Powering the Future: High-Performance Polymers in Electrolysers, Fuel Cells, and Energy Storage Systems
As the hydrogen economy scales, materials innovation is becoming just as important as system design. High-performance polymers, with their resistance to extreme conditions, are enabling breakthroughs in electrolysers, fuel cells, and hydrogen storage systems.
These advanced materials offer a powerful combination of chemical resistance, thermal stability, mechanical strength, and gas impermeability, making them ideal for demanding hydrogen applications.
Electrolysers: Surviving Alkaline & Acidic Environments
Electrolysers (especially PEM and alkaline types) rely on materials that can withstand corrosive environments, high temperatures, and electrical isolation.
Applications:
- Seals, gaskets, insulators, manifolds, and plates.
Materials in use:
- PTFE (Polytetrafluoroethylene) – Chemically inert and stable up to 260°C. Ideal for gaskets and seal systems.
- PFA (Perfluoroalkoxy) – Offers high purity and excellent chemical resistance in acid electrolytes.
- ETFE (Ethylene tetrafluoroethylene) – High mechanical strength with good resistance to hydrogen embrittlement.
- PEEK (Polyetheretherketone) – Used for load-bearing structural components with excellent thermal stability and low water absorption.
- PVDF (Polyvinylidene fluoride) – Excellent for backplates and structural parts where strength and chemical resistance are both critical.
Fuel Cells: Operating in Compact, Hot, Wet Conditions
Fuel cells operate in compact assemblies where every component must maintain tight tolerances and chemical resistance while handling moisture and heat.
Applications:
- Seals between bipolar plates, internal insulation, fastening systems.
Materials in use:
- Expanded PTFE – Conforms well to surfaces, provides reliable sealing under pressure.
- FEP (Fluorinated ethylene propylene) – A good choice for coatings and linings with high electrical insulation.
- Silicone/PTFE composites – Used for flexible sealing in moist and reactive gas environments.
- PCTFE (Polychlorotrifluoroethylene) – High barrier to gas permeation, ideal for seals in humid and hydrogen-rich environments.
Hydrogen Storage: Managing Pressure & Permeation
Storage systems, particularly for compressed hydrogen at 350–700 bar, require materials that can endure intense internal pressure, temperature swings, and gas diffusion risks.
Applications:
- Tank liners, end cap seals, valve seals, compression rings.
Materials in use:
- PCTFE – Exceptional hydrogen barrier performance and low creep, often used in cryogenic or high-pressure seals.
- UHMW-PE (Ultra-high-molecular-weight polyethylene) – Used as liners in Type IV tanks, offering impact resistance and low permeability.
- PEEK – For load-bearing components and precision-machined valve parts.
- PTFE-based composites (with glass, carbon, or bronze fillers) – Custom-engineered for structural support with low friction and improved wear.
Fluorocarbon’s Role: Materials That Meet the Moment
At Fluorocarbon, we specialise in tailoring Fluoroglide® PTFE-based solutions and other high-performance polymer components to meet the exacting requirements of hydrogen systems. Whether you’re designing next-generation electrolysers, deploying mobile fuel cell units, or scaling up hydrogen storage, our materials offer:
- Reliable sealing under extreme pressure
- Low gas permeability
- Resistance to aggressive chemical media
- Stable performance across wide temperature ranges
Example: PTFE Slide Bearings in Hydrogen Infrastructure
Our Fluoroglide® PTFE slide bearings have already proven effective in supporting structures for hydrogen fuelling stations, reducing maintenance by resisting chemical degradation and thermal stress.
Ready to upgrade your hydrogen systems with materials built for the future?
Connect with our engineers at info@fluorocarbon.co.uk to explore how we can help accelerate your innovation.