PRODUCTION OF FUEL

CELL COMPONENTS

2nd edition
The chair “Production Engineering of E- The VDMA Fuel Cells Working Group
Mobility Components” (PEM) of RWTH supports manufacturers of fuel cell com-
Aachen University deals with the production ponents and systems in Germany in ex-
engineering of fuel cells. Within the panding their industry network. It currently
mechanical engineering sector, the activities offers more than 80 leading, nationally and
range from the cost-efficient production of internationally active manufacturers and
hydrogen-powered drivetrain components suppliers a communication platform for
to innovative mobility solutions and overall networking and joint representation of
emission reduction. Through national and interests. Technical solutions for optimizing
international projects in companies at and reducing the costs of fuel cell systems
various stages of the value chain as well as and their respective components as well as
participation in numerous research projects, for setting up series production are de-
PEM offers extensive expertise. veloped in project groups.

PEM of RWTH Aachen University VDMA

Chair „Production Engineering of Fuel Cells Working Group
E-Mobility Components” Friedrichstraße 95
Bohr 12 10117 Berlin
52072 Aachen
www.pem.rwth-aachen.de www.vdma.org/fuel-cells

Authors
PEM of RWTH Aachen University VDMA
Gerd Krieger
Managing Director of the Fuel Cellls
Dr.-Ing. Heiner Heimes Working Group
Executive Chief Engineer [email protected]
[email protected]

Jana Müller
Project Manager Fuel Cells
Mario Kehrer, M. Sc. [email protected]
Chief Engineer
[email protected]

Do you have any questions?

Sebastian Hagedorn, M. Sc.
Group Leader Fuel Cell
[email protected] Contact us!

Julius Hausmann, M. Sc.

Research Associate Fuel Cell Aachen, November 2022
PEM of RWTH Aachen University and
[email protected]
VDMA AG Fuel Cell
2nd edition
ISBN: 978-3-947920-31-0
Overview
of PEM fuel cells
Fuel cell components Fuel cell stack

Fuel cell system

Component production Stack production System production

In this guide, the manufacturing of fuel cell components as part of the pro-
duction process of polymer electrolyte membrane (PEM) fuel cells is presented
schematically.
The fuel cell components bipolar plate, gas diffusion layer, and catalyst-coated
membrane are manufactured by using different materials in different production
processes. Based on the current state of the art, this guide shows a manufacturing
sequence for the component production. This selection serves as a basis for
discussion within the industry. Other process step configurations are conceivable
and desired. Alternative manufacturing processes for the production of fuel cell
components are therefore referred to in excerpts. Further process variants can be
specified in more detail in joint discussion with the RWTH PEM chair or VDMA.

Technology Development
of PEM fuel cells
The widespread introduction of fuel cell technology requires product and process
innovations aimed at reducing production costs. This requires a scaling of
production quantities while meeting constant quality requirements. The PEM chair
of RWTH Aachen University has set itself this goal and identified the following
research topics, among others:

Process innovation (example) Product innovation (example)

Component production Component production

● Substitution of the decal process ● Development of adhesive bipolar plates
● Increase in the share of “roll-to-roll” ● Construction of “intermediate plates” to
processes in the fuel cell production increase product modularity
Stack production Stack production
● High-speed stacking ● Combination of membrane electrode
● Reduction of stack activation time assembly (MEA) and bipolar half plate
(BPHP) into one component
Operating Principle
of PEM fuel cells
Structural design
Electric
e-
load
e-
H2 inlet H2 O2 O2 inlet
H2
H2 e- O2
H+ O2
e- H+
e-
e- H2 O O2
O2 & H2O
H2 outlet H2 H2 O
outlet

Bipolar half plate Gas diffusion layer Catalyst Membrane Catalyst Gas diffusion layer Bipolar half plate
Anode oxidation Overall reaction Cathode reduction
2 H2 → 4 H+ + 4 e- 2 H2 + O2 → 2 H2O O2 + 4 H+ + 4 e- → 2 H2O

The conversion of chemical energy into electrical energy by the PEM fuel cell is
based on the following operating principle:
● Hydrogen is supplied on the anode side and oxygen on the cathode side via
the flow channels of the bipolar half plates (BPHP).
● The hydrogen diffuses via the gas diffusion layer (GDL) to the anode side of
the catalyst-coated membrane (CCM).
● The hydrogen is catalytically oxidized and protons (H+) are formed with the
release of electrons which pass across the wet membrane to the cathode side.
The electrons are conducted to the cathode side via an external circuit.
● The oxygen on the cathode side is reduced by the electrons and reacts with
the protons (H+) from the membrane to form H2O (water) which is dissipated.

Fuel Cell Types

in comparison
The following diagram shows an overview of the fuel cell types currently available
in industry and research, their reaction media and usual operating temperature.

