Bipolar plates and stack components
Enabling green hydrogen production
Components for electrolyzers
HOERBIGER offers complete solutions for metallic bipolar plates and stack components from a single source. Our "simply sorted" approach enables the development, production and validation of components under one roof to ensure the best possible product. HOERBIGER takes care of all production steps up to the finished component.
Thanks to our optimized process technology from the automotive industry, we create real value add for stack suppliers and complete elektrolyzer system manufacturers. The bipolar plate developed by HOERBIGER is marketed and distributed in collaboration with a technical cooperation partner.
Benefit from our expertise and maximize efficiency and quality for your application.
Why HOERBIGER is the right partner
- Early cooperation in engineering: We work closely with you in the early design phases to ensure the best possible "design to manufacture".
- Optimum performance and robustness: Complete solutions to increase efficiency and stack life by reducing material degradation.
- Perfect compatibility: Coatings, substrates and seals are carefully designed with quality gates to ensure smooth integration.
- Your partner for industrialization: Seamless and cost-efficient scaling with flexible adaptation to market demand.
- Simplified supply chain: By consolidating processes, we reduce the logistical effort for our customers by 80 percent.
- Over 40 years of automotive experience: We are committed to 100% delivery performance with 0 ppm defects. You can find our certifications here.
Requirements analysis and feasibility study
HOERBIGER evaluates customer requirements in order to define an optimum process flow. Common methods such as CFD/FEM and forming simulations are used for this purpose. This also enables the best possible selection of partners and suppliers.
Design to manufacture, material selection and specification
HOERBIGER optimizes the component design together with the customer. We see ourselves in an advisory role with regard to the process chain in order to further develop the components not only functionally, but also in terms of process technology. This reduces costs, but also increases the robustness and quality of the components.
HOERBIGER uses specially specified material (e.g. for titanium), which is adapted to the requirements of sheet metal forming. This enables even more precise forming and further stabilizes component quality.
Forming, cutting and laser welding
Sheet metal forming is a core competence of the HOERBIGER Automotive Division. Decades of experience in sheet metal formed transmission components for the global automotive industry form the basis for highest quality in medium to very high volumes of components. The in-house development and production of the necessary tools and equipment guarantee innovation and flexibility for the highest customer requirements.
We transfer this know-how to the production of metallic bipolar plates, manufactured from titanium and stainless steel with sheet thicknesses between 0.1 and 1 mm and with active areas of 3,000 cm2 and beyond.
Welding of bipolar plates depends on the customer's concept. If required, HOERBIGER can weld various sheet metal components on modern laser welding systems. Sample quantities can already be produced in-house, and scaling is also possible. Our experience in toolmaking helps with construction, in particular to ensure the high requirements for tightness.
Coating and additional treatment
The aggressive oxidative environment in the (PEM) electrolysis cell requires a robust surface of the bipolar plate. HOERBIGER offers various solutions based on different technologies for this purpose.
For the high-performance coating of the formed metallic bipolar plate, HOERBIGER works with a technical cooperation partner who has many years of experience in electrochemistry.
The focus is on increasing the corrosion resistance and conductivity of the bipolar plates. This enables degradation rates of < 4µV/h, which significantly increases the service life of the stacks and reduces the overall operating costs of the electrolyzer.
Depending on customer requirements, further process steps may be necessary, such as washing the parts or surface activation for subsequent gasket application. We develop specific processes and take care of industrialization.
Sealing application
The seal is not only a central component of the bipolar plate for safety reasons, but is also crucial for its functionality. The seal is exposed to the aggressive cell environment and must meet high requirements for temperature and ageing resistance.
HOERBIGER offers various technologies, whereby the application and ultimately the customer requirements are decisive. With injection molding and dispensing of all common materials (FKM, EPDM, silicone), we are the partner for integrated solutions.
Quality control
The final quality control ensures compliance with all performance-determining characteristics of the bipolar plate. Customer-specific validations are also possible, including the determination of leakage rates or the contact resistance of the surface. This enables our customers to stack the components directly. The benefits for the customer are minimized waste, reduced logistics costs in the assembly plant and lowered process times.
Find out more on our product specific website Ready2StackTM.
Why electrolysis?
Due to its outstanding storage capacity, hydrogen is considered an indispensable key element of the energy transition. However, both the production of hydrogen and its use must beCO2-free in the future - otherwise the decarbonization of the energy and economic cycle can hardly succeed. Water electrolysis is therefore becoming increasingly important worldwide.
The electrochemical principle is simple: water is charged with electricity and broken down into its components hydrogen and oxygen. Greenhouse gases are not involved in the reaction, nor are they required for secondary processes.
Despite this concept, the technical implementation faces demanding challenges. In order to replace the current petroleum-based energy sources, it must be possible to produce enormous quantities of hydrogen quickly. This requires a large number of electrolysers in a short space of time. The latter must have an optimized power density, the highest possible efficiency and a long service life - this is the only way to achieve an acceptable total cost of ownership (TCO).
This can only be achieved if the development and production of each individual component is optimized and coordinated. HOERBIGER helps to achieve precisely this goal. As a long-standing supplier to the automotive industry, we specialize in the production of complex and tightly toleranced metal components in large quantities and at competitive prices. Our manufacturing and engineering expertise allows us to develop customized solutions for our customers and thus achieve the best possible result in terms of cost efficiency and product quality.
Do you have any questions?
We have the answers - contact us today.
Lothar Kern
Head of Sales
+49 8861 2566 2070
electrolysercomponents@hoerbiger.com