The climate crisis confronts us with unprecedented problems and it challenges existing energy solutions in a radical way. Hydrogen as an energy source will play a key role in our efforts towards a global energy transition. The transformation of renewable electrical energy into easily storable and transportable chemical energy in a unique scale is enabled by hydrogen.
The basis for the hydrogen revolution are disruptive technical solutions. Electrolysis and fuel cell stacks are the heart of the transformation and the key between renewable electrical and chemical energy. As the core component of these stacks, bipolar plates are the backbone of all hydrogen applications and responsible for various significant tasks. Most importantly, the geometrical properties and the active pattern formed on the plates are determine the performance and efficiency of the chemical reaction in the stack in a crucial way.
We at CellForm developed an all new way to manufacture bipolar plates with the most sophisticated and advantageous design and shape. These plates provide unique conditions in the stack for the best possible stack power and efficiency for both electrolysers and fuel cells.
CellForm combines the know-how of forming, welding and press automation. Our experience manifests in a history of welding bipolar plates which goes way back to the beginning of the Mercedes-Benz NECAR series in 1994. Based on more than 50 years of experience in tool development and manufacturing, our unique forming strategy is putting us in a leading position within the industry regarding accuracy and filigree of welded bipolar plates.
We excel at pushing the limits. We are forming future efficiency.
High quality plates
Reliability and durability are crucial for the successful implementation of hydrogen applications. Our deeply rooted focus on innovation enables us to form and weld bipolar plates of highest quality. Tools are designed for maximum accuracy and every part is manufactured with cutting-edge machinery in a fully air conditioned plant.
Main channels: The gases and liquids are fed in and out through the main channels.
A hydrogen stack usually consists of several hundred individual cells that are connected to the infrastructure of the aggregate via these channels. They are supplied with hydrogen and air in the fuel cell. In electrolysers, the produced gases are exported through these channels accordingly.
Via a third channel, the cells are kept in an optimal temperature window by a temperature control fluid.
Distribution area: The gases and liquids required for the reaction in a hydrogen stack must be transferred from the main channel to the flowfield and distributed. It is important that all channels are supplied equally.
Flow field: This is the heart of the bipolar plate and the entire hydrogen stack because here, the electrochemical reaction takes place. In the fuel cell, hydrogen and oxygen become water and electrical energy, and during electrolysis the opposite reaction takes place. The flow field is, in a way, the place of the conversion.
Ambient geometry: A stack must cover many other topics, such as cell voltage monitoring, i.e. monitoring of the overall reaction. In addition, a very high accuracy is required in all features of the stack.
Together with CellForm, stack manufacturers are developing plate geometries that will further increase this accuracy and produce even better, more reliable and more efficient stacks in the future.
Design freedom
Following a build to print production approach, CellForm provides bipolar plates according to the individual needs of its customers. We developed a unique multi-stage forming process which is designed for maximum channel accuracy. In combination with a substrate thickness of down to 0.05 mm, we are able to implement highly sophisticated and filigree flow field designs leading to an optimized efficiency of the electrolysis and fuel cell systems.
Our production setup is designed for small, medium as well as large plates up to 2000 mm in length.
We defined an all-new way of building a forming tool. Not only did we question every single step of setting up a tool, but we also developed a new way of technical coordination and fine-tuning.
Product Example
Product Example
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Series production:
Flow plates are the core of hydrogen production as well as fuel cell applications. One passenger vehicle alone requires 300 to 500 bipolar plates within the fuel cell stack in order to achieve a reasonable power output. Thus, the demand for bipolar plates on the market will be enormous – not only millions but billions of individual plates generate hydrogen in electrolysers and enable the electrochemical reaction in a fuel cell.
The scale up of hydrogen and therefore the transition towards climate friendly applications can only be achieved if this demand for bipolar plates can be met in terms of volume and price.
Hence, from the beginning of our research activities, there was always one important premise: cycle time. We developed a production process that allows us to form, weld and test bipolar plates in an industry leading time. Additionally, the production setup can be scaled up easily.
Therefore, CellForm’s series production not only enables flow plates with the best possible technical design but also with leading conditions in terms of price and economic efficiency.
Over the next few years, there will be various promising applications for fuel cell systems stationary as well as mobile sectors. Especially in the mobility applications, lightweight and efficient fuel cell stacks are crucial for the fuel cell technology to succeed.
We offer exceptionally thin and filigree bipolar plates in order to pave the way for a successful ramp up of hydrogen utilization.
Career:
Become a part of the hydrogen future and join our team!