Fuel cell type Anode in/out Ion transport Cathode in/out Temp. [°C]
H2 gas
Natural CO2
160 220 650 900

SOFC Solid Oxide Fuel Cell H2 O O2- O2 air

CO
Natural
H2 gas CO2 O2 air
MCFC Molten Carbonate Fuel Cell H2 O CO32-
CO CO2

PAFC Phosphoric Acid Fuel Cell H+ H2 O gaseous O2 air

H2
High Temperature Polymer H2 O
HT-PEMFC H2 H+ gaseous O2 air
Electrolyte Membrane FC
DMFC Direct Methanol Fuel Cell CO2 H+ H2 O
90

CH3OH liquid O2 air

Low Temperature Polymer H2 O

LT-PEMFC H2 H+ liquid O2 air
Electrolyte Membrane FC
80

pure substance
AFC Alkaline Fuel Cell H2 O OH- O2
H2
 Production Process
of PEM fuel cell components

● The process chain for series production of PEM fuel cell systems differs
depending on the application and the number of units produced annually.
Uniform standards are currently not yet available due to the manufactory
nature of fuel cell production.
● The production of a PEM fuel cell system can be divided into three
superordinate steps: component production, stack production, and system
production.
● This guide presents the process steps that make up the current state of the art
in the production of PEM fuel cell components.
● The production of the fuel cell stack and system is explained in more detail in a
separate guide (“Production of Fuel Cell Systems”).

Component production:

Decal coating & Hot pressing & Subgasket

CCM
Mixing
drying decal removing application

Joining &

MEA
separating

Carbon fiber Carbon paper Impreg- Hydropho- MPL application

GDL

Graphitizing
chopping forming nating bing & sintering

Stamping Leakage Gasket

BPP

Coating Joining
Hydroforming Separating testing application

Stack production*:

Stacking & Leakage Insulation Break-In &

Stack

Compressing Tensioning Finalizing

Preassembly testing testing testing

System production*:
System

Balance-of-Plant assembly Electrical integration End of Line testing

*Essential part of the brochure "Production of Fuel Cell Systems".

Process step Intermediate product Final product

Overview
of PEM fuel cell components

Catalyst-coated membrane

Membrane
● The polymer membrane coated with
platinum catalyst is called a “catalyst-
coated membrane” (CCM).
Sub- ● There is one catalyst layer on the
gasket anode side and one on the cathode
side. The layers differ in their chem-
ical composition and thickness.
● Proton transport takes place via the
CCM, while the catalyst layers enable
Catalyst oxidation or rather reduction.
coating

Gas diffusion layer

Carbon paper
● The gas diffusion layer (GDL) consists
or fabric
of carbon paper or fabric and has a
significant influence on the efficiency
of the fuel cell.
● The GDL enables the uniform dis-
tribution of the reaction media to the
catalyst layers on the anode and
cathode sides.
● The microporous layer (MPL) im-
Microporous proves the regulation of water re-
layer tention at the electrodes.

Bipolar plate

Coolant supply ● The bipolar plate (BPP) usually

H2 supply consists of two bipolar half plates,
O2 supply
which are formed, coated, and joined
depending on the material (metallic*
Flow field
or graphite).
(H2)
Flow field ● The reaction media are conveyed via
(coolant) the BPP, and the reaction heat is
dissipated from the fuel cell.
● The BPP is electrically conductive and
thus feeds the electrons into the
Gasket O2 & H2O consumer circuit.
H2 removal removal
*Focus of this guide
Graphite Bipolar Plate
Information on the product in the form of an excursus

Graphite bipolar plate

● The material of a bipolar plate for

Coolant supply use in long-life fuel cells brings with
H2 supply
O2 supply it ideal properties. These include
high corrosion resistance, high me-
Adhesive chanical strength, low interfacial
seam Flow field contact resistance, high contact
(H2) angle, impermeability to reaction
Flow field
(coolant) gases and no brittleness.
● Compound bipolar plates also
form an alternative to metal and
consist of polymer-bonded, highly
Gasket O2 & H2O filled graphite-based compound ma-
H2 removal removal terials.

Special Features
Due to the different material, the product- and process-related properties of
graphite bipolar plates differ significantly from those of metallic bipolar plates. For
example, two bipolar half plates are joined by an adhesive seam. The shaping
also differs significantly from the process of metallic bipolar plates. Both products
hold advantages and disadvantages.

Advantages Disadvantages

● Service life is more than 40,000 ● Higher volume

operating hours ● Brittleness
● High corrosion resistance ● Lower mechanical strength
● Low interfacial contact resistance ● Higher production costs for large
● For graphite composite: higher quantities
electrical conductivity due to a ● More difficult producibility due to
higher carbon/polymer ratio mechanical material behavior
 Production of Graphite BPP
Excerpt of essential production processes
Graphite bipolar plates differ from metallic bipolar plates in terms of production.
The shaping and bonding may entail essential differences in the production which
are explained in the following.

