Ein Roboter appliziert eine Dichtung auf einen graphitische Bipolarplatte

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.

Innovative manufacturing processes

In cooperation with industry, ZBT develops innovative manufacturing processes for fuel cell components such as the adhesive bonding of bipolar plates and fuel cells, laser surface structuring and options for automated quality assurance of bipolar plates and seals.

 

Are you developing production processes for fuel cell components? We would be happy to advise you on fuel cell-specific requirements and qualify the effects of manufacturing processes on the performance and service life of fuel cell stacks for you!

Design of bipolar plates

We develop designs for metallic and graphitic bipolar plates and optimise them specifically in terms of power density, service life and manufacturability. The quality of the starting materials – from raw materials to semi-finished products – forms the basis for the development of high-performance and reliable products.

 

Our focus:

  • Consulting and specification creation: Support in defining requirements and specifications
  • Cell component support: Consulting, benchmarking and optimisation of MEAs, materials and coatings for bipolar plates and sealing materials
  • CAD design: Development of bipolar plates for mobile and stationary applications
  • CFD simulation: Flow optimisation to increase efficiency
  • Test geometries: Production of prototypes for validating cell performance
  • Manufacturing support: Support in communication and coordination with production partners
  • Short stack and full stack development: Design, testing and validation

 

kleiner Stapel aus mehreren versetzt übereinander liegenden graphitischen Bipolarplatten

Material development Compound

ZBT develops highly filled compounds with carbon-based fillers such as graphite, carbon black, CNT and graphene. These materials are characterised by outstanding electrical and thermal conductivity and excellent chemical resistance. The quality of the starting materials – from raw materials to semi-finished products – is an essential basis for the development of high-performance products.


Our Services

We offer optimised standard materials for various production processes of graphitic bipolar plates suitable for NT-PEM and HT-PEM applications. These materials are distributed worldwide in cooperation with our licensing partners.


In addition, we develop customised compound formulations for individual applications:

  • Corrosion-resistant plate and tube heat exchangers
  • Electrode materials for fuel cells, batteries and electrolysis
  • Heat sinks for efficient heat dissipation

Continuous production of graphitic foil-based bipolar plates

In addition to conventional hot pressing or injection moulding of bipolar plates for fuel cells, batteries or electrolysers, ZBT is researching the continuous production of foil-based graphitic bipolar plates using an extrusion process.


The production of thin-walled graphitic bipolar plates with high corrosion resistance has been successfully demonstrated. This process offers great potential for reducing process costs in the manufacture of bipolar plates, especially when the flow field and cooling structures of the bipolar plates are integrated by embossing or continuous rolling.

Using various extrusion tools, foil widths of up to 350 mm and thicknesses of 400 µm to 2 mm can be produced in any length.

Sealing solutions for fuel cells

ZBT develops and produces innovative sealing solutions for fuel cell stacks that are used by numerous manufacturers worldwide. Our dispenser-based application process not only offers high design flexibility in the development and prototyping phase, but also impresses in series production with low application costs, high process stability and short cycle times – ideal for large quantities.


Advantages of our sealing solutions

  • Robust and versatile: Mechanically stable seals, also suitable for thin substrate materials
  • Higher power density: Up to 20% increase thanks to compact seal designs
  • Optimised port design: Integrated seals prevent water accumulation in the port area
  • Flexible development: Adaptable design for prototyping and individual requirements
  • Cost-efficient: Scalable process for economical series production
Ein automatisierter Dispenser bringt eine Dichtung auf eine Bipolarplatte auf

Test methods for bipolar plates and seals

The properties of bipolar plates and seals are crucial for the reliable operation of fuel cells. ZBT offers customised test methods for characterising, quality assuring and predicting the service life of these key components. Bipolar plates are tested for electrical conductivity, geometry, coating stability and corrosion behaviour, among other things – both during development and along industrial production lines. For seals, the focus is on media resistance, material fatigue and adhesion properties. In addition, ex-situ analyses such as REM, FTIR or XRM are used to evaluate material properties structurally and chemically. The goal: durable, scalable and reliable components for your fuel cell systems.

more about our Testing Procedures

Contact

Group Leader Compound Technology

Dr. Marco Grundler
+49 203 7598-1175

Contact

Group Leader Metallic Bipolar Plates

Lars Kühnemann
+49 203 7598-1257

Contact

Group Leader Graphitic Bipolar Plates

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.

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.

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.