Fuel Cells Production methods for MEAs. Thomas Kolbusch, Vice President

Transcription

1 Fuel Cells Production methods for MEAs Thomas Kolbusch, Vice President COATEMA Coating Machinery GmbH 1

2 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 2

3 Connect Like Follow COATEMA Coating Machinery GmbH 3

4 innovations Introduction Coatema quality made in Germany founded 1974 customize d equipment Film/Paper Printed Electronics Prepreg Renewables working widths from100 mm up to 5,400 mm Membranes Textile Glass From Lab2Fab R&D projects & network worldwide service coating printing laminating COATEMA Coating Machinery GmbH 4

5 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 5

6 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 6

7 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 7

8 Equipment COATEMA Coating Machinery GmbH 8

9 Products Lab units Lab COATEMA Coating Machinery GmbH 9

10 Products Pilot lines Pilot COATEMA Coating Machinery GmbH 10

11 Products Production lines Production COATEMA Coating Machinery GmbH 11

12 Products Production systems Production COATEMA Coating Machinery GmbH 12

13 Products Bespoke equipment Custom made COATEMA Coating Machinery GmbH 13

14 Scaling up new technologies Tools for Lab2Fab COATEMA Coating Machinery GmbH 14

15 Our markets COATEMA Coating Machinery GmbH 15

16 Markets Smart Textiles Printed electronics Prepreg Batteries Solar Cells Membranes Medical/Pharmaceutical Fuel Cells Smart Textiles COATEMA Coating Machinery GmbH 16

17 Markets Fuel Cells COATEMA Coating Machinery GmbH 17

18 R&D Projects COATEMA Coating Machinery GmbH 18

19 R&D Associations COATEMA Coating Machinery GmbH 19

20 R&D customers COATEMA Coating Machinery GmbH 20

21 R&D Projects Currently 14 Projects in operation Coatema follows Open Pilot Line Philosophy COATEMA Coating Machinery GmbH 21

22 Proof of concept COATEMA Coating Machinery GmbH 22

23 Industrial References COATEMA Coating Machinery GmbH 23

24 Introduction Coatema Our latest awards COATEMA Coating Machinery GmbH 24

25 Upscaling from Lab2Fab Overview on the basics COATEMA Coating Machinery GmbH 25

26 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 26

27 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 27

28 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 28

29 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 29

30 Overview on the basics Manufacturing Methods Parts of an MEA a) b) c) d) COATEMA Coating Machinery GmbH 30

31 Equipment in 1999 Deskcoater 500 W DMFC-Stack Quelle: Juelich Research Center part of Helmholtz-Community COATEMA Coating Machinery GmbH 31

32 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 32

33 The vision in 1999 Overview on the basics Impregnation- & Coating Plant: GDE COATEMA Coating Machinery GmbH 33

34 Realization in 2008 Overview on the basics COATEMA Coating Machinery GmbH 34

35 Coatema`s today products Overview on the basics Membrane GDE method CCM direct CCM indirect Gasket COATEMA Coating Machinery GmbH 35

36 Coatema`s today products Overview on the basics GDE method CCM direct CCM indirect Membrane Manufacturing COATEMA Coating Machinery GmbH 36

37 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 37

38 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 38

39 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 39

40 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 40

41 Coating Systems COATEMA Coating Machinery GmbH 41

42 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 42

43 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 43

44 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 44

45 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 45

46 Coating Systems Dipping System Variation of the Coating Weight Depending on the textile Range of Viscosity (mpas) COATEMA Coating Machinery GmbH 46

47 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 47

48 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 48

49 Coating Systems Gravur Coating Variation of the Coating Weight 2 to 200 g/m 2 Range of Viscosity (mpas) COATEMA Coating Machinery GmbH 49

50 Coating Systems Micro Roller Coating Variation of the Coating Weight 2 to 100 g/m 2 Range of Viscosity (mpas) COATEMA Coating Machinery GmbH 50

