only on one side of both surfaces of the second wire rod group 20” means that the first wire rod 11 and the second wire rod. 21 is not knitted.

  In the following description, “first wire 11” is “thick yarn 11”, “first wire group 10” is “thick yarn group 10”, and “second wire 21” is “thin yarn 21”. , “Second wire group 20” may be referred to as “thin yarn group 20”.

[Porous sheet 30 manufacturing apparatus 100]
The manufacturing apparatus 100 of the porous sheet 30 of this embodiment which embodied the manufacturing method of the porous sheet 30 is demonstrated.

  With reference to FIGS. 2, 3, and 4, the manufacturing apparatus 100 of the porous sheet 30 can be summarized as a first reel 41 (a first reel 41 that supplies the thick yarn group 10 with respect to the thick yarn group 10 (first wire group). 1st supply part), pinch 61, 62, 63, 64, 65 (1st fixing | fixed part), and at least 1 1st collar 51 are provided. Regarding the fine yarn group 20 (second wire group), at least a second reel 71 (second supply unit) for supplying the fine yarn group 20, pinches 91, 92, 93, 94 (second fixing unit), and at least One second rod 81 is provided. The thick yarn group 10 includes a set of thick yarns 11 (first wire rods) arranged side by side. The first fixing portion is configured so that the thick yarn group 10 can be pulled out and fixed. The first hook 51 is passed through the thick yarn group 10 fixed to the first fixing portion so as to be freely scanned. The fine yarn group 20 includes a set of fine yarns 21 (second wire rods) arranged side by side. The thin yarn 21 has a core-sheath structure, and the sheath layer 22 has a lower melting point than the core layer 23. The second fixing portion is configured to be freely fixed without pulling out the thin yarn group 20 and bringing it into contact with the thick yarn group 10. The second ridge 81 is passed through the thin yarn group 20 fixed to the second fixing portion so as to be freely scanned. The manufacturing apparatus 100 further includes a joining portion and a cutting portion. The joining portion includes a first heater 67, a pressurizing mechanism 68, a second heater 96, a pressurizing mechanism 97, and the like. The cutting part is composed of a cutter 66. The joining portion intersects the area scanned by the first ridge 51 in the thick thread group 10 and the area scanned by the second ridge 81 in the thin thread group 20 when the thick thread 11 and the fine thread 21 intersect in plan view. Make contact with each other. The joining portion joins the thick yarn group 10 and the fine yarn group 20 by heating and melting the sheath layer 22 of the fine yarn 21. The cutting part cuts at least one of the thick yarn group 10 and the fine yarn group 20 at a non-joined portion where the thick yarn group 10 and the fine yarn group 20 are not joined. In the porous sheet manufacturing apparatus, the thick yarn 11 and the fine yarn 21 intersect in plan view, but all the thick yarns 11 in the thick yarn group 10 exist only on one side of both surfaces of the fine yarn group 20. Thus, a porous sheet 30 joined to the fine yarn 21 is obtained. Hereinafter, the manufacturing apparatus 100 of the porous sheet 30 will be described in detail.

  The porous sheet 30 manufacturing apparatus 100 includes a first processing line 101 for processing the thick yarn group 10 and a second processing line 102 for processing the fine yarn group 20. The first processing line 101 and the second processing line 102 are relatively close to and away from each other. For example, the second processing line 102 is configured to be movable up and down toward the first processing line 101. When the thick yarn group 10 and the fine yarn group 20 are joined, the second processing line 102 rises toward the first processing line 101, and a part of the thick yarn group 10 and a part of the fine yarn group 20 overlap. In the illustrated embodiment, the thick yarn group 10 and the fine yarn group 20 are joined, and then the thick yarn group 10 is cut in the first processing line 101. Then, the porous sheet 30 is wound up in the second processing line 102.

  The first processing line 101 includes a first reel 41 around which the thick yarn group 10 is wound, a plurality of guide rollers 42 for guiding the thick yarn group 10 drawn from the first reel 41, and a pair of rotating rollers 43 and 45. And a dancer roller 44 arranged between the pair of rotating rollers 43 and 45 for adjusting the tension, at least one first rod 51 through which the thick yarn group 10 is passed, and presser and release of the thick yarn group 10 A plurality of free pinches 61, 62, 63, 64, 65 and a cutter 66 for cutting the thick yarn group 10 are provided.

  The first reel 41 is rotatably held on a mounting base (not shown). The first reel 41 is replaced with a new reel 41 when the wound thick yarn group 10 is used up.

  The dancer roller 44 feeds the thick yarn group 10 from the first reel 41 while controlling the tension. The dancer roller 44 is movable in the vertical direction.

  The first rod 51 is slidable along a guide rail (not shown) arranged in the direction in which the thick yarn group 10 extends. The first rod 51 is slide-driven by an actuator such as a motor or an air cylinder. The first ridge 51 is configured by arranging ridges at regular intervals like comb teeth. A minute slit 51a is formed between adjacent toothed teeth. A slit 51a is formed in the first hook 51, and only one thick thread 11 is inserted into each slit 51a. The slits 51 a are formed more than the number of thick threads 11 to be inserted or the number of thick threads 11. The thick yarn group 10 is scanned by sliding the first hook 51. At the stage where the thick yarn group 10 is pulled out and fixed, intermolecular forces, static electricity, and the like are acting, so the adjacent thick yarns 11 approach and move away, and the spacing between the thick yarns 11 is regulated to an appropriate size. Or difficult to maintain (see FIG. 5A). From this state, when the thick yarn group 10 is scanned at least once by the first ridge 51, the action of intermolecular force, static electricity, or the like can be reduced, and the thick yarn 11 can be trimmed (see FIG. 5B). ).

  In the illustrated embodiment, a hook 52 through which the thick yarn group 10 is passed is also arranged at a position upstream of the first hook 51. The collar 52 is configured by arranging toothed teeth at regular intervals like a comb tooth. A minute slit 52a is formed between adjacent toothed teeth. The arrangement position of the collar 52 is fixed and does not slide. For convenience of explanation, in the following description, the first rod 51 is also referred to as “first moving rod 51”, and the fixed rod 52 is also referred to as “first fixed rod 52”. The first moving rod 51 is housed in a casing 53 that is slidable.

  When scanning with the first moving rod 51, a planarizing member 55 (see FIGS. 3 and 5) that moves with the rod 51 in order to align the upper surface or the lower surface of the wire group (thick yarn group 10) with the same plane. , Before or after the ridge 51, and at the upper or lower portion of the wire group.

