Fuel Cells Production methods for MEAs. Thomas Kolbusch, Vice President
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- Merilyn Paul
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1 Fuel Cells Production methods for MEAs Thomas Kolbusch, Vice President COATEMA Coating Machinery GmbH 1
2 innovations Introduction Coatema quality made in Germany Part of the ATH Holding working widths from100 mm coating Bespoke equipment up to 5,400 mm printing laminating founded 1974 Film/Paper Printed Electronics Prepreg Membranes Renewables Textile Glass From Lab2Fab R&D projects & network worldwide service COATEMA Coating Machinery GmbH 2
3 Group of Companies Foundation 1903 Approx. 200 employees Located in Hamburg Foundation 1995 Approx. 50 employees Located in Norderstedt Foundation 1974 Approx. 45 employees Located in Dormagen Foundation 1919 Approx. 140 employees Located in Hamburg COATEMA Coating Machinery GmbH 3
4 Summary Fuel Cell basics Coating systems Drying & curing MEA production technology GDE approach CCM approach Todays equipment Production line for MEAs Summary COATEMA Coating Machinery GmbH 4
5 Connect Like Follow COATEMA Coating Machinery GmbH 5
6 innovations Introduction Coatema quality made in Germany Part of the ATH Holding working widths from100 mm coating Bespoke equipment up to 5,400 mm printing laminating founded 1974 Film/Paper Printed Electronics Prepreg Membranes Renewables Textile Glass From Lab2Fab R&D projects & network worldwide service COATEMA Coating Machinery GmbH 6
7 Group of Companies Foundation 1903 Approx. 200 employees Located in Hamburg Foundation 1995 Approx. 50 employees Located in Norderstedt Foundation 1974 Approx. 45 employees Located in Dormagen Foundation 1919 Approx. 140 employees Located in Hamburg COATEMA Coating Machinery GmbH 7
8 Vision From Lab2Fab Lab Pilot Production Custom made Custom made Custom made Process development Pilot production Production line Coatema equipment platform strategy for Lab2Fab COATEMA Coating Machinery GmbH 8
9 R&D Services R&D centre Coating Printing Laminating Imprinting Pretreatment Drying Curing Crosslinking Cutting units on sqm Sheet to Sheet up to 300 x 500 mm Roll to Roll up to 700 mm width Operation Speed 0.1 to 200m/min COATEMA Coating Machinery GmbH 9
10 R&D Services Process Development Feasibility study Ink process study Process analysis Proof of concept Smale scale prototype After sales service and ramp up of processes of Coatema units Test Production Prototyping Near to market testing TRL evaluation Training of staff Development of custom made design for equipment Prototyping Proof of concept Education Coatema Conference Training of customers Education of students Funded Research Projects German funded Horizon 2020 Global 2+2 projects B2B projects COATEMA Coating Machinery GmbH 10
11 Equipment COATEMA Coating Machinery GmbH 11
12 Products Lab units Lab COATEMA Coating Machinery GmbH 12
13 Products Pilot lines Pilot COATEMA Coating Machinery GmbH 13
14 Products Production lines Production COATEMA Coating Machinery GmbH 14
15 Products Production systems Production COATEMA Coating Machinery GmbH 15
16 Products Bespoke equipment Custom made COATEMA Coating Machinery GmbH 16
17 Scaling up new technologies Tools for Lab2Fab COATEMA Coating Machinery GmbH 17
18 Our markets COATEMA Coating Machinery GmbH 18
19 Markets Smart Textiles Printed electronics Prepreg Batteries Solar Cells Membranes Medical/Pharmaceutical Fuel Cells Smart Textiles COATEMA Coating Machinery GmbH 19
20 Markets Fuel Cells COATEMA Coating Machinery GmbH 20
21 R&D Projects COATEMA Coating Machinery GmbH 21
