Technological innovations and advantages
The “HyCoFC” project aims to develop a hybrid compound bipolar plate consisting of a carrier foil made of low-alloy steel and a conductive compound foil. This combination merges the advantages of both materials: on the one hand, it enables high conductivity and mechanical stability; on the other hand, it can be produced cost-effectively and has a long service life. Bipolar plates are used, for example, in mobile applications such as commercial vehicles, buses and even in aviation, where they are a key component influencing fuel cells' performance and service life and thus contribute to the efficiency and range of fuel cell vehicles.
“The compound film is manufactured using a process patented by Fraunhofer UMSICHT, which enables material-friendly processing,” explains Dr. Michael Joemann, Head of the Electrochemical Energy Storage Department at Fraunhofer UMSICHT. “By selecting suitable input materials and fine-tuning the composition, we can control both the electrical and thermal conductivity and the connection to the carrier film.”
The metallic carrier film is produced by thyssenkrupp Steel. “Our steel foils offer high strength combined with considerable forming potential. By applying a chrome layer to the steel surface, compatibility with the compound foil is improved,” says Tatjana Legchilo, development engineer at thyssenkrupp Steel.
FEV develops and designs the hybrid bipolar plate made of compound and steel foil and the associated cell stack - the so-called fuel cell stack. The project partners hope this hybrid design will reduce costs and ensure a long service life.
Significance and outlook
The hybrid compound bipolar plate offers a promising solution to the challenges of fuel cell technology. It enables the use of large-format fuel cells for mobile applications such as commercial vehicles and stationary applications. “Thanks to the intensive preparatory work and the extensive experience of our partners, the prospects for success are very positive,” emphasizes Prof. Dr.-Ing. Arnold Gillner, Head of Business Development Research Markets at Fraunhofer ILT.
About the project partners
The “HyCoFC” research project is being carried out by thyssenkrupp Steel, FEV, Schepers, cleanLASER and the Fraunhofer UMSICHT and Fraunhofer ILT institutes. It is being funded as part of the “Energie.IN.NRW” innovation competition for European regional funding.
thyssenKrupp Steel is one of the world's leading suppliers of high-quality steel products. Based in Duisburg, Germany, the company offers innovative solutions for the automotive, construction, and electrical industries. With a strong focus on sustainability and technological innovation, ThyssenKrupp Steel sets standards in steel production.
FEV is a leading global provider of engineering services and a driver of innovation in various industries. Founded in 1978, FEV offers technological and strategic solutions for the entire mobility, transportation, aerospace and energy sectors. With its software and systems expertise, the company also plays a pioneering role, making intelligent solutions accessible to everyone. FEV stands for outstanding technological expertise and sustainable innovation.
Schepers is an experienced provider in the field of embossing and printing tool manufacturing and their applications. The company develops and produces high-precision machines and systems for the production of printing and embossing tools and special embossing calendars, which are used in various industries, including metal processing and packaging. Schepers is known for its innovative strength and customized, client-specific solutions.
Clean-Lasersysteme GmbH (cleanLASER) is a world leader in laser systems for industrial surface processing and cleaning. The company develops high-precision and environmentally friendly laser technologies used in various sectors, such as automotive, aerospace, and medical technology.
The Fraunhofer Institute for Environmental, Safety, and Energy Technology (UMSICHT) supports industry and society in transitioning to a climate-neutral and circular economy. The research focus includes Circular Economy, Green Hydrogen, Carbon Management, and Local Energy Systems.
The Fraunhofer Institute for Laser Technology ILT in Aachen is one of the world's leading research and development centers for laser technology. The institute provides comprehensive solutions ranging from developing new laser components to implementing complete laser systems for industrial applications. Fraunhofer ILT is recognized for its innovative strength and contributions to advancing laser technology.