  As such a planarizing member 55, at least one of a contact member that contacts the wire group and presses the wire group, and a non-contact member that presses the wire group without contacting the wire group can be used. Both contact members and non-contact members can be used. Examples of the contact member include a roller, a round bar, and a slider. Examples of the non-contact member include a member that utilizes compressed air, static electricity, and the like. By using a contact member or a non-contact member, it is possible to push in the wire group while preventing problems such as generation of excessive frictional force or cutting of the wire, and to align the upper surface or the lower surface of the wire group on the same plane.

  The upper or lower surface of the minute slit 52a can be used for such a purpose. However, by separately using the planarizing member 55, it is possible to prevent problems such as generation of excessive frictional force and cutting of the wire due to the use of the upper surface or the lower surface of the minute slit 52a.

  As shown in FIG. 5, when a roller that is an example of a contact member is used as the planarizing member 55, it is longer than the width of the thick yarn group 10, just before the first moving rod 51 and on the upper surface of the thick yarn group 10, and The roller 56 which can move simultaneously with the 1 moving rod 51 is provided. Following the scanning by the first moving rod 51, the lower surface of the roller 56 is brought into contact with the upper surfaces of all the wire rods (thick yarns 11), whereby the thick yarn group 10 composed of a good flat surface can be configured. In order to bring the lower surface of the roller 56 into contact with the upper surfaces of all the thick yarns 11, the reference surface (refers to a reference height defined by a guide roller, a rotating roller, a pinch, etc. before and after the first moving rod 51). Therefore, it is necessary to apply an offset by pressing a certain size. Although it is possible for those skilled in the art to appropriately determine the offset amount according to the scale of the apparatus and the ease of sagging of the wire, it is preferably approximately 0.1 mm or more and 50 mm or less. When the offset amount is less than 0.1 mm, the planarizing member 55 may not contact all the wires when the wire is easy to sag. When the offset amount is 50 mm or more, there is a possibility that an unnecessary tension may act on the wire group, which is not preferable.

  The diameter of the roller or round bar is not particularly limited, but is preferably 0.1 mm or more and 100 mm or less. When the diameter of a roller or a round bar is less than 0.1 mm, these and the wire group are easily damaged, which is not preferable. When the diameter of the roller or the round bar is 100 mm or more, the planarizing member 55 becomes too large, and an unnecessary frictional force may act on the wire group, which is not preferable. The contact length when using the slider is also preferably 0.1 mm or more and 100 mm or less.

  The pinch 61 has an upper pinch 61a disposed on the upper side of the thick yarn group 10 and a lower pinch 61b disposed on the lower side of the thick yarn group 10 so as to face the upper pinch 61a. The upper pinch 61a and the lower pinch 61b are driven toward and away from each other by an actuator such as an air cylinder. The thick yarn group 10 is pressed by driving the upper and lower pinches 61a and 61b to approach each other. By pressing the upper and lower pinches 61a and 61b away from each other, the presser of the thick yarn group 10 is released.

  Similarly, the other pinches 62, 63, 64, and 65 have upper pinches 62a, 63a, 64a, and 65a and lower pinches 62b, 63b, 64b, and 65b, respectively. Release is free.

  The second pinch 62 from the upstream side is provided in the casing 53 so as to be positioned immediately downstream of the first moving rod 51. The pinch 62 moves together with the first moving rod 51. The end of the thick yarn group 10 is pressed by the pinch 62, and the thick yarn group 10 is fed out from the first reel 41 by sliding the casing 53 to the downstream side.

  The cutter 66 is disposed on the upper side of the thick yarn group 10 in the illustrated example. The cutter 66 is driven toward and away from the thick yarn group 10 by an actuator such as an air cylinder. The cutter 66 is disposed so as to face a non-joined portion where the thick yarn group 10 and the fine yarn group 20 are not joined. By driving the cutter 66 closer, the thick yarn group 10 is cut at the non-joined portion. By driving the cutter 66 away, the conveying path of the thick yarn group 10 is opened.

  The cutter 66 may be disposed below the thick yarn group 10. The cutter may be composed of an upper cutter disposed on the upper side of the thick yarn group 10 and a lower cutter disposed on the lower side of the thick yarn group 10 so as to face the upper cutter. In this case, the upper cutter and the lower cutter are driven toward and away from each other by an actuator such as an air cylinder. By driving the upper and lower cutters closer, the thick yarn group 10 is cut at the non-joined portion. By driving the upper and lower cutters apart, the transport path of the thick yarn group 10 is opened.

  The form of the cutter 66 is not particularly limited. The cutter 66 is composed of, for example, a cutting blade, a hot blade, or the like. The cutter can also consist of a laser cutter.

  The first processing line 101 is provided with a first heater 67 that generates heat for heating and melting the sheath layer 22 of the thin yarn 21. After a part of the thick yarn group 10 and a part of the fine yarn group 20 are overlapped, the first heater 67 is driven downward and heated to a temperature at which the sheath layer 22 is melted. The first heater 67 may be heated before the thick yarn group 10 and the fine yarn group 20 are overlapped. The type of the first heater 67 is not particularly limited, but an electric heater, a halogen heater, an induction heater, or the like can be used. The heating temperature and heating time of the first heater 67 at the time of joining are appropriately selected according to the melting point and the yarn diameter of the sheath layer 22 of the thin yarn 21 and the thick yarn 11.

  A pressurizing mechanism 68 that presses the first heater 67 against the thick yarn group 10 is connected to the first heater 67. The pressure mechanism 68 is configured by a pressure press, a pressure roller, or the like.

  When the thick yarn group 10 and the fine yarn group 20 are heated, the thick yarn 11 and the fine yarn 21 made of resin fibers show individual behaviors, and variations in the thermal contraction of each individual yarn occur. If the thermal shrinkage varies, the stress acts on the porous sheet 30 after joining the thick yarn group 10 and the fine yarn group 20, resulting in problems such as talmi and cold drawing. Therefore, in order to alleviate the impact of thermal contraction during joining, preferably, the thick yarn group 10 may be subjected to a preheating treatment before the fixed thick yarn group 10 is scanned by the first moving rod 51. The first heater 67 is also used during this preheating process. The heating temperature and heating time of the heater during the preheating treatment are appropriately selected according to the melting point, the yarn diameter, and the like of the thick yarn 11.