22 R&D Associations COATEMA Coating Machinery GmbH 22
23 R&D customers COATEMA Coating Machinery GmbH 23
24 R&D Projects Currently 14 Projects in operation Coatema follows Open Pilot Line Philosophy COATEMA Coating Machinery GmbH 24
25 Proof of concept COATEMA Coating Machinery GmbH 25
26 Industrial References COATEMA Coating Machinery GmbH 26
27 Introduction Coatema Our latest awards COATEMA Coating Machinery GmbH 27
28 Upscaling from Lab2Fab Overview on the basics COATEMA Coating Machinery GmbH 28
29 Overview on the basics MEA-components Diffusion layer Anode Diffusion layer Cathode Methanol Air Carbon cloth, Carbon paper (Substrate) Micro layer: PTFE + Carbon CatalystNafion- membrane layer Pt-Ru + Naf. Catalyst layer Pt + Naf Micro layer: PTFE + Carbon Carbon cloth, Carbon paper (Substrate) Carbon dioxide Water Anode Cathode COATEMA Coating Machinery GmbH 29
30 MEA production technology Structure of an MEA catalyst, ionomer colloid, solvent mixture, additives mixing Catalyst ink Polymer electrolyte (Nafion) Coating on GDL or Membrane (Spraying, screen printing, ink jet, knife..) Hot pressing Carbon particles (20-40 nm) Pt particles (2-3 nm) Backing layer MEA Quelle: Institute of Energy Research - Fuel Cells (IEF-3), Juelich Research Center part of Helmholtz-Community COATEMA Coating Machinery GmbH 30
31 Overview on the basics Manufacturing methods GDE method CCM direct CCM indirect MEA: Membrane-Electrode- Assembly GDL: Gas Diffusion Layer GDE: Gas Diffusion Electrode PEM: Polymer Electrolyte Membrane CCM: Catalyst Coated Membrane COATEMA Coating Machinery GmbH 31
32 MEA production technology Status MEA CCM Method Application of catalyst layer to membrane by direct coating or decal, transfer by hot pressing Laminating GDL to CCM GDE Method Application of catalyst layer to Gas Diffusion Layer (GDL) Laminating GDE to Membrane Membrane dimension instability Reinforced membranes needed Easy to transfer from laboratory scale to mass production scale Less flexibility to GDE/MEA configuration or dimension change Flexibility in MEA Flexibility in MEA configuration & dimension change Difficult to scale up for mass production expensive laboratory instrument investment and expensive to scale up Difficulty in catalyst layer thickness (low catalyst loading) Quelle: Institute of Energy Research - Fuel Cells (IEF-3), Juelich Research Center part of Helmholtz-Community COATEMA Coating Machinery GmbH 32
33 Overview on the basics Manufacturing Methods Parts of an MEA a) b) c) d) COATEMA Coating Machinery GmbH 33
34 Equipment in 1999 Deskcoater 500 W DMFC-Stack Quelle: Juelich Research Center part of Helmholtz-Community COATEMA Coating Machinery GmbH 34
35 Conclusion in 1999 Overview on the basics Common points for Fuel cell development are: Thinner coatings with defined edges for the CCM are needed thin film coating methods, intermittend coatings etc. Laminating of GDL/GDE with CCM/Membran - Research on parameters in the continous laminating process has to be focused New developments of reinforced membranes are needed to get higher production speed Where are the mass markets for fuel cell application? COATEMA Coating Machinery GmbH 35
36 The vision in 1999 Overview on the basics Impregnation- & Coating Plant: GDE COATEMA Coating Machinery GmbH 36
37 Realization in 2008 Overview on the basics COATEMA Coating Machinery GmbH 37
38 Coatema`s today products Overview on the basics Membrane GDE method CCM direct CCM indirect Gasket COATEMA Coating Machinery GmbH 38
39 Coatema`s today products Overview on the basics GDE method CCM direct CCM indirect Membrane Manufacturing COATEMA Coating Machinery GmbH 39
