Development

At ZBT, the geometric design of bipolar plates is carried out using 3D CAD and simulation-based optimisation. The aim is to develop flow- and contact-optimised structures for metallic and compound-based designs. Relevant parameters such as media distribution, pressure loss, cooling concepts and electrical contacting are taken into account with precision.

Metallic plates also require consideration of forming limits and welding specifications, while compound BPPs allow design freedom in combination with a form-friendly design. The design is based on application-specific requirements and is iteratively refined in close coordination with material development and manufacturing technologies.

At ZBT, catalysts and inks for electrochemical applications – especially for CCMs – are developed to meet specific requirements. The work includes the selection of suitable catalyst materials, their synthesis and the formulation of stable and processable inks. Properties such as particle size, distribution, binder content and solvent are specifically tailored to the planned coating process.

The aim is to achieve high electrochemical activity, good adhesion and reproducible processing. The developed ink is applied on a laboratory or pilot scale and characterised electrochemically before scaling up to series production processes.

The ZBT develops functionalised polymer-based materials for bipolar plates and sealing systems. The focus is on electrically conductive compounds consisting of a thermoplastic matrix and fillers, as well as elastomeric sealing formulations with defined chemical and mechanical properties.

Material development takes into account the requirements for conductivity, media resistance and processing, as well as compatibility with downstream processes such as injection moulding or dispenser application. Formulations are systematically varied, tested for processability in the technical centre and then characterised in terms of their electrical, thermal and chemical properties.

The aim is to achieve reliable integration into scalable manufacturing processes.

ZBT develops customised operating strategies for membrane electrode assemblies (MEAs) that are tailored to specific operating conditions and service life tests. Parameters such as current density, temperature profile and humidity are optimised to maximise the efficiency and service life of the MEA.

Operating strategies are iteratively adjusted through simulation-based analysis and experimental validation. The aim is to increase the overall efficiency of fuel cells while minimising MEA degradation. These optimisations contribute significantly to long-term stability and reduced operating costs.

As part of the development of fuel cell stacks, ZBT focuses on optimising operating strategies to ensure consistent performance and a long service life. Various parameters such as pressure, temperature and gas ratios are specifically adjusted to achieve optimum load distribution and minimal resistance.

Operating strategies are developed through detailed simulations and tests under real operating conditions. The aim is to maximise the efficiency of the entire system and minimise degradation mechanisms in the stack components in order to extend service life and reduce costs.

ZBT develops holistic operating strategies for fuel cell systems that are tailored to the interaction of the individual components. In addition to the MEAs and stacks, interactions between system components such as balance-of-plant (BoP) and system control are also taken into account.

The aim is to maximise the efficiency and performance of the entire system under real operating conditions. To this end, experimental tests and model-based simulations are used to develop optimal operating profiles for various load scenarios and environmental conditions. These strategies ensure the long-term reliability and cost-efficiency of the entire fuel cell system.