Fraunhofer Institute for Solar Energy Systems ISE
Fraunhofer Institute for Solar Energy Systems ISE

Laboratory for Production Research on Fuel Cell and Electrolyzer Membrane Electrode Assemblies

The membrane electrode assembly (MEA) is the electrochemical heart of fuel cells and electrolysers. Our production research considers the entire value chain, from catalyst powder to a 7-layer MEA, including quality control. We investigate the influence of process design and parameters, materials, and component architectures on the cost, quality, and performance of the MEA. We focus on laboratory-scale manufacturing processes with precisely defined conditions – typically sheet-to-sheet production – as well as industrial-scale processes such as roll-to-roll manufacturing.

We therefore target component manufacturers who want to improve their production processes or use new materials, stack manufacturers who want to process supplied semi-finished products into finished MEAs, machine builders who want to approve their equipment or integrate new processes into their machines, and customers who are looking for a research service provider for their prototype development.

Virtual Tour of our Fraunhofer ISE Production Research Lab for Membrane Electrode Assemblies

Our Services in this Lab Include:

 

  • Design of membrane electrode assemblies (MEAs)
  • Evaluation of machines, components, and materials (raw materials, pastes and inks, membranes)
  • Paste and ink development, including homogenization and ex-situ analytics
  • Development of processes and quality assurance methods along the entire MEA value chain
  • Ex-situ analysis and in-situ characterization of layers and cell components
  • Techno-economic evaluation of production processes

Our R&D Services along the Production Steps of MEAs

MEA-Production: Solvent Mixing
© Fraunhofer ISE / Foto: Dirk Mahler
1. Solvent Mixing: Different solvents are mixed and weighed with the ionomer dispersion according to a designed recipe. We offer research services for solvent and ionomer mixing.
MEA-Production: Addition of the catalyst powder
© Fraunhofer ISE
2. Addition of the catalyst powder to the solvent and ionomer dispersion inside nitrogen atmosphere in a glovebox. We investigate the catalyst ink formulation with respect to different coating technologies.
MEA-Production: Mixing process
© Fraunhofer ISE
3. Within the glovebox, the mixing process and first dispersing steps are conducted to break up agglomerates within the catalyst ink. We develop catalyst ink mixing processes.
MEA-Production: catalyst ink is dispersed
© Fraunhofer ISE
4. The catalyst ink is dispersed with an ultrasonic rod, to further reduce the agglomerates. We analyze ink homogenisation processes to break up agglomerates.
MEA-Production: slot die coating
© Fraunhofer ISE / Foto: Dirk Mahler
5. The catalyst layer is produced by slot die coating onto a decal transfer foil. For control of the platinum-loading, volume flow, coating velocity and solid content can be adjusted. We develop optimized coating processes and process parameters.
MEA-Production: continuous convection oven
© Fraunhofer ISE
6. The wet catalyst layer is dried within a continuous convection oven on top of a metal drying carrier. We investigate and improve processes for drying wet catalyst layers.
MEA-Production: printing technologies
© Fraunhofer ISE / Foto: Dirk Mahler
7. At Fraunhofer ISE, different printing technologies are available to produce catalyst layers: screen printing, slot die coating, inkjet printing, flexographic and gravure printing. We offer research on both laboratory sheet-to-sheet and industrial roll-to-roll processes.
MEA-Production: optical analysis
© Fraunhofer ISE / Foto: Dirk Mahler
8. Each catalyst layer is optically analyzed to quantify the number and size of defects, which can result from agglomerates, air bubbles or cracks. We develop quality control methods for the entire value chain from catalyst powder to MEA.
MEA-Production: Roll Calander
© Fraunhofer ISE
9. The roll calander is used to transfer the two electrodes (anode and cathode) onto the membrane. We investigate the transfer quality and the impact on the catalyst layer during process parameter variations.
MEA-Production: transfer process
© Fraunhofer ISE
10. After hot pressing, both decal foils are peeled off to create the CCM (catalyst coated membrane), also called 3-layer MEA. We evaluate the peel-off process with respect to the transfer quality.
MEA-Production: 5-layer MEA
© Fraunhofer ISE
11. The CCM is cutted to the right dimensions and positioned between two subgaskets, which both have only the active area taken out. This is called 5-layer MEA. We analyze the lamination and CCM cutting processes.
MEA-Production: 7-layer MEA
© Fraunhofer ISE
12. The ports for gas flow of the subgaskets are opened and the GDL (gas diffusion layer) is applied on both sides. This is the last production step, resulting in a 7-layer MEA. We analyze the GDL cutting and application processes.