Injection molding
● The powder compound is fed to
an extruder and melted into a
Powder compound
homogeneous mass.
Extruder cylinder
● The homogeneous mass is
transported through the ex-
truder screw to the injection
mold and added to it.
● This is followed by component
shaping and ejection of the
Extruder screw Injection mold component geometry from the
mold.

Compression molding
● Compression molding requires a
Heated upper Hold-down clamp press, a molding tool, and
die
molding compound.
● Hold-down or pressing force are
relevant parameters to be con-
sidered.
● Excess molding compound ma-
terial provides void filling.
● Losses due to high process
scrap rates and the excess ma-
Heated lower Bipolar half terial
die plate

● Adhesive or sealant is applied

Bonding the BPHP directly to the BPHP and no
Adhesive longer slips.
layer Bonded BPP ● For sealing, “cure in place gas-
kets” are used, for example,
which cure after application.
● “Non-adhesive” materials have
the properties of a gasket after
curing.
● “Permanently adhesive” sub-
stances form a bond in the
classical sense.
● Pressure-sensitive adhesives are,
BPHP for example, adhesive tapes or
transfer films.
 Mixing
CCM production
Anode formula (example)
Intensive mixer
Catalyst powder:
with mixing tool
Platinum-coated carbon substrate (about
15 wt%)
Solvent: e.g. water,
Dry catalyst powder ionomer,
Deionized water (approx. 40 wt.%) and
(e.g. platinum, isopropanol
methanol (approx. 40 wt.%), e.g.
carbon substrate)
Binder:
Ionomer solution (approx. 5 wt.%)

Cathode formula (example)

ω2
Catalyst powder:
Platinum-coated carbon substrate (about
20 wt%).
Solvent:
Deionized water (35 wt.%) and methanol ω1
(35 wt.%), e.g. Heat source
Binder:
Ionomer solution (approx. 10 wt.%)

Component production Stack production System production

● By applying energy, several raw materials are combined via a rotating tool to
form a catalyst ink.
● The catalyst ink consists mainly of carbon substrate (e.g. carbon black) and
catalyst material (e.g. platinum, platinum-ruthenium, platinum-cobalt). Ionomer
and solvent (e.g. water, isopropanol) are also required to produce the catalyst
ink.
● The catalyst ink for the anode layer and the cathode layer of the CCM is mixed
separately due to the different compositions.

Process parameters & requirements Alternative technologies

• Platinum load cathode: approx. 0.4 mg/cm² • Paddle mixer
• Platinum load anode: approx. 0.1 mg/cm² • Rotary ball mixer
• Atmosphere: contamination-free • Ultrasonic mixer
• Mixing time: >1 h
• Mixing temperature: 2°C
• Mixing speed: 600 - 4,000 rpm

Quality influences Quality characteristics

• Mixing time • Porosity
• Mixing temperature • Uniform platinum loading
• Mixing tool • Viscosity
• Ambient conditions

Production costs [excerpt] Invest for machinery and plant: € 0.3 - 0.4 m
Decal Coating & Drying
CCM production

Slot
nozzle Catalyst
layer

XRF IR/DC
Pump

Decal Tempered
Convection oven rollers

Catalyst ink

Component production Stack production System production

● The decal process is an indirect coating of the polymer membrane by means of

decal transfer carrier film, hereinafter referred to as “decal”. The process enables
dry coating of the moisture-sensitive polymer membrane.
● The catalyst ink prepared in the previous step is applied to the decal (e.g.
polytetrafluoroethylene [PTFE], polypropylene [PP]) by slot die.
● The coated decal is then transferred to a convection oven and dried.
● After evaporation of the solvents, the decal is inspected for homogeneity as well
as particle size and thickness of the catalyst layer. This can take place using
infrared/direct current (IR/DC) and/or X-ray fluorescence (XRF) systems.

Process parameters & requirements Alternative technologies

• Coating thickness (anode): 3 - 15 µm • Transfer roller
• Coating thickness (cathode): 10 - 30 µm • Screen printing, inkjet printing, gravure
printing
• Belt speed: 0.1 - 1 m/min
• Squeegee
• Drying time: approx. 4 min
• Infrared drying, laser drying
• Drying temperature: approx. 30°C - 70°C (air)
120°C - 160°C (heated rollers) • Extrusion

Quality influences Quality characteristics

• Viscosity of the catalyst ink • Layer homogeneity
• Application tool • Particle size
• Oven temperature • Layer thickness
• Residual moisture after drying

Production costs [excerpt] Invest for machinery and plant: € 0.8 - 1.2 m
Hot Pressing & Decal Removing
CCM production
Used cathode
Catalyst-coated cathode decal (waste
decal product)

Tempered
F top roller
Polymer membrane Catalyst layer

Tempered
F bottom CCM
Compressive
roller
force
Used anode
decal
Catalyst-coated anode decal (waste product)

Component production Stack production System production

● The transfer of the dry catalyst layer from the decal to the polymer membrane
is done by hot pressing process. Since the productivity of this step is largely
dependent on the hot pressing method, a roll-to-roll process is recommended.
● Cathode and anode decal are fed to the top and bottom of the polymer
membrane simultaneously and placed between the pair of rollers.
● For good transferability of the catalyst layer, the temperature-controlled roller
pair (100°C to 170°C) brings the polymer membrane to glass transition tem-
perature and generates a constant line pressure.
● The cathode and anode decal are then peeled off, analogous to the removal of
a decal, to form a waste product.
● The CCM is finished and wound onto a coil.

