Fraunhofer Institute for Production Technology IPTResearch Project "CoBiP"
Fuel cell technology is regarded as one of the key technologies in the energy revolution. The aim of the CoBiP project was to develop a production technology suitable for continuous manufacture of bipolar plates, one of the central components of a fuel cell.
Continuous production of metallic bipolar plates in roll-to-roll operations
The production of bipolar plates remains generally complex and is associated with high costs: This stems from expensive materials coupled with often complex transport and handling steps for forming, joining and coating processes. As part of the "CoBiP" project, the Fraunhofer IPT was developing an integrated system for cost-efficient production of bipolar plates that brought together the individual steps involved in their production: This system was based on the modular roll-to-roll process developed by the Fraunhofer IPT, combining roll forming, laser welding and cutting processes as well as coating in continuous production. The manufacturing technology was suitable for forming the microgeometry of metallic foils of less than 100 μm in thickness, within defined aspect ratios. This enabled various designs of bipolar plates for fuel cells to be produced regardless of the material used.
More efficient production processes save fuel cell production costs
The modular structure of the system and the integration of each individual process step in a continuous production chain guaranteed high process and cost efficiency: The automated production of bipolar plates in a continuous roll-to-roll process provided a robust and replicable process, capable of achieving high volume production with constant product quality. The new manufacturing processes promised less costly bipolar plates, which are among the principal cost drivers in fuel cells in conjunction with higher quality, resource and energy efficiency compared with other energy converters at all system levels. The "CoBiP" research project thus contributed to the cost-effective expansion of the next generation powertrain via this new production technology - as an important part of the shift towards sustainable and, at the same time highly competitive production.
Consortium
Project coordinator
- Fraunhofer Institute for Production Technology IPT
Project partners
- e.Go Rex GmbH
- Forschungszentrum Jülich GmbH
- Fraunhofer Institute for Laser Technology ILT
- Matthews International GmbH
- Precors GmbH