Welded PEM electrolyzers with carbon-based bipolar plates
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In contrast to the state of the art, the stack concept developed by Fraunhofer UMSICHT promises high material efficiency through the use of alternative, polymeric materials for bipolar foils as well as fundamentally rethought cell and stack concepts based on materially bonded components. In contrast to bipolar foils made of titanium, for example, the bipolar foils offer electrical conductivity through the use of a highly filled composite made of carbon and thermoplastic, while at the same time being manufactured cost-effectively and continuously using the powder-to-roll calendering process. Additionally, the bonding of the bipolar foil, frame elements, and membrane electrode units can replace any seals in the electrolysis cell. This drastically reduces the number of components in the cell, which in turn reduces the number of stacking processes and thus the assembly effort. In addition, the joining process eliminates vulnerable sealing surfaces and replaces them with robust weld seams, which contributes significantly to a reduction in production waste.