Process parameters & requirements Alternative technologies

• Line force: 150 - 250 N/cm • Direct membrane coating
• Temperature: 100°C - 170°C • Screen printing, inkjet printing, gravure
printing, squeegee, additive layer production
• Indirect membrane coating
• Transfer roller
• Coating of GDL (GDE approach)

Quality influences Quality characteristics

• Decal quality • Residue free decal
• Combination of roller temperature, feed • Non-destructive catalyst layer and polymer
speed, and contact pressure membrane
• Duration of active force application • Uniform adhesion of catalyst layer

Production costs [excerpt] Invest for machinery and plant: € 0.3 - 0.6 m
 Alternative Catalyst Application
Coating concepts and research approaches
The decal method shown previously is considered a possible option for
membrane coating. Alternatively, the following procedures are conceivable:

CCM direct coating:

● The polymer membrane is
Slot nozzle coated on both sides in a ver-
tical direction using slot nozzles.
● The vertical orientation saves
installation space and allows
Catalyst ink
coating on both sides with the
same layer quality.
● Due to the high moisture sen-
sitivity of the polymer mem-
brane, cracking and wave for-
mation must be counteracted.
Polymer
membrane

Indirect coating by transfer roller:

● The catalyst ink is applied to
a teflon-coated intermediate
element (e.g. a roller) and
(partially) dried.
Slot nozzle ● The transfer takes place along
Coated
roller the lines of hot pressing on the
underside of the intermediate
Polymer element where the polymer
membrane
CCM membrane is guided along.
● The intermediate element must
be cleaned before it is coated
again.
C

GDE approach:
● The catalyst ink is applied
directly to the GDL, forming a
Squeegee so-called gas diffusion electrode
(GDE).
● The GDE is then applied to the
Catalyst ink top and bottom of a polymer
membrane and laminated to
form the MEA.
GDL ● Depicted is the coating by
squeegee, where the thickness
of the catalyst ink can be pre-
cisely adjusted.
 Subgasket Application
CCM production Waste product CCM with gasket
(subgasket)
Seperating film Sealing layer

Adhesive Support material

CCM Perforation

Gasket material
(upper half)

= Counter roll

= Die

Waste product = Guide roll

Gasket material = Laminating roll
CCM (lower half)
Waste product
= Vacuum die
Shown is a procedure based on patent US2011/0151350A1.

Component production Stack production System production

● The upper half of the subgasket, consisting of carrier material, adhesive, PET
sealing layer and release film, is first perforated by means of a die. Afterwards,
excess release film is removed.
● From the supplied CCM, material is separated in a specified shape by means of
a vacuum die and stapled to the upper half of the gasket.
● The lower half of the gasket, consisting only of carrier material and PET sealing
layer, is also first perforated and pressed onto the underside of the CCM
material by laminating roller.
● At the same time, the perforated part of the upper carrier material, including
the release film, is removed and disposed.
● Finally, the perforated part of the lower carrier material is removed.

Process parameters & requirements Alternative technologies

• Belt speed: 30 m/min • Injection molding of a framegasket

• Die geometry: Product-dependent • Application of the subgasket by robot
• Contact pressure during joining process:
Material-dependent

Quality influences Quality characteristics

• Axial, radial and angular misalignment of the • Accurate positioning of the gasket
rolls relative to each other
• No contamination on the MEA surface
• Position tolerance between seal and CCM
• Strength of the joint

Production costs [excerpt] Invest for machinery and plant: € 0.8 - 1.0 m
Carbon Fiber Chopping
GDL production
Press roll

Carbon fiber
Blade roller

Plastic rib Cutting head

Steel roller Plastic rib filled

with air Crushed
carbon fibers

Component production Stack production System production

● Dry carbon fibers are shredded to produce the GDL.

● The fiber ribbon is guided over a steel roller with plastic ribs (blue) and held in
position by a press roller.
● The cutting heads of the rotating blade roll apply pressure to the fiber ribbon in
the transverse direction, causing the fiber filaments to break until the fiber is
completely severed. In the process, air-filled plastic ribs (orange) eject the cut
fibers silently.
● The rotary cutting tool is capable of operating at high speed. The cutting head
wear typical of the process is minimized by cutting “into the void”.
● The six to twelve millimeter fibers are collected in a collection bin and used for
subsequent carbon paper production.