  The second processing line 102 includes a second reel 71 around which the fine yarn group 20 is wound, a plurality of guide rollers 72 for guiding the fine yarn group 20 drawn from the second reel 71, and at least the fine yarn group 20 passes therethrough. One second ridge 81, a plurality of pinches 91, 92, 93, 94 that can freely press and release the fine yarn group 20, a winding reference roller 99, and the fine yarn group 20 to which the thick yarn group 10 is joined A take-up reel 95 is provided.

  The second reel 71 is rotatably held on a mounting base (not shown). The second reel 71 is replaced with a new reel 71 when the wound thin yarn group 20 is used up.

  Similar to the first moving rod 51, the second rod 81 is slidable along a guide rail (not shown) arranged in the direction in which the thin yarn group 20 extends. The second rod 81 is slide-driven by an actuator such as a motor or an air cylinder. A slit 81a is formed in the second collar 81, and only one thin thread 21 is inserted into each slit 81a. The slits 81a are formed more than the number of the fine yarns 21 to be inserted or the number of the fine yarns 21. The fine yarn group 20 is scanned by sliding the second hook 81. By scanning the fine yarn group 20 at least once with the second ridge 81, the action of intermolecular force, static electricity, etc. can be reduced and the fine yarn 21 can be knitted.

  In the illustrated embodiment, a hook 82 through which the fine yarn group 20 is passed is also disposed at a position upstream of the second hook 81. In the flange 82, a minute slit 82a is formed between adjacent teeth. The collar 82 has a fixed arrangement position and does not slide. For convenience of explanation, in the following description, the second rod 81 is also referred to as “second moving rod 81”, and the position-fixed rod 82 is also referred to as “second fixed rod 82”.

  Similarly to the first moving rod 51 having the planarizing member 55, the second moving rod 81 can have the planarizing member 85 (see FIG. 4). That is, when scanning with the second moving rod 81, in order to align the upper surface or the lower surface of the wire group (thin yarn group 20) on the same plane, the planarizing member 85 that moves together with the rod 81 is placed in front of the rod 81 or It can be provided at the upper part or the lower part of the wire group.

  When a roller is used as the flattening member 85, for example, a roller 86 that is longer than the width of the fine yarn group 20 and can move simultaneously with the second movable rod 81 immediately before the second moving rod 81 and on the upper surface of the fine yarn group 20 is provided. Prepare. Following the scanning by the second moving rod 81, the lower surface of the roller 86 is brought into contact with the upper surfaces of all the wires (thin yarns 21), whereby the fine yarn group 20 composed of a good flat surface can be formed.

  The pinches 91, 92, 93, and 94 are the same as the pinches 61, 62, 63, 64, and 65 in the first processing line, and the upper pinches 91a, 92a, 93a, and 94a, and the lower pinches 91b, 92b, 93b, and 94b, respectively. The presser of the fine yarn group 20 and the presser release can be freely performed at each position.

  The fine yarn group 20 is wound around the take-up reel 95 without being cut. For this reason, the second processing line 102 is not provided with a pinch that moves together with the second moving rod 81 or a cutter that cuts the fine yarn group 20.

  Also in the second processing line 102, in order to reduce the impact of thermal shrinkage at the time of joining, preferably, before the fixed thin yarn group 20 is scanned by the second moving rod 81, the thin yarn group 20 is preheated. You may give it. A second heater 96 is provided for this preheating treatment. The type of the heater is not particularly limited, but as with the first heater 67, an electric heater, a halogen heater, an induction heater, or the like can be used. The heating temperature and heating time of the second heater 96 during the preheating treatment are appropriately selected according to the melting point, the yarn diameter, and the like of the fine yarn 21. Since the sheath layer 22 of the thin yarn 21 has a lower melting point than that of the thick yarn 11, the temperature of the preheating treatment is set lower than the temperature of the preheating treatment for the thick yarn 11.

  A pressure mechanism 97 that presses the second heater 96 against the thin yarn group 20 is connected to the second heater 96. The pressure mechanism 97 is configured by a pressure press, a pressure roller, or the like.

  In order to heat and melt the sheath layer 22 of the thin yarn 21, the second heater 96 is used together with the first heater 67, or the first heater 67 and the second heater 96 are alternately switched. Or heated only by the second heater 96 instead of the first heater 67.

  In the illustrated example, the dancer roller 44 is not provided in the second processing line 102, but the dancer roller 44 may be provided to adjust the tension.

[Procedure for Producing Porous Sheet 30]
With reference to FIG. 6, the manufacturing procedure of the porous sheet 30 will be outlined.

  First, a thick yarn group 10 consisting of a set of thick yarns 11 arranged side by side is prepared, and a fine yarn group 20 consisting of a set of fine yarns 21 arranged side by side is prepared (step S11).

  The thick yarn group 10 is pulled out and fixed through the first moving rod 51, and the thin yarn group 20 is pulled out through the second moving rod 81 and fixed without contacting the thick yarn group 10 (step S12). When pulling out the thick yarn group 10 from the first reel 41, the dancer roller 44 pulls it out so that too much tension does not act. Since stress does not act on the thick yarn group 10 that is pulled out and fixed, it is possible to prevent the thick yarn group 10 from suffering problems such as talmi and cold drawing.

  The thick yarn group 10 is preheated, and the thin yarn group 20 is preheated (step S13). The impact of heat shrinkage at the time of joining is alleviated, and variation in the heat shrinkage of each thick thread 11 and thin thread 21 is suppressed.

  The thick yarn group 10 is scanned at least once with the first moving rod 51, and the fine yarn group 20 is scanned at least once with the second moving rod 81 (step S14). Actions such as intermolecular force and static electricity are reduced, and the thick yarn 11 and the thin yarn 21 are trimmed.

  A region scanned by the first moving rod 51 in the thick yarn group 10 and a region scanned by the second moving rod 81 in the thin yarn group 20 so that the thick yarn 11 and the fine yarn 21 intersect in plan view. In contact with each other (step S15).

  The thick yarn group 10 and the fine yarn group 20 are joined by heating and melting the sheath layer 22 of the fine yarn 21 and then solidifying it by cooling (step S16). When the thick yarn group 10 and the fine yarn group 20 are joined, the thick yarn 11 and the fine yarn 21 are heated. You may compress, heating. The joining of the thick thread 11 and the thin thread 21 becomes more reliable.

  And the thick yarn group 10 is cut | disconnected in the non-joining part to which the thick yarn group 10 and the fine yarn group 20 are not joined (step S17). The porous sheet 30 is formed in a part of the fine yarn group 20, and the produced porous sheet 30 is wound into a roll shape by winding the fine yarn group 20.