51 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 51

52 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 52

53 Technologies & Processes Slot Die System COATEMA Coating Machinery GmbH 53

54 Coating Systems Slot Die Coating Variation of the Coating Weight < 1 to 200 g/m 2 Range of Viscosity (mpas) COATEMA Coating Machinery GmbH 54

55 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 55

56 Technologies & Processes Intermittent slot die coating COATEMA Coating Machinery GmbH 56

57 Drying & curing COATEMA Coating Machinery GmbH 57

58 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 58

59 Technologies Drying Technologies Drying with hot air technology COATEMA Coating Machinery GmbH 59

60 Technologies Drying Technologies COATEMA Coating Machinery GmbH 60

61 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 61

62 Drying Topics Drying systems: hot air technology Floatation dryer single nozzle COATEMA Coating Machinery GmbH 62

63 Technologies Drying Technologies IR-Sinter unit COATEMA Coating Machinery GmbH 63

64 Drying Topics Infrared dryers Combined hot air / IR dryer COATEMA Coating Machinery GmbH 64

65 MEA production technology COATEMA Coating Machinery GmbH 65

66 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 66

67 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 67

68 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 68

69 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 69

70 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 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 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 71

72 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 72

73 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 73

74 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 74

75 Deskcoater (F10) (F10) Zusatzmodul-Auswahlmenü 1 Rakelauftrag 2 Breitschlitz-Düsenauftrag 3 Rasterwalzenauftrag 4 Roationssiebdruck Status Controll Status Controll 5 Reverse-Roll-Coater 6 Kiss-Coater Status Controll Status Controll 7 Hot Melt 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 75

76 GDE approach Deskcoater 500 W DMFC-Stack Quelle: Juelich Research Center part of Helmholtz-Community COATEMA Coating Machinery GmbH 76

77 CCM approach COATEMA Coating Machinery GmbH 77

78 CCM approach Production steps 1st step: coating / drying / cooling Cathode base coating PEM MEA Anode base coating COATEMA Coating Machinery GmbH 78

79 CCM approach Production steps Single side step: coating / drying / cooling COATEMA Coating Machinery GmbH 79

80 CCM approach Production steps Double side step: coating / drying / cooling COATEMA Coating Machinery GmbH 80

81 Upscaling from Lab2Fab COATEMA Coating Machinery GmbH 81

82 Todays equipment The Basecoater COATEMA Coating Machinery GmbH 82

83 Todays equipment The Basecoater COATEMA Coating Machinery GmbH 83

84 Todays equipment The Basecoater COATEMA Coating Machinery GmbH 84

85 COATEMA Coating Machinery GmbH 85

86 Todays equipment The Basecoater 3rd Generation COATEMA Coating Machinery GmbH 86

87 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 87

88 Todays equipment The Basecoater Hot pressing COATEMA Coating Machinery GmbH 88

89 Todays equipment The Basecoater Hot pressing COATEMA Coating Machinery GmbH 89

90 Todays equipment The Linecoater COATEMA Coating Machinery GmbH 90

91 Todays equipment The Linecoater COATEMA Coating Machinery GmbH 91

92 Todays equipment The Click&Coat COATEMA Coating Machinery GmbH 92

93 Click&Coat Overview drawing COATEMA Coating Machinery GmbH 93

94 Click&Coat COATEMA Coating Machinery GmbH 94

95 Click&Coat Todays equipment TM Steel layout The Click&Coat COATEMA Coating Machinery GmbH 95

96 Click&Coat TM Steel layout COATEMA Coating Machinery GmbH 96

97 Click&Coat TM Steel layout COATEMA Coating Machinery GmbH 97

98 Click&Coat TM Steel layout 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 Production line for MEAs Production line for Fuel cells 1000 mm working width COATEMA Coating Machinery GmbH 102

103 Today`s equipment COATEMA Coating Machinery GmbH 103

104 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 104

105 Nuvera Layouts Layout proposal COATEMA Coating Machinery GmbH 105

106 COATEMA Coating Machinery GmbH THANK YOU Roseller Str. 4 D Dormagen / tkolbusch@coatema.de COATEMA Coating Machinery GmbH 106

107 COATEMA Coating Machinery GmbH 107