Process parameters & requirements Alternative technologies

• Cutting rate: 9 m/min • Guillotine cutting

• Particle size: 6 - 12 mm
• Contact pressure of the press roll: 0.1 MPa

Quality influences Quality characteristics

• Sharpness of the cutting heads • Particle shape

• Shape of the cutting heads • Surface morphology
• Material of the cutting heads

Production costs [excerpt] Invest for machinery and plant: € 0.05 - 0.1 m
Forming Carbon Paper
GDL production

Distribution Pressing Calandering zone

Drying zone
zone zone (optional)

Flow box Heated roll

Wet fleece
Carbon fiber (“paper”)
suspension Press roll Carbon
paper

Wastewater Inclined sieve

Mass sensor

Component production Stack production System production

● Chopped carbon fibers are processed together with a binder polymer inside a
“flowbox” to form a suspension and uniformly applied to an inclined wire.
● The inclined wire is covered with plastic fabric and allows water to drain off, but
retains the carbon fibers.
● During subsequent pressing, further removal of water increases the solids
content of the paper suspension. Wet laid nonwoven (“paper”) is produced.
● While retaining the sheet structure, the volume of the paper is reduced in the
drying unit and the binder is hardened.
● Optionally, the surface structure is fixed by calendering. Cooled rolls compress
the carbon paper and remove last fibers and sponge structures.

Process parameters & requirements Alternative technologies

• Productivity: 300 - 320 m²/h • Spunlace fleece production

• Basis weight: 15 - 70 g/m² • Fabric manufacturing
• Material thickness: 150 - 300 µm
• Binder content: <25%

Quality influences Quality characteristics

• Water content of the suspension • Uniform thickness of the material

• Height or force measurement during • Smoothness of the material
calendering
• Wet strength of the paper
• Quality of the fiber dispersion
• Damage-free surface
• Homogeneous binder distribution
• Web tension

Production costs [excerpt] Invest for machinery and plant: € 0.5 - 1.0 m
Impregnating
GDL production
Convection oven

Deflection
Carbon paper roller

Output
Impregnated
carbon paper
(<270 µm)
Impregnation
bath
Excess
Pressing process
fluid

Component production Stack production System production

● The carbon paper is impregnated with a thermosetting resin (e.g. phenolic

resin) so that a desired material strength as well as porosity are achieved. In
addition, the electrical and thermal conductivity are increased after passing
through the graphitization process.
● After passing through the impregnation bath, excess liquid is removed by a
pressing process.
● Remaining solvents are evaporated inside a convection oven at about 150°C,
and the resin is cured.
● As an alternative to the continuous process, after drying, the carbon paper is
stacked individually alternating with separator paper at elevated temperature
and then pressed.

Process parameters & requirements Alternative technologies

• Drying temperature: 150°C • Infrared drying

• Material thickness: 200 - 270 µm • Stacking with separator paper

Quality influences Quality characteristics

• Composition of the impregnation material • Material thickness

• Drying temperature • Material density
• Drying period

Production costs [excerpt] Invest for machinery and plant: € 0.35 - 0.7 m
Graphitizing
GDL production

Nitrogen injection
Nitrogen exhaust
Lock Cooling zone
Nitrogen atmosphere
GDL
substrate

Heating zone
Water cooling
Lock
Impregnated carbon paper

Component production Stack production System production

● Graphitization (also high-temperature carbonization) of the thermosetting resin

results in a higher modulus of elasticity, increased electrical and thermal con-
ductivity, and oxidative resistance.
● The carbon paper is heated in a furnace under an inert gas atmosphere
(nitrogen, argon) or in a vacuum to temperatures of about 1,400°C to 2,000°C
(in batch processes: more than 2,000°C).
● The strip material passes through different temperature zones within the
heating zone and is finally cooled to room temperature in a cooling zone.
● The end product has a material thickness of 150 to 300 µm.

Process parameters & requirements Alternative technologies

• Process temperature: 1,400°C - 2,500°C • Graphitization under inert gas atmosphere
• Material thickness: 150 - 300 µm • Batch carbonization under vacuum or inert
• Density of paper: 0.2 - 0.3 g/cm³ gas
• Process time <5 min. (< 15 min. for batch
process)
• Vacuum or inert gas atmosphere

Quality influences Quality characteristics

• Temperature profile • Degree of pyrolysis of the resin >99.5%

• Smoldering gas duct (removal of pyrolysis • Deposit free product
products)
• Conductivity of the material
• Inerting of the furnace
• Carbon content

Production costs [excerpt] Invest for machinery and plant: € 0.35 - 0.7 m
Hydrophobing
GDL production
Convection oven

Graphitized carbon Deflection

paper roller

Output
Hydrophobic
carbon paper
(<270 µm)

Water-based
PTFE suspension Excess
fluid Pressing process

Component production Stack production System production

● The GDL substrate is immersed in an aqueous polytetrafluoroethylene (PTFE)

suspension, with excess suspension removed by a pressing process. This
process helps improving the hydrophobic properties.
● The PTFE content of the subsequent GDL is adjusted by the amount of PTFE in
the suspension.
● Remaining solvents are removed by oven drying, and the PTFE particles are
bonded to the base material by sintering at about 300°C to 350°C.
● The speed of the drying process influences the PTFE distribution in the material.
Fast drying causes the PTFE to remain in surface zones, while slow drying
ensures holistic distribution.