  Returning to step S12, the processing is continued to obtain the porous sheet 30. In the porous sheet 30, the thick yarn 11 and the fine yarn 21 intersect each other in a plan view, but all the thick yarns 11 in the thick yarn group 10 exist only on one side of both surfaces of the fine yarn group 20. 21 is joined.

  Although the porous sheet 30 is heated and compressed in step S16, the porous sheet 30 may be heated and compressed after the cutting in step S17. The heat compression of the porous sheet 30 is performed using a heating press, a heating roll, or other heating and pressing members.

  In step S17, after the thick yarn group 10 is cut, the manufactured porous sheet 30 is wound in a roll shape, but the thin yarn group 20 is also cut and the manufactured porous sheet 30 is laminated in a sheet shape. Good.

[Operation of Manufacturing Device 100 for Porous Sheet 30]
With reference to FIGS. 7 to 12, the operation of the first processing line 101 in the manufacturing apparatus 100 for the porous sheet 30 will be outlined.

  With respect to the first processing line 101, the positions of the first moving rod 51 and the pinch 62 are defined as follows. The position moved to the most upstream side is called “first position P11”, the position moved to the most downstream side is called “third position P13”, and the first and second heaters 67, 96 and the third The position moved between the position P13 and the position P13 is referred to as “second position P12”.

FIG. 7 (A-S1)
The dancer roller 44 is lowered, and the first moving rod 51 and the pinch 62 are located at the first position P11. The pinch 62 holds the thick yarn group 10. The other pinches 61, 63, 64, 65 release the presser.

FIG. 7 (A-S2)
The first moving rod 51 and the pinch 62 move from the first position P11 to the third position P13, and the thick yarn group 10 is pulled out through the first moving rod 51 and the first fixed rod 52. When the thick yarn group 10 is pulled, the rotary roller 45 on the downstream side is driven to rotate, and the dancer roller 44 moves up. As a result, the thick yarn group 10 is pulled out without applying too much tension. Since stress does not act on the thick yarn group 10 that is pulled out and fixed, it is possible to prevent the thick yarn group 10 from suffering problems such as talmi and cold drawing.

FIG. 7 (A-S3)
The pinch 65 presses the thick yarn group 10.

FIG. 8 (A-S4)
The pinch 62 at the third position P13 releases the presser of the thick yarn group 10.

FIG. 8 (A-S5)
The first moving rod 51 and the pinch 62 at the third position P13 move to the second position P12.

FIG. 8 (A-S6)
The pinch 64 presses the thick yarn group 10.

FIG. 9 (A-S7)
The dancer roller 44 is moved downward, and the upstream rotation roller 43 is driven to rotate. As a result, the thick yarn group 10 is pulled out from the first reel 41. As the dancer roller 44 descends, tension is applied to the thick yarn group 10 existing between the dancer roller 44 and the pinch 64, and the deflection of the thick yarn group 10 is removed.

FIG. 9 (A-S8)
The pinch 61 presses the thick yarn group 10.

FIG. 9 (A-S9)
The first moving rod 51 and the pinch 62 at the second position P12 move to the first position P11. The first heater 67 is lowered to heat the thick yarn group 10, and the thick yarn group 10 is subjected to a preheating treatment. By the preheating treatment, the shock of thermal shrinkage at the time of joining the thick yarn group 10 is alleviated, and variations in the thermal shrinkage of the individual thick yarns 11 are suppressed.

FIG. 10 (A-S10)
The first heater 67 is raised, and the first moving rod 51 reciprocates between the first position P11 and the second position P12. By scanning the thick yarn group at least once with the first moving rod 51, the thick yarn 11 is subjected to warping with reduced effects of intermolecular forces, static electricity, and the like.

FIG. 10 (A-S11)
The first moving rod 51 and the pinch 62 move to the first position P11, and the scanning is finished.

FIG. 10 (A-S12)
The pinch 63 presses the thick yarn group 10.

FIG. 11 (A-S13)
The pinch 62 at the first position P11 presses the thick yarn group 10.

FIG. 11 (A-S14)
The 2nd processing line 102 is raised toward the 1st processing line 101, and it overlaps and contacts so that the thick thread 11 and the thin thread 21 may cross | intersect in planar view. The second heater 96 is raised and the sheath layer 22 of the thin yarn 21 is heated and melted. The thick yarn group 10 and the fine yarn group 20 are fused.

FIG. 11 (A-S15)
The second heater 96 is lowered and the cutter 66 is driven toward the thick yarn group 10 to cut the thick yarn group 10 at the non-joined portion.

FIG. 12 (A-S16)
The cutter 66 is driven away from the thick yarn group 10 to open the conveying path of the thick yarn group 10. The tension applied by the dancer roller 44 is lowered.

FIG. 12 (A-S17)
The pinches 61, 63, 64, and 65 release the presser of the thick yarn group 10. The pinch 62 at the first position P <b> 11 keeps pressing the thick yarn group 10 for the next drawing of the thick yarn group 10. The porous sheet 30 is wound up in the second processing line 102.

  With reference to FIGS. 13 to 16, the operation of the second processing line 102 in the porous sheet 30 manufacturing apparatus 100 will be outlined.

  With respect to the second processing line 102, the position of the second moving rod 81 is defined as follows. The most moved position is called “first position P21”, the most moved position is called “third position P23”, and the first and second heaters 67 and 96 and the third position are moved. The position moved between the position P23 and the position P23 is referred to as “second position P22”.

FIG. 13 (B-S1)
The second moving rod 81 is located at the first position P21. The pinches 91, 92, 93, and 94 release the presser.

FIG. 13 (B-S2)
The take-up reel 95 is driven to rotate, the fine yarn group 20 on which the porous sheet 30 is formed is taken up on the take-up reel 95, and the fine yarn group 20 is pulled out from the second reel 71.

FIG. 13 (B-S3)
The pinch 91 presses the thin yarn group 20.

FIG. 14 (B-S4)
The second moving rod 81 moves from the first position P21 to the third position P23.

FIG. 14 (B-S5)
The pinch 94 presses the thin yarn group 20.

FIG. 14 (B-S6)
The second moving rod 81 at the third position P23 moves to the second position P22.

FIG. 15 (B-S7)
The pinch 93 presses the thin yarn group 20.