40 Coatema`s today products Overview on the basics GDE method Coating Area / working width (ww) EC Fuel Cell (A4/A3) Test Solution Fuel Cell ww 100 mm Basecoater Fuel Cell ww 300 mm / 500 mm Smartcoater Fuel Cell ww 300 mm Linecoater Fuel Cell ww 500 mm / mm Production Line Fuel Cell ww and on request GDL Sintering station available in different ww Mixer for microporous and catalyst layer available Hotpressing of GDE to membrane available in different ww COATEMA Coating Machinery GmbH 40
41 Coatema`s today products Overview on the basics CCM method Coating Area / working width (ww) EC Fuel Cell (A4/A3) Smartcoater Fuel Cell ww 300 mm Linecoater Fuel Cell ww 500 mm / mm Double side coating CCM unit available in different ww Mixer for catalyst layer available Quality control system COATEMA Coating Machinery GmbH 41
42 Coatema`s today products Overview on the basics Indirect CCM Method Coating Area / working width (ww) EC Fuel Cell (A4/A3) Test Solution Combi ww 100 mm Basecoater Combi ww 300 mm / 500 mm Smartcoater Combi ww 300 mm Linecoater Combi ww 500 mm / mm Production Combi ww and on request Hot pressing station available in different ww COATEMA Coating Machinery GmbH 42
43 Coatema`s today products Overview on the basics Membrane production Coating Area / working width (ww) Basecoater Combi ww 300 mm / 500 mm Smartcoater Combi ww 300 mm Linecoater Combi ww 500 mm / mm Production Combi ww and on request COATEMA Coating Machinery GmbH 43
44 Coating Systems COATEMA Coating Machinery GmbH 44
45 Coating & Printing systems Versatility Knife Double Side Commabar Case Knife Slot Die Hotmelt Slot Die Engraved Roller Powder Scattering 3 Roller Combi Micro Roller 5 Roller Reverse Roll Double Knife Curtain Coating 2 Roller Combi Dipping Rotary Screen >30 application systems COATEMA Coating Machinery GmbH 45
46 Processes Definition of Coating Systems Category of coating methods Self-metered Doctored Pre-metered Examples of coating methods belong to the category - Dip roll - Nip forward roll - Reverse roll - Mayer rod - Blade/knife - Air knife - Dip & scrape -Slot die - Slide curtain - Spray Characteristics Wet thickness is determined the conditions of the coating meniscus Post applicator device determines the wet thickness All the ink fed into an applicator is transferred to the web COATEMA Coating Machinery GmbH 46
47 Technologies & Processes Process Parameters Process Parameters are: Operation speed Rheology of coating and printing inks Substrate condition Tension control MD/CD Edge control Resolution and registration accuracy of printing/laminating systems Precision of coating operations Curing / drying / crosslinking COATEMA Coating Machinery GmbH 47
48 Coating Systems Coating Parameters Coating Chemistry Coating Processes Process control Drying Rheology Viscosity Viscoleasticity Type of solvents Amount of solids Van der Waals force Sheer ratio Adhesion/Cohesion Coating systems Single or Multilayer coatings Direct coatings Transfer (indirect) coatings Substrate speed Layer Thickness Coating accuracy Process layout Tension control system Material guiding system Inline parameter control Quality control Convection drying Contact drying Infrared drying Sintering NIR High Frequency UV crosslinking systems Substrate Pretreatment Environment Finishing Surface tension Dimension stability Surface structure Contact angle Corona Plasma Cleaning Humidity Temperature Inert Conditions Calendaring Embossing Slitting COATEMA Coating Machinery GmbH 48
49 Coating Systems Dipping System Variation of the Coating Weight Depending on the textile Range of Viscosity (mpas) COATEMA Coating Machinery GmbH 49
