{"id":14962,"date":"2026-01-29T07:48:13","date_gmt":"2026-01-29T07:48:13","guid":{"rendered":"https:\/\/zbt.de\/projects\/h2coat-special-coating-for-silicone-seals-in-fuel-cells-to-reduce-permeation\/"},"modified":"2026-03-16T15:06:37","modified_gmt":"2026-03-16T15:06:37","slug":"h2coat-special-coating-for-silicone-seals-in-fuel-cells-to-reduce-permeation","status":"publish","type":"project","link":"https:\/\/zbt.de\/en\/projects\/h2coat-special-coating-for-silicone-seals-in-fuel-cells-to-reduce-permeation\/","title":{"rendered":"H2Coat - Special coating for silicone seals in fuel cells to reduce permeation"},"content":{"rendered":"
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H2Coat – Special coating for silicone seals<\/span> in fuel cells<\/span> to reduce permeation<\/span> <\/h1>\n

The denser, the better: silicone is the material of choice for seals in fuel cells. However, ZBT and Rhenotherm are convinced that the good properties can still be improved and are jointly developing a special coating to further reduce hydrogen permeation through the seal. <\/h4>\n
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Hydrogen fuel cells are a key technology for climate-friendly mobility. In addition to many other factors, careful handling of hydrogen as an energy source<\/strong> is crucial for their efficient operation – losses should be reduced to an absolute minimum. <\/p>\n

The problem: due to its small molecular size, the gas can also diffuse slowly through conventional silicone seals. This so-called permeation effect<\/strong> leads to a loss of efficiency and can also pose a safety risk under certain circumstances. <\/p>\n

Reduce hydrogen losses<\/h4>\n

In order to reduce this permeation, the ZBT is working with Rhenotherm Mini Parts in the ZIM project H2Coat to develop a new type of special coating for dispensed silicone seals<\/strong> on bipolar plates of fuel cells. The aim is to significantly reduce hydrogen permeation and thus increase both the efficiency and safety of fuel cell systems. The new coating is intended to form an effective barrier against hydrogen permeation without negatively affecting the mechanical properties of the seal. <\/p>\n<\/div>\n <\/div>\n

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<\/h2>\n

No easy task: reducing hydrogen permeation in silicone seals is technologically demanding. In addition to the impermeability to hydrogen, the secure and permanent adhesion of the coating to the silicone surface<\/strong> is a major challenge for the researchers. This is particularly tricky due to the low surface energy of silicone. <\/p>\n

Complex tests<\/h4>\n

To evaluate the newly developed coatings, coated and uncoated test specimens are examined on a specially developed permeation test stand<\/strong> and the permeation rates are determined. In order to be able to assess the mechanical stability and sealing effect of the coated materials in practice, the scientists are also adapting methods for measuring the compression set<\/strong> (DVR). In addition, the project partners are developing test protocols to validate the coated seals later under real operating conditions in fuel cells. <\/p>\n

In the H2Coat project, the partners are pooling their expertise in materials technology and fuel cell development. Rhenotherm Mini Parts develops and investigates suitable coating systems<\/strong>, evaluates their adhesion and barrier effect and later transfers the process to real fuel cell components. The ZBT provides test specimens and bipolar plates with seals, carries out permeation and DVR measurements<\/strong> and tests the coated seals in fuel cells under real operating conditions. The results are compared with reference stacks in order to evaluate the effect of the coating on performance and ageing. <\/p>\n

With the development of the H2Coat special coating, the project partners are making an important contribution to the economic and safe use of hydrogen in fuel cell technology. The significant reduction of hydrogen losses<\/strong> through silicone seals will increase the efficiency of fuel cells and create the basis for a broader industrial application – a step towards greater sustainability, safety and competitiveness in fuel cell technology. <\/p>\n<\/div>\n<\/section>\n

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PROJECT INFO<\/h2>\n

Project title:<\/strong>
\nDevelopment of a new type of special coating for dispensed silicone seals on bipolar plates of fuel cells<\/p>\n

Project acronym:<\/strong> H2Coat<\/p>\n

Funding:<\/strong> This project is funded by the Federal Ministry for Economic Affairs and Energy as part of the Central Innovation Program for SMEs (ZIM).<\/p>\n

Approval period: <\/strong>1. July 2025 – 30. June 2027<\/p>\n<\/div>\n<\/section>\n

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CONTACT<\/h3>\n

Project manager<\/p>\n<\/div>\n

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\n Salman Fettah\n <\/div>\n <\/div>\n
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\n <\/svg><\/i>\n +49 203 7598 1170<\/span>\n <\/div>\n
\n <\/svg><\/i>\n \n s.fettah@zbt.de<\/a>\n <\/span>\n <\/div>\n <\/div>\n <\/div>\n
\n \"Professional\n \n \n <\/div>\n <\/a>\n <\/figure>\n <\/div>\n
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Other current projects<\/h2>\n \n
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PEMELYonROLL: Scalable roll-to-roll production for PEM electrolysis MEAs<\/h4>\n

The PEMELYonROLL project is developing scalable manufacturing processes for high-performance CCM and MEA for PEM water electrolysis. The aim is to develop material-efficient, quality-assured and industry-oriented manufacturing processes. <\/p>\n <\/div>\n