FIG. 15 (B-S8)
The second moving rod 81 at the second position P22 moves to the first position P21. By scanning the fine yarn group 20 at least once with the second moving rod 81, the fine yarn 21 is knitted with reduced effects of intermolecular forces, static electricity, and the like.

FIG. 15 (B-S9)
The pinch 92 presses the thin yarn group 20.

FIG. 16 (B-S10)
The 2nd processing line 102 is raised toward the 1st processing line 101, and it overlaps and contacts so that the thick thread 11 and the thin thread 21 may cross | intersect in planar view. The first heater 67 is lowered, the second heater 96 is raised, and the sheath layer 22 of the thin yarn 21 is heated and melted. The thick yarn group 10 and the fine yarn group 20 are fused. The thick yarn 11 and the thin yarn 21 are compressed by the first and second heaters 67 and 96. By compressing while heating, the joining of the thick yarn 11 and the fine yarn 21 becomes more reliable.

FIG. 16 (B-S11)
The pinches 91, 92, 93, 94 release the presser of the thin yarn group 20.

  According to the manufacturing method of the porous sheet 30 and the manufacturing apparatus 100 of the porous sheet 30 that embodies this manufacturing method, the intermolecular force or static electricity is obtained by scanning the thick yarn group 10 with the first moving rod 51. For example, the thick yarn 11 can be knitted by reducing the action such as the above, and the fine yarn 21 can be knitted by reducing the action of intermolecular force or static electricity by scanning the fine yarn group 20 with the second moving rod 81. Thereafter, the thick yarn group 10 and the fine yarn group 20 that have been knitted are joined by heat-sealing to obtain a porous sheet 30. In the porous sheet 30, the thick yarn 11 and the fine yarn 21 intersect each other in a plan view, but all the thick yarns 11 in the thick yarn group 10 exist only on one side of both surfaces of the fine yarn group 20. 21 is joined. As a result of reducing the effects of intermolecular force, static electricity and the like and arranging the thick yarn 11 and the fine yarn 21 uniformly, a porous sheet 30 having uniform shaped openings can be obtained. In a normal net that is knitted, only one weft (for example, a thick thread) can be put one by one. On the other hand, in the present embodiment, a large amount of thick yarn 11 and a large amount of fine yarn 21 can be supplied at a time, so that the productivity is significantly higher than that of a normal net that is knitted. To up. Thus, since the thick yarn 11 and the thin yarn 21 are not knitted, the operation of knitting is not required, continuous production is facilitated, and the manufacturing time can be shortened.

[Fuel cell including porous sheet 30]
According to the present embodiment, it is possible to provide openings with a uniform shape through the uniform arrangement of the thick yarn 11 and the fine yarn 21, and it is easy to realize continuous production and shorten the manufacturing time. A method for producing the porous sheet 30 can be provided. Therefore, the porous sheet 30 having a uniform opening shape can be advantageously obtained in terms of cost. By using such a porous sheet 30 for a fuel cell, it is possible to improve the performance of a part to which the porous sheet 30 is applied in the fuel cell, and to reduce the cost of the entire fuel cell by reducing the part cost. be able to. Examples of components to which the porous sheet 30 is applied in a fuel cell include a filter disposed in the middle of a fuel gas or oxidant gas supply line, a base material for a gas diffusion layer, and the like.

[Fuel Cell Using Porous Sheet 30 as a Base Material for Gas Diffusion Layer]
As a specific example of the fuel cell including the porous sheet 30, a fuel cell using the porous sheet 30 as a base material for the gas diffusion layer will be described.

  17A and 17B are a schematic cross-sectional view and an exploded perspective view showing the basic structure of the fuel cell.

  The fuel cell 200 includes a polymer electrolyte membrane 210. On one surface of the polymer electrolyte membrane 210, a cathode catalyst layer 220c, a cathode gas diffusion layer 230c, and a cathode separator 240c that has conductivity and blocks gas. And are provided. On the other surface of the polymer electrolyte membrane 210, an anode catalyst layer 220a, an anode gas diffusion layer 230a, and an anode separator 240a that has conductivity and blocks gas are provided. Here, the polymer electrolyte membrane 210, the anode catalyst layer 220a, the anode gas diffusion layer 230a, the cathode catalyst layer 220c, and the cathode gas diffusion layer 230c constitute a membrane electrode assembly (MEA) 250 in a stacked state. A plurality of MEAs 250 are sequentially stacked via an anode separator 240a and a cathode separator 240c to constitute a fuel cell stack. The state in which the polymer electrolyte membrane 210, the anode catalyst layer 220a, and the cathode catalyst layer 220c are laminated is also referred to as “CCM”.

  A plurality of fuel gas flow channel openings 261, a cooling water flow channel opening 262, and an oxidizing gas flow channel opening 263 are provided as flow channel openings on the outer periphery of the two opposite sides (long sides) of the separators 240 a and 240 c. Is provided (see FIG. 17B). In the electrode layer of the MEA 250 shown in the figure, when the gas flow direction is the short side and the direction orthogonal to the gas flow direction is the long side, the aspect ratio R is defined as R = short side / long side, the aspect ratio R is less than 1. In the case of a separator having a low aspect ratio (R is 0.01 or more and less than 1), the flow length is shortened, so that the pressure loss is reduced. Therefore, even when the aspect ratio R is decreased and the height of the flow path is decreased, the pressure loss equivalent to that of a separator having a high aspect ratio (R is 1 or more) can be maintained, and the separators 240a and 240c are maintained. The height of itself can be lowered.

  As the base material of the cathode gas diffusion layer 230c and the anode gas diffusion layer 230a, the porous sheet 30 manufactured as described above is applied. Since the gas diffusion layers 230a and 230c are required to have conductivity, they are coated with a conductive surface layer material that covers the porous sheet 30 made of resin fibers. The surface layer material is not particularly limited as long as it is a conductive material. Specifically, metals such as gold, platinum, ruthenium, iridium, rhodium, palladium, silver, copper, iron, titanium and aluminum, and alloys thereof; conductive polymer materials, DLC (diamond-like carbon), etc. Examples thereof include conductive carbon materials. These may be used individually by 1 type and may use 2 or more types together.

  The porous sheet 30 as the base material of the cathode gas diffusion layer 230c is arranged with the fine yarn group 20 positioned on the cathode catalyst layer 220c side and the thick yarn group 10 positioned on the cathode separator 240c side. A plurality of thick yarns 11 are arranged in parallel on the thin yarn 21. The thick yarn 11 and the fine yarn 21 are orthogonal (90 degrees) in plan view. A space between adjacent thick yarns 11 becomes a gas flow path space 270c for supplying the oxidant gas to the cathode catalyst layer 220c.

