Stack Technologies

As part of research projects and industrial collaborations, we work with our partners to develop high-performance fuel cell stacks for mobile, stationary and portable applications.

We develop optimised clamping systems for fuel cells and research production-optimised fuel cell stack designs and automated assembly processes.

We characterise and qualify single cells, multi-cells and entire fuel cell stacks on numerous test benches.

 

Qualification of stack components

We have developed innovative test methods for the in-situ characterisation of coatings on metallic bipolar plates and for the material qualification of plastics for stacks and fuel cell systems. Our range of services includes a wide variety of modern analyses:

 

  • Resistance measurement: Electrical contact and surface resistances
  • Corrosion current measurement: Long-term stability and material degradation
  • Hydrogen permeation measurement: Testing of tightness and H2 permeability
  • Thermal conductivity measurement: Material properties for thermal management
  • Dynamic differential calorimeter (DSC): Analysis of thermal transitions such as glass and melting points
  • Thermogravimetric analysis (TGA): Determination of mass losses at increasing temperatures

 

We also offer tests for wetting properties (e.g. water contact angle), gas analysis, damage analysis (degradation of membranes, bipolar plates and catalysts) and comprehensive material characterisation (e.g. chemical and mechanical properties, pore structures).

 

Would you like to qualify your materials or stack components? We would be happy to test them for you as part of an order or develop customised test concepts together with you. Contact us – we would be happy to advise you!

Stack development

ZBT has many years of experience in developing efficient, robust and industrialisable fuel cell stacks for mobile and stationary applications.

 

Together with our partners, we optimise existing fuel cell stacks or develop new, independent fuel cell stack designs specifically tailored to the requirements of the respective application.

As part of stack development, we optimise the power densities, efficiencies and service life of the fuel cells. In close coordination with our manufacturing partners, however, our work also focuses in particular on the industrialisable, cost-efficient design of the stack components MEA, bipolar plates, seals and clamping system.

Would you like to develop a new fuel cell stack or optimise existing fuel cell stack designs? Feel free to contact us!

 

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Clamping concepts and stack mechanics

The defined clamping of the fuel cell stack is necessary to ensure homogeneous compression of the active area, achieve low contact resistances and reliably seal the media chambers.

 

Length changes in the fuel cell stack due to pressure and temperature changes during operation and component tolerances during assembly must be reliably compensated for.

ZBT develops assembly-optimised clamping systems, improves contact pressure distribution using FEM simulations and researches alternative manufacturing processes such as adhesive bonding of MEAs and bipolar plates for the construction of extremely lightweight fuel cell stacks.

Stack assembly

During stack assembly, the MEA and bipolar plate components must be precisely positioned and pressed together in a defined manner. Stack speeds of up to 10 Hz are required, especially for mobile applications.

After assembly, the fuel cell stack must be conditioned and tested for tightness, insulation and performance.

The ZBT has many years of experience in the automated assembly of fuel cell stacks and is working with partners to research optimised designs for MEAs, bipolar plates and clamping systems that enable high-speed stack assembly.

In addition, we are developing processes for inline quality control of fuel cell components and stacks.

Please contact us if you have any questions about automated stack assembly!

Stack testing

As part of research projects and as an industrial service, ZBT characterises and qualifies individual cells, short stacks and full stacks.

 

For this purpose, we have an extensive infrastructure of automated test benches at our disposal, on which fuel cell stacks are researched in highly dynamic operating cycles in continuous 24/7 operation.

Exemplary test programmes

  • Characterisation
  • Operational optimisation
  • Media supply
  • Temperature control
  • Electrochemical analysis of MEA condition and operating behaviour
  • Continuous operation
  • Harmful gas investigations
  • Load sequence operation
  • Cycle tests
  • Ageing investigations and accelerated stress tests
  • Climate tests
  • Tests

 

The modular design of our ZBT test benches also allows flexible adaptation of actuators and measurement technology to specific measurement tasks – please contact us if you are interested!

Contact for Stack Technologies

Head of Department Fuel Cell and Stack

Dr. Jörg Karstedt
+49 203 7598-1178

Contact for Metallic Stacks

Group Leader

Lars Kühnemann
+49 203 7598-1257

Contact for Graphite Stacks

Group Leader

Sebastian Brokamp
+49 203 7598-4286

Discover more topics

Membrane Electrode Assemblies

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.

Bipolar Plates and Seals

We support our customers and partners in the development and production of high-performance bipolar plate and sealing solutions for PEM fuel cell stacks – from material development and design to component qualification and the production of bipolar plates and sealing solutions, as well as the development of innovative manufacturing processes.

Fuel Cell Systems

We develop simulation-based fuel cell systems as part of research projects and industrial collaborations. We combine our expertise in system modelling with the operational management of component test benches to simulate real-life system environments.