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\n Read more<\/span>\n <\/svg><\/i>\n <\/div>\n <\/div>\n<\/a> <\/div>\n
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\n \"Laboratory\n <\/figure>\n <\/div>\n
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NEREUS – Next-Generation Scalable AEM Electrolysers as Sustainable Hydrogen Production System<\/h4>\n

NEREUS develops next-generation anion exchange membrane electrolysers (AEM electrolysers) for high-performance, long-lasting and cost-efficient hydrogen production.<\/p>\n <\/div>\n

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\n Read more<\/span>\n <\/svg><\/i>\n <\/div>\n <\/div>\n<\/a> <\/div>\n
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FeNCy-PEM – Production and use of precious metal-free Fe-N-C catalysts<\/h4>\n

FeNCy-PEM develops scalable, precious metal-free Fe-N-C catalysts and integrates them into the production and application of PEM fuel cells.<\/p>\n <\/div>\n

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\n Read more<\/span>\n <\/svg><\/i>\n <\/div>\n <\/div>\n<\/a> <\/div>\n
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\n \"3D\n <\/figure>\n <\/div>\n
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HyQualityLab4NRW – Laboratory for AI-supported quality control and assurance in H2 research<\/h4>\n

With the “HyQualityLab4NRW”, a high-performance AI-supported material analysis laboratory is being set up at the ZBT to enable research institutions and industry to carry out comprehensive quality control of their products.<\/p>\n <\/div>\n

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\n Read more<\/span>\n <\/svg><\/i>\n <\/div>\n <\/div>\n<\/a> <\/div>\n
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\n \"Blick\n <\/figure>\n <\/div>\n
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PARZELL: Qualitative and quantitative PFAS analysis in realistic PEM electrolysis and fuel cell operation<\/h4>\n

The PARZELL research project systematically investigates the release of PFAS from PEM electrolysers and PEM fuel cells and develops methods to realistically measure, evaluate and reduce emissions in the long term.<\/p>\n <\/div>\n

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\n Read more<\/span>\n <\/svg><\/i>\n <\/div>\n <\/div>\n<\/a> <\/div>\n
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HiHyPe: New AEM technology for electrochemical hydrogen compressors<\/h4>\n

The HiHyPe project is developing a low- to non-precious metal AEM technology for electrochemical hydrogen compressors, thereby strengthening the future of the hydrogen economy.<\/p>\n <\/div>\n

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\n Read more<\/span>\n <\/svg><\/i>\n <\/div>\n <\/div>\n<\/a> <\/div>\n
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HY-Infra \u2013 Cross-border Project to analyse Hydrogen Infrastructure in the Meuse-Rhine Region<\/h4>\n

Hy-Infra strengthens the cross-border hydrogen infrastructure in the Rhine-Meuse region. The interregional project creates transparency about future hydrogen requirements and derives the necessary infrastructure by 2030\/2035. <\/p>\n <\/div>\n

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\n Read more<\/span>\n <\/svg><\/i>\n <\/div>\n <\/div>\n<\/a> <\/div>\n
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\n \"Teststand\n <\/figure>\n <\/div>\n
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NH3Avi – Inline production of metal-supported SOFC MEAs for aviation<\/h4>\n

Climate-neutral flying requires new energy sources – and new production technologies. NH3Avi is developing metal-supported SOFC membrane electrode assemblies (MEA) for use with ammonia in aviation. <\/p>\n <\/div>\n

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\n Read more<\/span>\n <\/svg><\/i>\n <\/div>\n <\/div>\n<\/a> <\/div>\n <\/div>\n <\/section>
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Discover more<\/h2>\n
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Research<\/h4>\n

The ZBT – the Hydrogen and Fuel Cell Center in Duisburg conducts application-oriented research on hydrogen-related topics, thus building a bridge between fundamental research and industry.<\/p>\n <\/svg><\/i>\n<\/a>\n <\/div>\n

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Publications<\/h4>\n

The results of publicly funded research projects belong to the general public. Publications are therefore an important part of our work. <\/p>\n <\/svg><\/i>\n<\/a>\n <\/div>\n

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Events<\/h4>\n

ZBT conferences and workshops, ZBT speakers at industry events, participation in trade fairs and exhibitions \u2013 there are plenty of opportunities to meet us and get in touch. Here is an overview. <\/p>\n <\/svg><\/i>\n<\/a>\n <\/div>\n <\/div>\n<\/section>\n","protected":false},"excerpt":{"rendered":"

The denser, the better: silicone is the material of choice for seals in fuel cells. However, ZBT and Rhenotherm are convinced that the good properties can still be improved and are jointly developing a special coating to further reduce hydrogen permeation through the seal. <\/p>\n","protected":false},"featured_media":14171,"parent":0,"template":"","class_list":["post-14962","project","type-project","status-publish","has-post-thumbnail","hentry"],"acf":{"date":null},"yoast_head":"\nH2Coat - Special coating for silicone seals in fuel cells to reduce permeation - Zentrum f\u00fcr BrennstoffzellenTechnik GmbH<\/title>\n<meta name=\"description\" content=\"ZBT and Rhenotherm are developing a special coating for seals in fuel cells to reduce hydrogen permeation.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/zbt.de\/en\/projects\/h2coat-special-coating-for-silicone-seals-in-fuel-cells-to-reduce-permeation\/\" \/>\n<meta property=\"og:locale\" content=\"en_GB\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"H2Coat - 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