  The porous sheet 30 as a base material of the anode gas diffusion layer 230a is disposed with the fine yarn group 20 positioned on the anode catalyst layer 220a side and the thick yarn group 10 positioned on the anode separator 240a side. A plurality of thick yarns 11 are arranged in parallel on the thin yarn 21. The thick yarn 11 and the fine yarn 21 are orthogonal (90 degrees) in plan view. A space between adjacent thick yarns 11 becomes a gas flow path space 270a for supplying fuel gas to the anode catalyst layer 220a.

  With such a structure, the height of the gas flow path can be lowered while securing a sufficient gas flow path space. As a result, the single fuel cell can be made thin, and the fuel cell 200 can be miniaturized. In general, a separator is manufactured by pressing a metal plate. However, this method has a problem of the deflection of the separator accompanying the processing, the cracking of the separator accompanying the fine processing, and the strain hardening. On the other hand, when the porous sheet 30 is applied as the base material of the gas diffusion layer, a smooth separator can be used, and thus the above problem does not occur. Furthermore, when the porous sheet 30 is applied as the base material of the gas diffusion layer, the fine yarn 21 is disposed between the catalyst layers 220 c and 220 a and the thick yarn 11. For this reason, gas can be supplied to the whole catalyst layer 220c, 220a also in the thickness direction, and it is excellent in power generation performance. The thin yarn 21 suppresses or prevents the thick yarn 11 from sinking into the catalyst layers 220c and 220a against the compressive force acting when the fuel cell single cells are stacked. For this reason, good gas diffusibility and reduction of pressure loss can be achieved. Furthermore, the electrical conductivity between the catalyst layers 220c, 220a and the separators 240c, 240a can be sufficiently secured through the thick yarn 11 and the fine yarn 21 coated with the conductive surface layer material.

  Therefore, by applying the porous sheet 30 as the base material of the gas diffusion layers 230c and 230a, the fuel cell 200 can be thinned while ensuring sufficient gas diffusibility and conductivity. Furthermore, since the porous sheet 30 can be manufactured at a low cost, the cost of the gas diffusion layer base material as a part can be reduced, and the cost of the entire fuel cell 200 can be reduced through this.

  The diameter (D1) of the thick yarn 11 is appropriately selected from the standpoint that a sufficient amount of gas (fuel gas or oxidant gas) can be supplied to the catalyst layers 220c and 220a and the fuel cell 200 can be downsized. . For example, the diameter (D1) of the thick yarn 11 is preferably 10 to 300 μm, more preferably 50 to 200 μm, and particularly preferably 100 to 150 μm. The pitch (P1) between the adjacent thick yarns 11 is appropriately selected from the viewpoint of the diameter of the thick yarn 11, the viewpoint of supplying a sufficient amount of gas to the catalyst layers 220c and 220a, and the like. For example, the pitch (P1) of the thick yarn 11 is preferably 20 to 600 μm, more preferably 100 to 400 μm, and particularly preferably 200 to 300 μm.

  The diameter of the fine thread 21 is not particularly limited, but is appropriately selected from the viewpoint of exhibiting a function of suppressing or preventing the thick thread 11 from sinking into the catalyst layers 220c and 220a. For example, the diameter of the thin yarn 21 is preferably 300 μm or less, more preferably 5 to 200 μm, and particularly preferably 10 to 100 μm. The pitch (P2) of the adjacent fine yarns 21 is preferably smaller than the pitch (P1) of the thick yarns 11 (P2 <P1). In this case, since the fine yarns 21 are arranged in parallel at a small pitch (densely), the electricity generated in the catalyst layer can be efficiently transmitted to the separator side. On the other hand, since the thick yarn 11 is arranged in parallel at a certain pitch, it is possible to ensure a good gas flow from the separator side. Specifically, the ratio (P2 / P1) of the pitch (P2) of the fine yarn 21 to the pitch (P1) of the thick yarn 11 is preferably 0.1 to 0.8, and more preferably 0.2 to 0.6.

  The cross-sectional shape of the thick yarn 11 and the fine yarn 21 is not limited to a circle, and may be an ellipse, a circle, an indefinite shape, a rectangle, a triangle, or the like.

  The material of the thick thread 11 may be a metal such as stainless steel or titanium. This is because the electrical resistance can be further reduced.

[Vehicle equipped with fuel cell 200]
18A and 18B show an example of a vehicle on which the fuel cell 200 is mounted. A vehicle 18 shown in FIG. 18A has a fuel cell 200 mounted in an engine room. A vehicle 18 shown in FIG. 18B has a fuel cell 200 mounted below the floor. Since the vehicle 300 includes the fuel cell 200 including the porous sheet 30, the vehicle 300 is excellent in in-vehicle performance, productivity, and cost.

[Effect of this embodiment]
As described above, according to the method for manufacturing the porous sheet 30 and the manufacturing apparatus 100 described above, the action of intermolecular force, static electricity, etc. is reduced by scanning the thick yarn group 10 with the first moving rod 51. Thus, the thick yarn 11 is trimmed, and the fine yarn 21 can be trimmed by reducing the action of intermolecular force, static electricity and the like by scanning the fine yarn group 20 with the second moving rod 81. Thereafter, the thick yarn group 10 and the fine yarn group 20 that have been knitted are joined by heat-sealing to obtain a porous sheet 30. In the porous sheet 30, the thick yarn 11 and the fine yarn 21 intersect each other in a plan view, but all the thick yarns 11 in the thick yarn group 10 exist only on one side of both surfaces of the fine yarn group 20. 21 is joined. As a result of reducing the effects of intermolecular force, static electricity and the like and arranging the thick yarn 11 and the fine yarn 21 uniformly, a porous sheet 30 having uniform shaped openings can be obtained. Furthermore, since the thick yarn 11 and the fine yarn 21 are not knitted, the operation of knitting is not required, and continuous production is facilitated, and the manufacturing time can be shortened.

  Preferably, when the fixed thick yarn group 10 is scanned by the first moving rod 51, the planarizing member 55 that moves together with the first moving rod 51 in order to align the upper surface or the lower surface of the thick yarn group 10 on the same plane, It is provided before or after the first moving rod 51 and at the top or bottom of the thick yarn group 10. Then, when the fixed thick yarn group 10 is scanned by the first moving rod 51, the upper surface or the lower surface of the thick yarn group 10 is aligned on the same plane by the planarizing member 55 that moves together with the first moving rod 51. The upper surface or the lower surface of the thick yarn group 10 is aligned on the same plane, and the thick yarn group 10 having a good flat surface can be configured.