50 Coating Systems Knife Coating Variation of the Coating Weight Roller knife 10 to g/m 2 Air knife 5-6 to 60 g/m 2 Range of Viscosity (mpas) Paste (1000) Foam Air knife COATEMA Coating Machinery GmbH 50
51 Coating Systems Commabar Coating Variation of the Coating Weight Air Knife 5-6 to g/m 2 Range of Viscosity (mpas) Paste 5-6 to 60 g/m 2 Foam COATEMA Coating Machinery GmbH 51
52 Coating Systems Gravur Coating Variation of the Coating Weight 2 to 200 g/m 2 Range of Viscosity (mpas) COATEMA Coating Machinery GmbH 52
53 Coating Systems Micro Roller Coating Variation of the Coating Weight 2 to 100 g/m 2 Range of Viscosity (mpas) COATEMA Coating Machinery GmbH 53
54 Coating Systems Rotary Screen Coating Variation of the Coating Weight 10 to 300 g/m 2 Range of Viscosity (mpas) Paste Paste COATEMA Coating Machinery GmbH 54
55 Coating Systems Powder Scattering Coating Variation of the Coating Weight 10 to 300 g/m 2 Range of Viscosity (mpas) Application of powdery materials COATEMA Coating Machinery GmbH 55
56 Technologies & Processes Slot Die System COATEMA Coating Machinery GmbH 56
57 Coating Systems Slot Die Coating Variation of the Coating Weight < 1 to 200 g/m 2 Range of Viscosity (mpas) COATEMA Coating Machinery GmbH 57
58 Technologies & Processes Slot Die System Operating a slot die meniscus is formed between die lips and substrate adhesive stabilization of meniscus by die lips very low minimum flow rate possible range of rheological parameters limited for stability Slot die Distribution chamber meniscus Coating roller COATEMA Coating Machinery GmbH 58
59 Technologies & Processes Intermittent slot die coating COATEMA Coating Machinery GmbH 59
60 Drying & curing COATEMA Coating Machinery GmbH 60
61 Drying & curing Coating Parameters Coating Chemistry Coating Processes Process control Drying Rheology Viscosity Viscoleasticity Type of solvents Amount of solids Van der Waals force Sheer ratio Adhesion/Cohesion Coating systems Single or Multilayer coatings Direct coatings Transfer (indirect) coatings Substrate speed Layer Thickness Coating accuracy Process layout Tension control system Material guiding system Inline parameter control Quality control Convection drying Contact drying Infrared drying Sintering NIR High Frequency UV crosslinking systems Substrate Pretreatment Environment Finishing Surface tension Dimension stability Surface structure Contact angle Corona Plasma Cleaning Humidity Temperature Inert Conditions Calendaring Embossing Slitting COATEMA Coating Machinery GmbH 61
62 Technologies Drying Technologies Drying with hot air technology COATEMA Coating Machinery GmbH 62
63 Technologies Drying Technologies COATEMA Coating Machinery GmbH 63
64 Drying Topics General tasks of drying Substrate Coating Heat transfer Vapor removal 1.) transfer the drying energy into solids and dryer technology solvent to achieve the drying temperature solid heat capac 2.) evaporate the solvent 3.) remove the solvent vapor dryer COATEMA Coating Machinery GmbH 64
65 Drying Topics Drying systems: hot air technology Floatation dryer single nozzle COATEMA Coating Machinery GmbH 65
66 Technologies Drying Technologies IR-Sinter unit COATEMA Coating Machinery GmbH 66
67 Drying Topics Infrared dryers Combined hot air / IR dryer COATEMA Coating Machinery GmbH 67
68 MEA production technology COATEMA Coating Machinery GmbH 68
