Laufenberg and Wevo-Chemie have developed a new process for the continuous, high-throughput production of flat elastomer gaskets
Coating experts Laufenberg and Wevo-Chemie, specialists in epoxy and silicone, have developed a new roll-to-roll process that enables the continuous, high-throughput production of flat elastomer gaskets, giving manufacturers of fuel cells and electrolysers a scalable way to reduce costs and automate production
Individual moulds and discontinuous manufacturing are typically needed for sealing fuel cell and electrolyser stacks and redox flow batteries. However, the new process developed by Laufenberg and Wevo enables streamlined production of flat gaskets, which is expected to increase manufacturing efficiency for hydrogen and battery components.
The process involves Wevo's two-component elastomers, which are mixed and applied in liquid form to a carrier film using Laufenberg's coating equipment. The coating then occurs in a roll-to-roll process and can be applied to either one or both sides.
Curing takes place in a multi-zone tunnel oven, where the temperature in each zone is individually adjustable. Optional pre-curing using infrared emitters can shorten curing time and prevent air bubbles. Line speeds range from 0.5 to 50 m/min, enabling flexible scaling. The fully cured material is then available as either a roll or as precision-cut gaskets.
Layer thicknesses ranging from 20 µm to 2 mm can be achieved with this technique for pure elastomer gaskets. When combined with carrier films, hybrid seals with thicknesses ranging from 70 µm to 4 mm, depending on the core carrier, can be produced.
The type of electrolyser, redox flow battery or fuel cell, determines the choice of elastomer and carrier film.
Laufenberg contributed its expertise in silicone coatings, ensuring that where pure elastomer seals are required, a removable carrier film can be used, or a permanent carrier film can form hybrid seals.
Wevo has been developing special silicones and modified polyurethanes with low hydrogen permeation for years, and they are already in use as liquid sealants and adhesives in fuel cells and electrolyser stacks.
Typically, applications involve dispensing sealing beads onto bipolar plates or flow frames using screen printing or dispensing techniques. The process developed by the two companies now enables the production of prefabricated gaskets using a roll-to-roll process. Pot life, curing time, and other material properties are adjustable. These parameters can be tailored to individual customer requirements, ensuring flexibility across different applications.