  Preferably, preferably, when the fixed thin yarn group 20 is scanned by the second moving rod 81, the planarizing member that moves together with the second moving rod 81 to align the upper surface or the lower surface of the thin yarn group 20 on the same plane. 85 is provided in front of or behind the second moving rod 81 and on the upper or lower portion of the thin yarn group 20. When the fixed thin yarn group 20 is scanned by the second moving rod 81, the upper surface or the lower surface of the thin yarn group 20 is aligned on the same plane by the planarizing member 85 that moves together with the second moving rod 81. The upper surface or the lower surface of the fine yarn group 20 is aligned on the same plane, and the fine yarn group 20 having a good flat surface can be configured.

  Preferably, at least one of the flattening members 55 and 85 that contact the wire rod group and press the wire rod group (Ro La 56, 86) and the non-contact member that press the wire rod group without contacting the wire rod group is used. Prepare. Then, at least one of pressing the wire group by the planarizing members 55 and 85 contacting the wire group and pressing the wire group without the planarizing members 55 and 85 contacting the wire group is performed. The wire group can be pushed in while preventing problems such as generation of excessive frictional force and cutting of the wire, and the upper surface or the lower surface of the wire group can be aligned on the same plane.

  Preferably, the thick yarn group 10 may be preheated before the fixed thick yarn group 10 is scanned by the first moving rod 51. By the preheating treatment, the shock of thermal shrinkage at the time of joining the thick yarn group 10 is alleviated, and variations in the thermal shrinkage of the individual thick yarns 11 are suppressed.

  Preferably, the thin yarn group 20 may be preheated before the fixed thin yarn group 20 is scanned by the second moving rod 81. By the preheating treatment, the shock of thermal shrinkage at the time of joining of the fine yarn group 20 is alleviated, and variations in the thermal shrinkage of the individual fine yarns 21 are suppressed.

  When preparing the thick yarn group 10 by winding it around the first reel 41 and pulling out the thick yarn group 10 from the first reel 41, the tension acting on the thick yarn group 10 is adjusted, that is, too much tension acts. It is pulled out and fixed. Since stress does not act on the thick yarn group 10 that is pulled out and fixed, it is possible to prevent the thick yarn group 10 from suffering problems such as talmi and cold drawing.

  When the thick yarn group 10 and the fine yarn group 20 are joined, the thick yarn 11 and the fine yarn 21 are compressed while being heated. By heating and compressing, the joining of the thick yarn 11 and the fine yarn 21 becomes more reliable.

  The resin fiber forming the fine thread 21 is made of polyester, polyamide, or polyolefin. Since these materials are inexpensive and excellent in mechanical properties, they are used in various fields as various materials, and the porous sheet 30 can be manufactured at low cost, and desired mechanical properties can be imparted to the porous sheet 30. it can.

  Since the fuel cell 200 according to the present embodiment includes the porous sheet 30 manufactured as described above, it is possible to improve the performance of the component to which the porous sheet 30 is applied, and to reduce the fuel cost through the reduction of the component cost. The cost of the entire battery 200 can be reduced.

  By applying the porous sheet 30 as the base material of the gas diffusion layers 230c and 230a, the fuel cell 200 can be made thin while ensuring sufficient gas diffusibility. Furthermore, since the porous sheet 30 can be manufactured at a low cost, the cost of the gas diffusion layer base material as a part can be reduced, and the cost of the entire fuel cell 200 can be reduced through this.

  Since the vehicle 300 according to the present embodiment includes the fuel cell 200 including the porous sheet 30 manufactured as described above, the vehicle 300 is excellent in in-vehicle performance, productivity, and cost.

(Modification)
The combination of the material of the 1st wire 11 and the material of the 2nd wire 21 which has a core-sheath structure is not limited to the case where both form from a resin fiber. A combination in which the first wire 11 is formed from a resin fiber and the second wire 21 is formed from a metal, a combination in which the first wire 11 is formed from a metal, and the second wire 21 is formed from a resin fiber. It can be set as the combination which forms both the 1 and 2nd wire 11 and 21 from a metal.

  The first wire 11 is thicker than the second wire 21, and the pitch of the first wire 11 is not limited to an example wider than the pitch of the second wire 21. The first wire 11 may be thinner than the second wire 21 or may have the same thickness. Similarly, the pitch of the first wire 11 may be narrower than the pitch of the second wire 21 or the same pitch.

  It is not limited to the transport mode in which the first wire group 10 is the side to be cut (the lateral side) and the second wire group 20 is the side to be wound. On the contrary, it is good also as the side which winds up the 1st wire group 10 and the side (side-out side) which cuts the 2nd wire group 20.

  Furthermore, it can be set as the modification which combined the material-diameter / pitch-conveyance form mentioned above mutually.

  A dancer roller may also be incorporated in the second processing line 102 to draw out the thin yarn group 20 without applying too strong tension. Since the stress does not act on the fine yarn group 20 that is pulled out and fixed, it is possible to prevent the fine yarn group 20 from suffering problems such as talmi and cold drawing.

  Although the example which applied the porous sheet 30 to the base material of gas diffusion layer 230c, 230a was shown, this invention is not limited to this case. The present invention can be widely applied to conventional porous sheets that have been manufactured by knitting. For example, it can be applied to a porous sheet used as a filter substrate.

  After cutting the thick yarn group 10, the thick yarn 11 and the fine yarn 21 may be compressed while being heated. By further heat-compressing after cutting, the joining of the thick yarn 11 and the fine yarn 21 becomes more reliable.

  Although the example in which the porous sheet 30 is formed from the two wires 11 and 21 has been shown, the present invention can also be applied to the case where the porous sheet 30 is formed from three or more wires. Paying attention to two adjacent wires that overlap each other, one wire and the other wire intersect in plan view, but all one wire in one wire group is one side of both sides of the other wire group As long as it exists only on the side and is joined to the other wire, it is applicable.