Process parameters & requirements Alternative technologies

• Drying temperature: 300°C - 350°C • Infrared drying

• PTFE mass fraction: 5 - 10 wt.% • Air drying
• Paper thickness: 200 - 270 µm • Spraying
• Material alternative: Fluoroethylene • Brush application
propylene (FEP)

Quality influences Quality characteristics

• Composition of the impregnation material • Homogeneous PTFE distribution

• Drying temperature
• Drying period

Production costs [excerpt] Invest for machinery and plant: € 0.35 - 0.7 m
MPL Application & Sintering
GDL production
Squeegee
MPL material Quality
management

Preheating Sintering
(250°C) (350°C)
Camera Marker
system (ink)

GDL

Convection oven Longitudinal cutting tool Separating foil

Component production Stack production System production

● The microporous layer (MPL), consisting of carbon or graphite particles and

polymeric binder (e.g. PTFE), has a pore size between 100 and 500 nm, while
the carbon paper has a pore size of ten to 30 µm.
● The primary function of the MPL is water management, as it effectively removes
liquid water from the catalyst layers.
● Here, the MPL is applied to the carbon paper via a squeegee process with a
layer thickness of less than 50 µm.
● To reduce cracking, the solvent is slowly evaporated. Sintering enables sufficient
adhesion of the MPL.
● Finally, the material is trimmed, inspected for quality defects and marked.
Winding is carried out with the aid of release film.

Process parameters & requirements Alternative technologies

• Pore size: 100 - 500 nm • Slot nozzle

• Layer thickness: <50 µm • Screen printing
• Duration of the sintering process: <10 min. • Spray application
• Sintering temperature: approx. • Roll up
300°C - 350°C

Quality influences Quality characteristics

• Sintering time • Adhesion of MPL to carbon paper

• Temperature curve during sintering • No exceeding of the melting point
• MPL material • Damage-free MPL surface
• Smoothness

Production costs [excerpt] Invest for machinery and plant: € 0.9 - 1.8 m
 Joining & Separating
MEA production
Waste product
Top view
GDL Cutting tool
transverse
Tempered
top roller
F
CCM with
subgasket MEA

Assembly
F Longitudinal line
Tempered
Adhesive bottom roll Compressive cutting tool
force (optional)
= Counter roll
GDL = Die

= Guiding roll
Shown is a procedure based on patent US2011/0151350A1.

Component production Stack production System production

● The CCM is connected to the GDL on both sides and then separated. An MEA
with a seal is created.
● The GDL is provided with adhesive and perforated according to the specified
geometry.
● The perforated GDL is stapled to the top and bottom of the MEA with a seal.
● Joining is then carried out by means of a hot pressing process.
● The process step is completed with the separation. In addition to transverse
separation, longitudinal separation is also possible at this point, depending on
the product and process design.
● Since the MEA is the “less precise” component compared to the bipolar plate, it
requires special attention in tolerance management.

Process parameters & requirements Alternative technologies

• Hot pressing temperature: 100°C - 160°C • Discontinuous hot pressing process

• Contact pressure: 1,000 - 10,000 kg/cm² • Additive layer production

Quality influences Quality characteristics

• Axial, radial and angular misalignment of the • Positional accuracy of the GDL
rolls
• Strength of the joint
• Combination of roll temperature, feed speed,
and contact pressure • Dimensional accuracy of the cutting
geometry
• Duration of active force application
• Thickness variations and irregular cut edges
of the porous GDL

Production costs [excerpt] Invest for machinery and plant: € 1.2 - 1.8 m
Coating
BPP production
Target
Substrat heater (e.g. gold,
Output
titanium,
aluminum) Coated raw material
Plasma
Atom
Ion BPHP

s Magnet
Aspiration Cleaning device N
X-ray testing device

Ar

mm

N S N

X-rays
S N S

Raw material
Quality control
Vacuum pump

Component production Stack production System production

● The coating of the raw material for the bipolar half plates is carried out using
the PVD process (physical vapor deposition, CVD).
● The surface of the raw material is first cleaned from both sides. Afterwards, its
quality is checked.
● The raw material is positioned inside a vacuum chamber filled with inert gas
(e.g. argon). The inert gas is ionized and forms a plasma.
● The target (coating material, e.g. gold, titanium, aluminum) is fired at with ions
formed by the plasma. Atoms of the target are dissolved. They move to the
substrate (here: the raw material) and diffuse into its surface.
● After the coated raw material exits the vacuum chamber, its wall thickness is
measured using X-rays.

