The global automotive industry is undergoing a profound transformation, driven by the adoption of advanced technologies and a push for electrification. While lithium-ion batteries dominate the market, fuel cell technology is rapidly emerging as a viable alternative. Hydrogen fuel cells, particularly proton exchange membrane fuel cells (PEMFCs), are crucial for achieving zero-emission mobility. Fuel cells provide distinct advantages over battery-powered EVs. However, building reliable and efficient fuel cells requires addressing challenges such as minimizing ion leaching, ensuring hydrolytic resistance, and maintaining mechanical integrity under extreme conditions.

The core of PEM fuel cell technology

Fuel cell systems, powered by PEMFCs, convert hydrogen and oxygen into electricity, water, and heat. At the heart of each fuel cell stack is a layered structure composed of bipolar plates, gas diffusion layers (GDLs), and the proton exchange membrane (PEM) with a platinum catalyst. This system (see Figure 1 below) facilitates the movement of hydrogen ions, while electrons generate electrical current by traveling through an external circuit.

However, contaminants such as sulfur and carbon monoxide can poison the platinum catalyst, reducing efficiency and clogging the PEM. Additionally, fuel cells operate under harsh conditions, including temperatures of 80°C to 120°C, nearly 100% humidity, and acidic pH values of 3 to 5. This creates a pressing need for materials with low ion leaching, excellent hydrolytic resistance, and superior chemical stability.

Xytron® PPS: The optimal material for fuel cell components

Through extensive research, Envalior has identified polyphenylene sulfide (PPS) as the ideal material for PEMFC components. Xytron PPS 4080HR, a proprietary grade, is specifically engineered to deliver industry-leading performance, enabling long-lasting, high-efficiency fuel cell systems. Key advantages include:

• Unmatched ion leaching resistance: Xytron minimizes ionic contamination even at 120°C, preserving catalyst functionality and ensuring optimal fuel cell efficiency.
• Superior hydrolytic and chemical resistance: With unparalleled toughness and strength retention in hydrolytic environments, Xytron surpasses all other PPS and polyphthalamides (PPAs).
• Dimensional stability: Exceptional fatigue and creep resistance maintain system integrity throughout extended lifetimes.
• Enhanced weld-line strength: Superior weld strength before and after hydrolytic and heat aging ensures mechanical reliability.

These properties make Xytron the go-to material for critical components, such as media distribution plates, insulation plates, and hydrogen pressure regulation valves.

Envalior’s expertise extends beyond PEMFC components to other critical fuel cell system elements. For example, Type IV hydrogen storage tanks benefit from advanced material solutions, including a polyamide 6 blow-molded inner tank surrounded by carbon fiber-reinforced UD tape. This design achieves low weight and minimal hydrogen permeability without compromising strength or safety under high pressure (70 MPa).

Driving innovation and sustainability

Envalior’s Xytron PPS 4080HR addresses the most significant challenges in fuel cell system design, ensuring reliable, efficient, and eco-friendly solutions for the automotive industry. With its unmatched performance, this material is poised to revolutionize fuel cell manufacturing, helping OEMs and Tier suppliers achieve their sustainability and performance goals.

To learn more about Envalior PPS Xytron grades, contact our team or visit plasticsfinder.envalior.com. Let’s build a cleaner, more sustainable future together.