eine Membran-Elektroden-Einheit (MEA) die mit hilfe von zwei Pinzetten auseinandergebaut wird, stilistisch wird in einem Ausschnitt die Molekülstruktur vergrößert dargestellt

Membrane Electrode Assemblies

The membrane electrode assembly (MEA) forms the heart of both polymer electrolyte membrane fuel cells (PEMFC) and PEM electrolysers. In fuel cells, it is where chemical energy is converted into electrical energy, while in electrolysers, electrical energy is used to split water into hydrogen and oxygen.

In order to make this conversion or power generation process as efficient and stable as possible, targeted research is needed on the individual components and composite structures, taking into account the interactions between them. In particular, the production and transfer of catalyst layers onto the membrane involves a large number of possible manufacturing steps, each of which has its own parameter matrix. We value scalability from laboratory scale to roll-to-roll production and therefore take cost-efficient manufacturing strategies into account right from the start.

Areas of work

We analyse electrochemical processes in fuel cells and electrolysis systems and characterise their components, such as catalysts, polymers, membranes and gas diffusion layers (GDS), using physical and chemical methods.


Another focus is on the development of efficient manufacturing technologies – from catalyst dispersions to electrode layers and catalyst-coated membranes (CCM) to complete membrane electrode assemblies (MEA).


By investigating harmful side reactions, we improve energy efficiency and extend the service life of key components.

ZBT-Wissenschaftler Ivan Radev und Volker Peinecke begutachten elektrochemische Komponenten im Labor des ZBT

Coating processes and CCM production

We continuously develop and optimise our catalyst dispersions and coating processes – tailored to spray, inkjet or ultrasonic technology. We check the quality of the coatings using performance curves on our fuel cell test benches.


We use high-end technologies such as an ultrasonic coating unit with vacuum table, a precise inkjet system and a powerful hot press. This enables us to produce both indirect (I_CCM) and direct (D_CCM) coatings, as well as laminating electrodes and manufacturing edge-reinforced membranes.

 

Key technologies:

  • Coating processes: ultrasonic spraying, squeegee coating, inkjet
  • Lamination: hot pressing under controlled conditions
  • Analysis: 3D measurement technology for precise layer evaluations
Wissenschaftlerin durch einen Teststand hindurch fotografiert

Dispersion development for functional layers

A stable catalyst dispersion is the basis for the production of catalyst-coated membranes (CCM) and membrane electrode assemblies (MEA). We have extensive experience in the production of dispersions for electrodes, both on the anode and cathode sides.


For dispersion, we use ultrasonic baths, sonotrodes and shear force dispersers (e.g. Kinematica Polytron, Sugino). Equipment for measuring particle size, zeta potential and viscosity is available for analysing the dispersions. Together with the University of Duisburg-Essen, dispersion transmission data and a sedimentation centrifuge enable additional precise analyses.

 

Technologies and analysis:

  • Dispersion process: ultrasonic bath, sonotrode, shear force disperser
  • Analysis: particle size, zeta potential, viscosity, sedimentation/centrifuge

 

Fully automated in-situ tests for PEM-MEAs

The final performance test in fuel cell operation is a crucial step in layer development. Only comprehensive in-situ tests under individually configurable conditions allow reliable conclusions to be drawn about the material and manufacturing parameters of CCMs and MEAs.


Fully automated single-cell test benches are available for this purpose, enabling precise tests up to 120 A. Programmable test protocols, such as commissioning tests, accelerated ageing or sensitivity analyses, ensure reliable results. These are supplemented by advanced measurement methods such as EIS (electrochemical impedance spectroscopy), CV (cyclic voltammetry), HFR (high-frequency resistance) and H2 permeation measurements.

 

Performance features:

  • Customised test protocols: activation, ageing analyses, performance tests
  • Measurement methods: EIS, CV, HFR, H2 permeation
  • Fully automated tests: for CCMs and PEM-MEAs up to 120 A

 

Characterisation of MEA components

The quality of the starting materials, such as raw materials and semi-finished products, is a crucial basis for the development of high-performance MEA products. At ZBT, we use a comprehensive portfolio of methods that includes the characterisation of individual components as well as electrochemical analysis and material screening. This portfolio has been developed, tested and successfully optimised in numerous projects.


We would be happy to test your components as part of a contract or in the context of joint technology development. Please feel free to contact us – we will support you with our expertise!

our Characterisation Services

Contact

Head of Department Electrochemical Components

Dr. Volker Peinecke
+49 203 7598-3120

Discover more topics