Process parameters & requirements Alternative technologies

• Temperature: 450°C - 500°C • Alternative coating materials: titanium

nitride, chromium nitride, amorphous carbon
• Vacuum pressure: 1*10-1 – 1*10-7 mbar
• Chemical vapour deposition (CVD)
• Layer thickness: 0,1 - 6,3 µm
• Nitriding
• Cycle time: approx. 2 - 5 min.
• Electroplating

Quality influences Quality characteristics

• Inert gas • Electrical conductivity

• Coating material • Corrosion resistance
• Substrate shape

Production costs [excerpt] Invest for machinery and plant: € 1.8 - 2.0 m
Stamping
BPP production
Output
Isolated bipolar
half plate

Bipolar half plate with

(Coated) Raw
component geometry
material

Continuous
stamping process

Component production Stack production System production

● The (coated) raw material for the bipolar half plates (e.g. 1.4301, 1.4404) is
unwound from a coil and fed into the stamping line.
● The high-precision transfer positions the material below the forming tool and
applies the pressing force.
● The application of the pressing force results in plastic deformation of the
material and cutting of free contours.
● Different deformations and free contours of the bipolar half plates are possible;
these are realized by different tool stages.
● Advantages of forming stamping are a high repeatability and a high cycle time.

Process parameters & requirements Alternative technologies

• Cycle time: 30 - 50 BPP/min • Deep drawing
• Pressing force: 460 - 11,000 kN (46 - 1,100 t) • Injection molding
• Stroke path: 200 - 600 mm • Rubber cushion pressing
• Minimum number of pressure points: 4 • Roll-to-roll molding
• Possible material thickness: 0.05 - 1 mm
• Hydroforming
• Material thickness tolerance: approx. 0.01 mm

Quality influences Quality characteristics

• Forming pressure • High cycle time

• Clamping force • Freedom from breakage and damage
• Forming properties of the base material • Uniform flowfield structure
• Component geometry • High repeatability
• Machine stiffness

Production costs [excerpt] Invest for machinery and plant: € 1.5 - 2.0 m
 Hydroforming
BPP production
Molding tool Output
Upper die Geometry of the
bipolar half plate
Bipolar half
plate

Perforated Water
plate

Bipolar half plate with

(Coated) Raw
part geometry
material

Pressure intensifier
Component production Stack production System production
● The (coated) raw material for the bipolar half plate (e.g. 1.4301, 1.4404) is
unwound from a coil, fed into the hydroforming system and positioned under
the forming die.
● By lowering the upper die, a contact pressure (also clamping force) is applied to
the material, forming die and lower die.
● Water is then brought under high pressure by means of a pressure intensifier
and passed through the die plate. This leads – predetermined by the design of
the forming die – to plastic deformation of the material and thus to the
formation of the component geometry.
● To increase the output rate, several component geometries can be formed
simultaneously.
● A final cleaning process removes residues from the formed material.

Process parameters & requirements Alternative technologies

• Forming pressure: 1,000 - 4,000 bar • Punching

• Process time: approx. 5 - 10 sec. per plate • Deep drawing

• Working medium: water • Injection molding

• Embossing
• Possible material thickness: 0.05 - 1 mm
• Rubber cushion pressing
• Material thickness tolerance: approx. 0.01 mm
• Roll-to-roll molding

Quality influences Quality characteristics

• Forming pressure • Freedom from breakage and damage

• Clamping force • Uniform flowfield structure
• Forming properties of the base material • High repeatability

• Component geometry • Very low springback

• Machine stiffness

Production costs [excerpt] Invest for machinery and plant: € 1.5 - 1.8 m
Separating
BPP production
Output
Bipolar half plate
(BPHP)

Cutting
head
Nozzle
Laser
beam

Assembly Bipolar half

line plate (BPHP)

Component production Stack production System production

● The production step of “separating” is only necessary in the case of hydro-

forming. For “stamping” it is obsolete.
● Bipolar half sheets are separated and brought into the desired geometry by
means of laser trimming.
● Inside the cutting head, the laser beam is focused by a lens and projected onto
the sheet. The high energy input leads to a separation of the material.
● The cutting optics are mounted on a so-called XY gantry, allowing precise
movement of the cutting head within a predefined range.
● Coated as well as uncoated materials can be processed.