69 Deskcoater (F10) Zusatzmodul-Auswahlmenü 1 Rakelauftrag 2 Breitschlitz-Düsenauftrag 3 Rasterwalzenauftrag 4 Roationssiebdruck 5 Reverse-Roll-Coater 6 Kiss-Coater 7 Hot Melt Status Controll Status Controll Status Controll Status Controll Status Status Status Controll Controll Controll Status Controll Status Controll Status Controll Status Controll GDE approach Production steps for MEAs 1st production step: hydrophobization Impregnation of carbon substrate by dipping into a PTFE solution Carbon Substrate PTFE Impregnated Material Quelle: Institute of Energy Research - Fuel Cells (IEF-3), Juelich Research Center part of Helmholtz-Community COATEMA Coating Machinery GmbH 69
70 GDE approach Production steps for MEAs 1st production step: hydrophobization Carbon Substrate PTFE PTFE content adjustable by PTFE concentration of the solution 1st sub-step: impregnation + drying 2nd sub-step: sintering Impregnated Material Quelle: Institute of Energy Research - Fuel Cells (IEF-3), Juelich Research Center part of Helmholtz-Community Carbon cloth COATEMA Coating Machinery GmbH 70
71 Deskcoater (F10) Zusatzmodul-Auswahlmenü 1 Rakelauftrag 2 Breitschlitz-Düsenauftrag 3 Rasterwalzenauftrag 4 Roationssiebdruck 5 Reverse-Roll-Coater 6 Kiss-Coater 7 Hot Melt Status Controll Status Controll Status Controll Status Controll Status Status Status Controll Controll Controll Status Controll Status Controll Status Controll Status Controll GDE approach Production steps for MEAs 2nd production step: micro layer Impregnated Material Carbon Base Coating GDL Quelle: Institute of Energy Research - Fuel Cells (IEF-3), Juelich Research Center part of Helmholtz-Community COATEMA Coating Machinery GmbH 71
72 GDE approach Production steps for MEAs 2nd production step: micro layer microporous layer Impregnated Material Carbon Base Coating GDL PTFE 1st sub-step: coating and drying 2nd sub-step: sintering Quelle: Institute of Energy Research - Fuel Cells (IEF-3), Juelich Research Center part of Helmholtz-Community COATEMA Coating Machinery GmbH 72
73 GDE approach Production steps for MEAs 2nd production step: micro layer Dispersed in Dissolver Adjustment of speed and dispersing time Impregnated Material Carbon Base Coating GDL 1st sub-step: coating and drying 2nd sub-step: sintering 100 µm great agglomerates of 50 µm small aggregates with a few µm in diameter COATEMA Coating Machinery GmbH 73
74 Deskcoater (F10) Zusatzmodul-Auswahlmenü 1 Rakelauftrag 2 Breitschlitz-Düsenauftrag 3 Rasterwalzenauftrag 4 Roationssiebdruck 5 Reverse-Roll-Coater 6 Kiss-Coater 7 Hot Melt Status Controll Status Controll Status Controll Status Controll Status Status Status Controll Controll Controll Status Controll Status Controll Status Controll Status Controll GDE approach Production steps for MEAs 3rd production step: catalyst layer Catalyst Layer GDL GDE Quelle: Institute of Energy Research - Fuel Cells (IEF-3), Juelich Research Center part of Helmholtz-Community COATEMA Coating Machinery GmbH 74
75 GDE approach Production steps for MEAs 3rd production step: catalyst layer Catalyst Layer 0,5 0,45 0,4 Variation des Dispersionsmittelanteils GDL GDE Viskosität [Pas] 0,35 0,3 0,25 0,2 0,15 0,29 solid/liquid 0,275 solid/liquid 0,2475 solid/liquid 0,1 0,05 The structure of catalyst layer depends on catalyst paste coating technique / coating speed drying conditions Scherrate [1/s] COATEMA Coating Machinery GmbH 75
76 GDE approach Production steps for GDE 3rd production step: catalyst layer Catalyst Layer 5 4 GDL GDE viscosity [Pas] The structure of catalyst layer depends on catalyst paste coating technique / coating speed drying conditions shear rate [1/s] The viscosity of catalyst depends on catalyst dispersing agent dispersing method COATEMA Coating Machinery GmbH 76
77 GDE approach Production steps for GDE 4th production step: laminating / sealing GDE Cathode PEM = Nafion or other membrans MEA & GDE GDE Anode COATEMA Coating Machinery GmbH 77
