Exploring Foam, Film, and Tape Solutions for Hydrogen Applications

Could you please explain the difference between electrolyzers and fuel cells in simple terms?

Yes. Very simply — electrolyzers generate hydrogen. This hydrogen can then be fed into a fuel cell to generate electricity and power a wide range of systems.

An electrolyzer takes water and by applying an electric current, splits the water into hydrogen and oxygen. The hydrogen is then collected to be used in other systems. Fuel cells take hydrogen and through a chemical reaction, split the hydrogen into an electron and proton. The electrons are transported through an external circuit, generating a flow of electricity to power systems.

There are different types of electrolyzers and fuel cells and they may all function slightly differently, however, PEM (Polymer Electrolyte Membrane) is currently the most common technology.

What is the MEA or the Membrane Electrode Assembly?

The MEA is the membrane electrode assembly and it could be thought of as the heart of the PEM fuel cell and electrolyzers. If we look at a typical fuel cell stack, we will see that it generally is comprised of about 50–200 MEA layers.

The proton exchange membrane (PEM) is encapsulated by a cathode and anode catalyst layer, creating the catalyst coated membrane (CCM). The CCM are then layered together with gaskets and gas diffusion layers to form the MEA, which is needed for the fuel cell to be able to convert chemical energy to electrical energy.

When we look at the utilization of fuel cells, what are some of the most common applications and use-case scenarios?

Fuel cell applications can span across the value chain. They can be utilized in stationary power applications, as backup power for data centers, communication towers and commercial buildings. They can be used in mobility applications such as busses, trucks, vans or even to power boats, planes or submarines.

If we look at the role of foam, film and tape solutions for specific hydrogen applications, could you break down where customers find opportunities for our material solutions?

That’s a bit of a loaded question and I will address it in parts.

First, while customers often approach our teams with specific material needs such as decal release liner materials, initial conversations often unveil other suitable applications for our materials that might not have otherwise been considered. Most customers have their own methodologies, their own designs and their own processes and that’s why initial exploratory conversations with our team are vital. We can either propose an existing solution or work together to design something entirely new.

Let’s break it down a bit more.

Electrolyzers such as PEM (proton exchange membrane) require materials capable of surviving high-pressure and high moisture environments. Materials such as sealing tapes, gaskets or protective films can help provide protective sealing. Our Norgard® products have high temperature and chemical resistance. These are key considerations when it comes to ensuring protective barriers within the electrolyzer systems, which face challenging conditions such as frequent chemical exposure, elevated pressures and high pressures.

If we look at fuel cells, many materials from our Norgard product line can be utilized as gaskets or subgaskets within the MEA. For example, products such as skived PTFE are often top considerations for flat gasket applications. However, products such as ETFE, Polyimide and PEN (Polyethylene-napthalate pressure sensitive adhesive tape) were also successful. When looking at gaskets and sub-gaskets, customers seek material with good chemical resistance, high operating temperatures, high mechanical strength and excellent compression resistance.

In terms of manufacturing the CCM, decal transfer films are very important for helping to layer catalyst materials in membrane electrode assemblies (MEAs). In these applications, customers seek products that have high release for decal substrates and smooth uniform surfaces. ETFE, PFA or T500 are often top contenders for serving as a processing aid to create the catalyst-coated membranes. We also offer several options for materials that can be used as compression pads during the hot press lamination of the MEA.

What are some current challenges for finding the right hydrogen materials?

Undoubtedly, challenges go hand in hand with immense potential. We are equipped to work together with customers to tackle issues such as scalability, cost-effectiveness, as well as material durability and compatibility. While we are ready to offer the materials listed above today, we are also looking forward to next generation materials and designs ready to meet the challenges of the evolving hydrogen landscape.

Albert Einstein once said, “The important thing is not to stop questioning. Curiosity has its own reason for existing.” As the hydrogen economy continues to grow and evolve, it is more important than ever to explore innovative material solutions that can help define the next generation of clean energy technology. By testing materials, co-developing new innovations and collaborating with materials specialists, the possibilities are endless.

Whether it’s identifying the right films for electrical insulation or developing robust adhesives for sealing hydrogen components, our teams are ready to help you transform curiosity into solutions and look forward. Connect with us today to start exploring how Tape Solutions could be exactly what you need to drive your hydrogen projects forward!