Fuel cell module and manufacturing method thereof

1. A fuel cell module comprising:

an electrode member having:

a membrane electrode assembly, which is formed from an electrolyte membrane and a pair of electrode catalyst layers that is disposed on both sides of the electrolyte membrane in a thickness direction, and

a pair of porous layers disposed on both sides of the membrane electrode assembly in the thickness direction;

a separator disposed layered on the electrode member so as to contact at least one of the porous layers; and

an adhesive rubber member sealing a peripheral edge portion of the electrode member,

wherein:

the pair of porous layers each include a gas diffusion layer;

a planar area of the membrane electrode assembly is larger than that of at least one gas diffusion layer;

at least one porous layer among the pair of porous layers includes a gas flow path whose porosity is larger than that of the gas diffusion layer, the gas flow path layer being disposed on an opposite side of the gas diffusion layer from the membrane electrode assembly, and a planar area of the gas flow path layer being smaller than that of the gas diffusion layer;

the electrode member and the separator are adhered together by the adhesive rubber member so as to be integrated;

the adhesive rubber member is formed from solid rubber containing at least one rubber component selected from the group consisting of ethylene-propylene rubber, ethylene-propylene-diene rubber, acrylonitrile-butadiene rubber, hydrogenated acrylonitrile-butadiene rubber, styrene-butadiene rubber, and butadiene rubber, and has a tensile product of 1,500 MPa·% or more;

a preformed pre-crosslinking composition of the solid rubber is arranged so as to coat the peripheral edge portion of the electrode member and contact the separator;

the preformed pre-crosslinking composition is crosslinked while impregnating the porous layer of the electrode member with the preformed pre-crosslinking composition; and

the electrode member, the separator, and the adhesive rubber member are integrally molded.

2. The fuel cell module according to claim 1 , wherein the preformed pre-crosslinking composition of the solid rubber includes the following contents of (A) to (D):

(A) at least one rubber component selected from the group consisting of ethylene-propylene rubber, ethylene-propylene-diene rubber, acrylonitrile-butadiene rubber, and hydrogenated acrylonitrile-butadiene rubber;

(B) a crosslinking agent selected from organic peroxides of which a 1-hour half-life period temperature is greater than or equal to 100° C. and lower than or equal to 130° C.;

(C) a crosslinking auxiliary agent; and

(D) an adhesive component that is formed of at least one of a resorcinol compound together with a melamine compound and a silane coupling agent, wherein the adhesive component bonds the adhesive rubber member, the electrode member, and the separator.

3. The fuel cell module according to claim 1 , wherein a preform, which is produced in advance by integrating the preformed pre-crosslinking composition of the solid rubber with the peripheral edge portion of the electrode member, is arranged so as to contact the separator.

4. The fuel cell module according to claim 1 , wherein the preformed pre-crosslinking composition of the solid rubber has a compression portion which impregnates the porous layer.

5. The fuel cell module according to claim 3 , wherein the preformed pre-crosslinking composition of the solid rubber has a compression portion which impregnates the porous layer.

6. A fuel cell module comprising:

an electrode member having:

a membrane electrode assembly, which is formed from an electrolyte membrane and a pair of electrode catalyst layers that is disposed on both sides of the electrolyte membrane in a thickness direction, and

a pair of porous layers disposed on both sides of the membrane electrode assembly in the thickness direction;

a separator disposed layered on the electrode member so as to contact at least one of the porous layers; and

an adhesive rubber member sealing a peripheral edge portion of the electrode member,

wherein;

at least one porous layer among the pair of porous layers has a gas diffusion layer;

a planar area of the membrane electrode assembly is larger than that of at least one gas diffusion layer;

the electrode member and the separator are adhered together by the adhesive rubber member so as to be integrated;

the adhesive rubber member is formed from solid rubber containing at least one rubber component selected from the group consisting of ethylene-propylene rubber, ethylene-propylene-diene rubber, acrylonitrile-butadiene rubber, hydrogenated acrylonitrile-butadiene rubber, styrene-butadiene rubber, and butadiene rubber, and has a tensile product of 1,500 MPa·% or more;

a preformed pre-crosslinking composition of the solid rubber is arranged so as to coat the peripheral edge portion of the electrode member and contact the separator;

the preformed pre-crosslinking composition is crosslinked while impregnating the porous layer of the electrode member with the reformed pre-crosslinking composition;

the preformed pre-crosslinking composition of the solid rubber includes the following contents of (A) to (D):

(A) at least one rubber component selected from the group consisting of ethylene-propylene rubber, ethylene-propylene-diene rubber, acrylonitrile-butadiene rubber, and hydrogenated acrylonitrile-butadiene rubber;

(B) a crosslinking agent selected from organic peroxides of which a 1-hour half-life period temperature is greater than or equal to 100° C. and lower than or equal to 130° C.;

(C) a crosslinking auxiliary agent; and

(D) an adhesive component that is formed of a resorcinol compound together with a melamine compound, or both the resorcinol compound together with the melamine compound and the silane coupling agent, wherein the adhesive component bonds the adhesive rubber member, the electrode member, and the separator; and

the electrode member, the separator, and the adhesive rubber member are integrally molded.