78 Deskcoater (F10) (F10) Zusatzmodul-Auswahlmenü 1 Rakelauftrag 2 Breitschlitz-Düsenauftrag 3 Rasterwalzenauftrag 4 Roationssiebdruck 5 Reverse-Roll-Coater 6 Kiss-Coater 7 Hot Melt Status Controll Status Controll Status Controll Status Controll Status Controll Status Controll Status Controll Status Controll Status Controll Status Controll GDE approach Production steps for GDE 4th production step: laminating / hot pressing Quelle: Juelich Research Center part of Helmholtz-Community COATEMA Coating Machinery GmbH 78
79 GDE approach Deskcoater 500 W DMFC-Stack Quelle: Juelich Research Center part of Helmholtz-Community COATEMA Coating Machinery GmbH 79
80 CCM approach COATEMA Coating Machinery GmbH 80
81 CCM approach Production steps 1st step: coating / drying / cooling Cathode base coating PEM MEA Anode base coating COATEMA Coating Machinery GmbH 81
82 CCM approach Production steps Single side step: coating / drying / cooling COATEMA Coating Machinery GmbH 82
83 CCM approach Production steps Double side step: coating / drying / cooling COATEMA Coating Machinery GmbH 83
84 Upscaling from Lab2Fab COATEMA Coating Machinery GmbH 84
85 Todays equipment The Basecoater COATEMA Coating Machinery GmbH 85
86 Todays equipment The Basecoater COATEMA Coating Machinery GmbH 86
87 Todays equipment The Basecoater COATEMA Coating Machinery GmbH 87
88 COATEMA Coating Machinery GmbH 88
89 Todays equipment The Basecoater 3rd Generation COATEMA Coating Machinery GmbH 89
90 Todays equipment The Basecoater 3rd Generation Facts Cantilever Rollers Delamination / Lamination Contact cleaning Corona station Slot Die System Rotary Screen System 2 Roller System Hot Air Dryer IR Dryer UV unit Edge sealing & glue application Cross-directional cutting system COATEMA Coating Machinery GmbH 90
91 Todays equipment The Basecoater Hot pressing COATEMA Coating Machinery GmbH 91
92 Todays equipment The Basecoater Hot pressing COATEMA Coating Machinery GmbH 92
93 Todays equipment The Linecoater COATEMA Coating Machinery GmbH 93
94 Todays equipment The Linecoater COATEMA Coating Machinery GmbH 94
95 Todays equipment The Click&Coat COATEMA Coating Machinery GmbH 95
96 Click&Coat Overview drawing COATEMA Coating Machinery GmbH 96
97 Click&Coat COATEMA Coating Machinery GmbH 97
98 Click&Coat Todays equipment TM Steel layout The Click&Coat COATEMA Coating Machinery GmbH 98
99 Click&Coat TM Steel layout COATEMA Coating Machinery GmbH 99
100 Click&Coat TM Steel layout COATEMA Coating Machinery GmbH 100
101 Click&Coat TM Steel layout COATEMA Coating Machinery GmbH 101
102 Click&Coat TM Steel layout COATEMA Coating Machinery GmbH 102
103 Click&Coat TM Steel layout COATEMA Coating Machinery GmbH 103
104 Click&Coat TM Steel layout COATEMA Coating Machinery GmbH 104
105 Production line for MEAs Production line for Fuel cells 1000 mm working width COATEMA Coating Machinery GmbH 105
106 Today`s equipment COATEMA Coating Machinery GmbH 106
107 Layout The pathway to production Single side coating of catalyst layer Single side coating of gasket Coating of second side catalyst Coating of second side gasket Die cutting of the MEA and stapling Included are mixers, regisration control and splicing table Missing atomated assembly of CCM with GDL and hotpressing in a discontinous step COATEMA Coating Machinery GmbH 107
108 Nuvera Layouts Layout proposal COATEMA Coating Machinery GmbH 108
109 COATEMA Coating Machinery GmbH THANK YOU Roseller Str. 4 D Dormagen / tkolbusch@coatema.de COATEMA Coating Machinery GmbH 109
110 COATEMA Coating Machinery GmbH 110