10 thick yarn group (first wire group),
11 Thick thread (first wire),
20 Fine yarn group (second wire group),
21 Fine yarn (second wire),
22 sheath layer,
23 core layer,
30 porous sheet,
41 1st reel (1st supply part),
42 guide rollers,
43, 45 Drive roller,
44 Dancer roller,
51 First moving rod (first rod),
51a slit,
52 First fixed rod,
52a slit,
55 Planarizing member,
56 Roller (contact member) as a planarizing member,
61, 62, 63, 64, 65 pinch (first fixing part),
66 Cutter (cutting part),
67 1st heater (joint part),
68 Pressure mechanism (joint),
71 second reel (second supply unit),
72 guide rollers,
81 Second moving rod (second rod),
81a slit,
82 second fixed rod,
82a slit,
85 planarizing member,
86 Roller (contact member) as a planarizing member,
91, 92, 93, 94 pinch (second fixing part),
95 take-up reel,
96 second heater (joint),
97 Pressurization mechanism (joint),
99 winding reference roller,
100 Porous sheet manufacturing apparatus,
101 First processing line,
102 second processing line,
200 fuel cells,
210 polymer electrolyte membrane,
220c, 220a catalyst layer,
230c, 230a gas diffusion layer,
240c, 240a separator,
250 membrane electrode assembly (MEA),
300 vehicles.

Claims (18)

Preparing a first wire group consisting of a set of first wires arranged side by side;
A second wire group consisting of a pair of second wires arranged side by side, wherein the second wire has a core-sheath structure, and the sheath layer has a melting point lower than that of the core layer. Prepare a wire group of
Pulling out and fixing the first wire group through at least one first rod;
Scanning the first group of wires at least once with the first scissors,
Pulling out the second wire group through at least one second rod, and fixing without contacting the first wire group;
Scanning the second group of wires at least once with the second scissors,
An area scanned by the first ridge in the first wire group and an area scanned by the second ridge in the second wire group are the first wire and the second wire. And so that they intersect with each other in plan view,
The first wire group and the second wire group are joined by cooling and solidifying after heating and melting the sheath layer of the second wire,
Cutting at least one of the first wire group and the second wire group at a non-joined portion where the first wire group and the second wire group are not joined, and the first wire and the The second wire rod intersects in plan view, but all the first wire rods in the first wire rod group exist only on one surface side of both surfaces of the second wire rod group, and the second wire rod A method for producing a porous sheet, wherein a porous sheet joined to the wire is obtained.   The upper surface or the lower surface of the first wire group is aligned on the same plane by a planarizing member that moves with the first ridge when the fixed first wire group is scanned by the first ridge. 2. A method for producing a porous sheet according to 1.   The upper surface or the lower surface of the second wire group is aligned on the same plane by a planarizing member that moves with the second scissors when the fixed second wire group is scanned by the second scissors. A method for producing a porous sheet according to claim 1 or 2.   The said planarizing member contacts at least one of pressing the wire group by contacting the wire group and the planarizing member pressing the wire group without contacting the wire group. Manufacturing method of porous sheet.   The porous sheet according to any one of claims 1 to 4, wherein the first wire rod group is subjected to a preheating treatment before the fixed first wire rod group is scanned by the first scissors. Production method.   The porous sheet according to any one of claims 1 to 5, wherein a preheating treatment is applied to the second wire group before the fixed second wire group is scanned by the second ridge. Production method. Preparing the first wire group by winding it around a first reel;
The porous structure according to any one of claims 1 to 6, wherein when pulling out the first wire group from the first reel, the tension acting on the first wire group is adjusted and pulled out and fixed. Manufacturing method of adhesive sheet. Prepare the second wire group by winding it around a second reel,
The perforation according to any one of claims 1 to 7, wherein when pulling out the second wire group from the second reel, the second wire group is pulled out and fixed while removing a tension acting on the second wire group. Manufacturing method of adhesive sheet.   9. The method according to claim 1, wherein when the first wire rod group and the second wire rod group are joined, the first wire rod and the second wire rod are compressed while being heated. Manufacturing method of porous sheet.   The first wire rod group and the second wire rod group are cut and then compressed while being heated, after cutting at least one of the first wire rod group and the second wire rod group. A method for producing a porous sheet as described in 1.   The manufacturing method of the porous sheet of any one of Claims 1-10 in which the material which forms a said 2nd wire consists of resin fiber in any one of polyester, polyamide, and polyolefin. A first supply unit that supplies a first group of wires made of a set of first wires arranged side by side;
A second wire group consisting of a pair of second wires arranged side by side, wherein the second wire has a core-sheath structure, and the sheath layer has a melting point lower than that of the core layer. A second supply unit for supplying a wire group of
A first fixing portion that is free to pull out and fix the first wire group;
A second fixing portion that can be fixed without pulling out the second wire group and contacting the first wire group; and
At least one first rod passed through the first wire rod group fixed to the first fixing portion in a scannable manner;
At least one second scissors passed through the second wire rod group fixed to the second fixing portion so as to be freely scanned;
An area scanned by the first ridge in the first wire group and an area scanned by the second ridge in the second wire group are the first wire and the second wire. Are joined so as to cross each other in plan view, and the sheath layer of the second wire rod is heated and melted to join the first wire rod group and the second wire rod group,
A stepped portion for cutting at least one of the first wire group and the second wire group at a non-joined portion where the first wire group and the second wire group are not joined. ,
The first wire rod and the second wire rod intersect in plan view, but all the first wire rods in the first wire rod group are on one surface side of both surfaces of the second wire rod group. A porous sheet manufacturing apparatus for obtaining a porous sheet that is present only and is bonded to the second wire.   When the fixed first wire group is scanned by the first ridge, a planarizing member that moves with the first ridge to align the upper surface or the lower surface of the first wire group on the same plane, The manufacturing apparatus of the porous sheet of Claim 12 provided in the upper part or lower part of the said 1st wire rod group before or after the said 1st ridge.   When the fixed second wire group is scanned by the second ridge, a planarizing member that moves with the second ridge to align the upper surface or the lower surface of the second wire group on the same plane, The porous sheet manufacturing apparatus according to claim 12 or 13, which is provided before or after the second rod and at an upper portion or a lower portion of the second wire group.   The porous member according to claim 13 or 14, wherein the planarizing member includes at least one of a contact member that contacts the wire group and presses the wire group, and a non-contact member that presses the wire group without contacting the wire group. Sheet manufacturing equipment.   A fuel cell comprising a porous sheet produced by the method according to claim 1.   The fuel cell according to claim 16, wherein the porous sheet is used as a base material of a gas diffusion layer.   A vehicle comprising the fuel cell according to claim 16 or 17.