Fuel cells from EKPO.
Highly efficient, environmentally compatible, future-proof.

PEMFC stack modules

A fuel cell stack is usually a stack of cells consisting of bipolar plates, membrane electrode assemblies (MEAs), seals and end plates, and the tensioning system.

Stack modules from EKPO also include other system functionalities that make integration into customer systems vastly easier and significantly reduce the potential for leakages in the system. These are integrated into a special media module made of plastic and typically contain sensors for pressure and temperature, valves, condensate separators for the anode circuit and optional customer-specific functionalities.

ElringKlinger currently offers three standardized stack platforms: NM5-EVO, NM12, and NM12-TWIN. We additionally develop customer-specific stack solutions that are optimally tailored to the respective system environment.

Metal bipolar plates

Metal bipolar plates offer tangible advantages with regard to costs and – an aspect that is particularly important for mobile applications – power density as well as the cold-start capability of fuel cells. Using high-precision, progressive tooling suited to volume production, EKPO produces bipolar plates in a fully automated, interlinked manufacturing process.

PEMFC stacks consist of alternating stacks of membrane electrode assemblies (MEAs) and bipolar plates. They are interspersed with porous layers that serve to distribute the gas and transfer the electric current. The bipolar plate separates the media and distributes them within the stack. It also ensures uniform cooling of the stack and transfers the electric current to the adjacent cells.

Media modules

Fuel cell stacks have to be permanently tensioned with a uniform contact pressure over the entire surface of the cell. This is achieved by means of end modules consisting of the tensioning system and possibly media modules.

Production-ready end modules for PEMFCs are hybrid assemblies consisting of metal components and high-performance plastics that meet the full range of requirements while offering excellent dimensional stability. Like the media modules, they have to be mechanically stable, chemically resistant, and as light as possible. Using injection molding processes, EKPO produces highly complex end modules that meet the most stringent tolerance specifications. A special feature of these modules is the integration of parts of the system technology directly on the stack in the form of a media module, thereby extensively simplifying the system.

Sealing systems

Thanks to our comprehensive expertise in sealing technology and stack platform production, we are also able to offer bespoke sealing systems for fuel cells. These seals can be fitted both on the soft goods (GDL, sub-gasket) and on the bipolar plates. To do this, we employ our own materials or materials specified by the respective customer as well as cutting-edge production processes. For high-performance, reliable, and low-cost sealing solutions.

VOLUMETRIQ is a Fuel Cells and Hydrogen Undertaking project funded under the call FCH-01.2-2014 on “Cell and stack components, stack and system manufacturing technologies and quality assurance”. It will demonstrate operational OEM stack performance requirements for ElringKlinger’s automotive PEM fuel cell platform, with production readiness via validated volume capable manufacturing processes and quality control systems for both automotive fuel cell stack platform, and for major constituent cell components.  Stack components will be manufactured, involving improvement of existing methods and enhancement through automated manufacturing processes and tests to achieve robust volume yield and cost delivery.
The project will validate a complete “at scale” stack production package which will be overseen by the automotive OEMs, BMW and Daimler.

Grantor: FCHJU-EU

More information: http://www.volumetriq.eu/

The Giantleap project is an European project funded by the European Commission’s Fuel Cell and Hydrogen 2 Joint Undertaking, with the objective of improving the lifetime and reliability of fuel-cell systems in city buses.

Giantleap is a recursive acronym for Giantleap Improves Automation of Non-polluting Transportation with Lifetime Extension of Pem fuel cells; the objective of the project is to realise a control system that can increase the lifetime and reliability of fuel-cell systems installed in buses by means of novel diagnostic and prognostic approaches.

Grantor: FCHJU-EU

More information: http://www.giantleap.eu

The project aims at the development of a design of a flexible, scalable, high quality production line (process steps) for the manufacturing of PEMFC’s (Proton Exchange Membrane Fuel Cells).
The spectrum of automation in fuel cell manufacturing tasks investigated in the project includes tasks that require:

• The design of a flexible production process that allows a scale-up to 50.000 parts per year.
• The definition of automatic quality control strategies and processes to ensure quality on high-volume production, including the organization of necessary re-work.
• The development of flexible assembly stations that allow a gradual transition from manual operation to fully automatic processes.
• Data collection, documentation and tracking methods that fulfill traceability requirements.

The design that will be considered in the project include the manufacturing of parts of smaller quantity as well as very large quantities of PEMFC’s.

Grantor: FCHJU-EU

More information: http://www.inline-project.eu/