Quality assurance systems for hydrogen

Applying the catalyst layer is one of the most critical steps in fuel cell manufacturing. Whether using slot-die coating, gravure, or decal transfer methods, the challenge remains the same: achieving uniform catalyst distribution with precise edge definition and minimizing the use of expensive platinum-group metals. Coating irregularities such as pinholes, thickness variations, or edge defects directly impact fuel cell efficiency and lifespan. BST COATINGControl^® enables real-time monitoring of coating position and quality, detecting deviations before they propagate downstream. Our web guiding systems ensure stable substrate transport even at high line speeds, while winder control maintains consistent tension across sensitive membrane materials. iPQ-Surface ENERGY adds a layer of 100% defect detection identifying particles, scratches, and coating anomalies that could compromise the finished cell.

The catalyst coated membrane is the electrochemical heart of every PEM fuel cell. During CCM production, anode and cathode layers must be precisely aligned on opposite sides of an ultra-thin polymer membrane. Any misregistration between layers reduces the active area and degrades cell performance. Hot pressing and lamination processes add further complexity: temperature and pressure must be carefully controlled to ensure proper bonding without damaging the delicate membrane structure. BST's web guiding and winder control systems provide the positioning accuracy needed for reliable layer-to-layer registration. Dimensional measurement verifies geometric precision in real time, while iPQ-Surface ENERGY monitors both sides for surface defects and contamination which is critical for maintaining membrane integrity.

The subgasket defines and protects the active area of the CCM while creating the sealing surfaces needed for stack assembly. Precise placement is essential: gaps or overlaps between subgasket and active area can cause gas leakage, membrane degradation, or reduced cell performance. Modern fuel cell production uses roll-to-roll processes for subgasket application, requiring tight control over material positioning and lamination accuracy. BST web guiding ensures exact material placement, while winder control prevents tension variations that could stretch or distort the substrate. CELLInspection and iPQ-Surface ENERGY provide comprehensive quality verification, checking for placement accuracy, adhesion defects, and foreign particles. Dimensional measurement confirms that every subgasketed CCM meets specification before moving to final assembly.

In the final assembly stage, subgasketed CCMs are combined with gas diffusion layers to create the complete membrane electrode assembly. This multi-layer laminate requires exceptional precision: each layer must be accurately positioned and aligned to ensure uniform gas distribution and electrical contact across the active area. BST addresses this challenge through networked BST web guiding systems with master/slave and offset correction functions enabling precise alignment of transparent, translucent, and opaque materials in a single process. BST SLITTINGControl^® ensures accurate slitting to final dimensions, while iPQSurface ENERGY and CELLInspection verify surface quality and detect defects across all layers. The result: MEAs that are ready for stack integration with documented quality data for every unit produced.