Process parameters & requirements Alternative technologies

• Working range: 500 - 1,500 mm • Punching

• Laser output power: 500 - 2,000 W • Fine cutting, shear cutting
• Feed rate: 20 to max. 300 m/min at 0.2 mm • Remote laser cutting
wall thickness
• Accuracy: 10 - 50 µm

Quality influences Quality characteristics

• Type of laser • Burr-free edges

• Cutting speed • No impairment of the coating
• Focusing • Distortion-free trimming
• Process-related impurities

Production costs [excerpt] Invest for machinery and plant: € 0.5 - 0.6 m
Joining
BPP production
Output
Bipolar plate
Laser (BPP)

Arm robot
Remote
scanner

High-resolution
camera

Laser beam

Shielding gas
nozzle

Bipolarhalb-
platten
Welding points

Component production Stack production System production

● In the joining process, two bipolar half plates are welded to form a bipolar plate.
● The focusing of the laser beam and the resulting high energy input into the
metal surface heats the metal to melting temperature and creates a material
bond.
● To avoid oxidation, the welding process is carried out in an inert gas atmo-
sphere.
● For process monitoring and quality assurance, the welding process can be
recorded and evaluated by means of sensors.

Process parameters & requirements Alternative technologies

• Cycle time: 10 - 120 sec. • Adhesive technology

• Feed rate: <60 m/min • Brazing
• Laser power: approx. 500 - 1,000 W • Additive manufacturing
• Material thickness: approx. 100 - 250 µm

Quality influences Quality characteristics

• Positioning and bracing of the bipolar half • Component distortion

plates
• Strength of the weld spots
• Size of the heat-affected zone
• Media tight welding
• Process temperature in the weld spot
• No flash
• Wavelength of the laser beam
• Type of shielding gas

Production costs [excerpt] Invest for machinery and plant: € 0.8 - 0.9 m
Leakage Testing
BPP production

Nozzle

Bipolar
Leak detector plate

Test medium
(e.g. air, helium)
End plates
Vacuum chamber
(for vacuum test)

Component production Stack production System production

● Eventually, the bipolar plates are checked for leakages.

● In the vacuum test, they are placed inside a vacuum chamber, filled with a test
medium (e.g. helium) and its partial pressure is measured in a vacuum chamber.
● If the test medium’s partial pressure in the chamber is elevated, leakage from
the bipolar plates can be identified using a mass spectrometer leak detector
(MSLD). This method can be used for more stringent test specifications.
● In the pressure decay test, air is introduced into the device under testing (DUT)
as the test medium. Leaks are detected by a drop in air pressure in the system.
● The general conditions for passing the leakage test are to be determined by the
manufacturer. After passing the leakage test, the production of the bipolar plate
is completed.

Process parameters & requirements Alternative technologies

• Test pressure: approx. 1 - 1.5 bar • Flow measurement

• Cycle time: approx. 40 sec. • Ultrasonic detection
• Test sensitivity: 3*10-2 mbar l/s (air) 2*10-6 • Outside-in method
mbar l/s (helium)
• Test gas: air, helium, nitrogen, hydrogen

Quality influences Quality characteristics

• Test pressure • No deformation or destruction of the bipolar

plate
• Accuracy leak detector
• Leak tightness of the bipolar plate
• Geometry of the fuel gas channels

Production costs [excerpt] Invest for machinery and plant: € 0,2 - 0,4 m
Gasket Application
BPP production
Output
Image area Stencil carrier Coated bipolar plate
with gasket

Squeegee

Gasket
material Hydraulic arm
Automatic valves
Sieve frame
Image position

Fibers

Bipolar half Printed gasket

plate
Bipolar half plate
Barrier layer

Component production Stack production System production

● The BPP seals are applied to the bipolar plate by means of screen printing.
● The sealant is applied to the stencil carrier by a nozzle and pressed through the
image areas by the movement of the squeegee.
● While the barrier layers cannot transfer any sealing material to the bipolar plate,
the image zones of the stencil carrier are permeable. These zones can be
individually adjusted.
● The bipolar plate is brought into close proximity of the stencil carrier by means
of a hydraulic arm, so that perfect application of the seal is possible.
● The excess printing substance is transported by the squeegee to the edge of the
printing form and used for the next printing process.

Process parameters & requirements Alternative technologies

• Cycle time: <3 sec. • Dispensing

• Wall thickness seal: 0.3 – 0.5 mm • Formed in-place foam gasket (FIPFG)
• Belt speed: 50 mm/s • Insert molding
• Punching

Quality influences Quality characteristics

• Process speed • Positional accuracy of the seal

• Distance between the fibers of the stencil • Uniform sealing ring
carrier
• Dosing quantity

Production costs [excerpt] Invest for machinery and plant: € 1.2 - 1.5 m
Further Information
on fuel cell stacks and systems
The production chain of the fuel cell components explained in the context of this
guide is continued by the production of the stack and the system. For more
information on this, please refer to the guide listed below. It further details the
production steps for the assembly of the stack as well as the system and the
associated total costs.

ISBN: 978-3-947920-31-0