The project aims to use sintered paper technology to develop an all-metal gas diffusion layer (GDL) with improved application properties, manufacturability and assembly properties. Using paper technology processes, organic fibres, fillers and additives are processed together with metal powder to form a flat, paper-like product. The organic components are then removed by means of heat treatment and the structure is converted into a purely metallic, highly porous material. Macroscopic structuring of the GDL should enable the use of simplified 3D screen-printed bipolar plates (BPP) in the future.
In parallel, a structured SinterGDL with integrated flow field is to be tested in combination with a simplified BPP with the aim of simplifying production and reducing size.
Half-measurement fuel cell single cell and various GDL materials
Photo of one half of a measuring fuel cell single cell and a carbon-based GDL as well as two sintered paper-based GDLs with different coatings
Currently, fuel cells (FC) for mobile applications still have considerable potential for improvement in terms of minimising installation space, reducing manufacturing costs and increasing service life. The GDL is an important component of the FC stack for all of these properties. The GDL is located between the BPP and the electrode and must ensure optimum gas distribution and the removal of water, heat and electricity. The GDL is currently preferably made of porous graphite mats or plates, which have deficits in terms of mechanical stability, service life and costs. The long-term durability of Fuel Cells with graphite GDLs, measured against the intended service life in the particularly interesting application of buses and lorries (~ 25,000 hours; target set by the US Department of Energy), is also still far too low.
The aim of the project is to develop a new, cost-effective and compact PEM stack unit. The focus is on the simplest possible up-scaling for large-scale production of all required components.
SinterGDL at a glance
Project
Development of sintered paper gas diffusion layers for space-, production- and cost-optimised mobile fuel cells (SinterGDL)
Duration
April 2022 - 31. March 2025
Project participants
Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. - Institut für Fertigungstechnik und Angewandte Materialforschung
Papierfabrik Louisenthal GmbH
balticFuelCells GmbH
Papiertechnische Stiftung (PTS)
FHR Anlagenbau GmbH
Deutsches Zentrum für Luft- und Raumfahrt e.V. - Institut für Technische Thermodynamik