Catalyst Ink Mixing Process

Technical data:

  • Semi-automatic weighing and dosing of catalyst powder, ionomer, and solvent
  • Ink circulation with eccentric screw pump through heat exchanger for temperature control
  • Advanced dispersion via ultrasonic bypass
  • Up to 4 liters of ink volume can be mixed

We offer you:

  • Material screening: Catalyst inks from different catalyst powders can be mixed.
  • The formulations are specifically adapted to different powder properties and the respective coating method.
  • Various mixing and dispersing methods are available, e.g., magnetic stirring, speed mixer, rotor-stator mixer, or ultrasound
  • Different ink volumes can be produced, from 5 ml to 4 l

Roll-to-Roll Coating and Drying Machine

Technical data:

  • Various application systems: slot die coating, rotary screen printing, indirect gravure printing
  • Heated coating roller
  • Maximum web width: 500 mm, maximum coating width 470 mm
  • Web speed 0.1-10 m/min
  • Convection drying temperature up to 180°C, controllable in three different zones Can be used as a conveyor roller dryer or floating dryer.
  • Various ink feed configurations (200 ml to 4 liters)
  • In-line quality control via optical line scan cameras (reflection), XRF, basis weight measurement at 3 positions, and wet film thickness sensors
  • In-line web cleaning and track & trace via inkjet printer & reader

We offer you:

  • Material screening: Catalyst inks from different catalyst powders can be examined.
  • A wide variety of substrates such as decal films, membranes, or gas diffusion layers can be coated.
  • Investigation of various coating processes
  • Slot die coating width can be adjusted by using shims.
  • Investigation of various process windows adapted to the respective materials
  • Process chain up to electrochemical in-situ characterization possible in the test bench

Roll-to-Roll Transfer Machine

Technical data:

  • Preheating of the web using infrared heaters
  • Roll calender with up to 200°C and up to 10kN
  • Double belt hot press with independently controllable temperature zones, up to 200°C, static pressure up to 1.5N/cm², and maximum line pressure up to 200N/cm
  • In-line quality control of CCM and decal films after peel-off via optical line scan cameras (reflection and transmission)
  • Cutting of CCM in the direction of web 
  • Maximum web width: 500 mm
  • Web speed 0.1-10 m/min
  • In-line web cleaning and track & trace via inkjet printer & reader

We offer you:

  • Processing of a wide variety of substrates such as decal films or membranes
  • Investigation of various hot pressing processes
  • Investigation of various process windows (temperature, pressure, and time) adapted to the respective materials
  • Converting of web material: laminating, delaminating, and cutting
  • Process chain up to electrochemical in-situ characterization possible in the test bench

Roll-to-Roll MEA Machine

Technical data:

  • Production of 5-layer MEAs as a roll-to-roll process
  • GDE & GDL cutting
  • Preparation of CCM and subgasket rolls via rotary cutting blade (so-called “kiss cut”) on carrier films
  • Assembly of CCM and 2 subgaskets with heat sealing
  • Optical in-line quality control of the alignment of subgaskets and CCM via register marks
  • Format limits CCM: web width (cross direction) min. 60 mm to max. 300 mm
  • Format limits GDL: web width (cross direction) min. 70 mm to max. 330 mm, GDL length (machine direction) less than 600 mm
  • Format limits MEA subgasket: web width (cross direction) min. 105 mm to max. 316 mm, MEA subgasket length (machine direction) min. 100 mm to max. 550 mm
  • All MEA designs must be checked individually.
  • Web speed up to 10 m/min
  • Maximum heat sealing temperature for subgaskets: 160°C

We offer you:

  • Prototype production for individual MEA designs with external or ISE-manufactured CCM
  • Investigation of various subgasket and CCM materials, as well as their adhesion to various carrier films 

Roll-to-Roll Machine for Quality Control and Converting

Technical data:

  • Maximum web width: 500 mm
  • Web speed 0.1-10 m/min
  • In-line web cleaning and track & trace via inkjet printer & reader
  • In-line quality control using optical line scan camera

We offer you:

  • A wide variety of web material can be inspected for quality
  • Converting of web material, i.e., lamination and delamination of foil composites possible, e.g., protective or carrier foils
  • Companies of inspection systems can test new systems and methods for quality control of web material

Laboratory Hot Press

Technical data:

  • Maximum pressing force 400 kN ± 1 kN
  • Size of the pressing surface: 600 x 600 mm
  • Maximum temperature 250 °C
  • Pressing height 600 mm (corresponds to approx. 300 cells in the stack)

We offer:

  • Hot pressing of CCMs for decal transfer
  • Heat sealing of subgaskets of a 5-layer MEA
  • Pressing of a short stack
  • Leakage test and performance and aging characterization in the fuel cell test bench

Hand Laminator for 5-Layer MEA

Technical data:

  • Manufacturing of 5- und 7-layer MEAs as Sheet-to-Sheet process
  • Roll-based laboratory machine with upscalable manufacturing concept 
  • Format limit CCM: width min. 40 mm until max. 300mm
  • Format limit GDL: width min. 36 mm until max. 330mm, GDL-length smaller than 600mm
  • Format limit MEA-Subgasket: width min. 70 mm until max. 316mm, MEA-Subgasket length min. 70 mm until max. 550mm
  • All MEA designs must be checked individually.

We offer:

  • Semi-automatic prototype production for individual MEA designs with external or ISE-manufactured CCM
  • Investigation of various subgasket and CCM materials, as well as their adhesion to various carrier films

More Information on this Topic

Research Topic

Fuel Cell

more Info

Research Topic

Electrolysis and Hydrogen Infrastructure

more Info

Related Links: