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Hydrogen Fuel Cells & Electrolyzers

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Supporting sustainable and responsible energy

VERSIV™ monolayer films enhance the performance of hydrogen fuel cells

VERSIV™  multi-material composites work as industry-leading protection and barrier solutions when used as cells, seals, and separators within hydrogen fuel cells and electrolyzers. Our films and fabrics increase membrane electrode assembly efficiency and help manufacturers achieve reduced stack height, high-speed decal productivity, and thinner, more homogenous catalyst layers.

Hydrogen fuel cells provide a clean and efficient way to store and transport energy for use in homes, businesses, and vehicles. VERSIV™ monolayer films enhance the performance of fuel cells, irrespective of the most stressful and challenging conditions, including working at high pressures and temperatures of up to 300˚C (572˚F) and in harsh chemical environments. By helping to maximize fuel cell performance and longevity, our solutions are contributing to their wider usage, both as components and as process aids.

VERSIV™ film is ideal for customized fuel cell and electrolyzer solutions as it can be further processed by various techniques such as stretching, laminating, or surface treating to enhance its properties for specific applications.

Hydrogen Fuel Cell Stack
H2 Electrolyzer

Applications within fuel cells

VERSIV™ films are used in a wide range of applications due to their unique properties, including non-stick capability while still allowing wettability, chemical and heat resistance, and electrical installation. Our films can be used to support hydrogen fuel cells and electrolyzers in several ways, supporting their durability, stability, and performance.

fuel cell plate protection diagram

Gaskets

Gaskets made out of VERSIV™ films can be used to protect graphite Bi-polar plates in fuel cells. The films help to increase the durability and stability of the Bi-polar plate by protecting it from corrosion and other forms of degradation. This can lead to longer-lasting and more efficient fuel cells.

fuel cell decal production diagram

Decal transfer process aid

Our films can be used as a substrate/carrier during the Decal Transfer Method. Our materials are ideal for the process as they provide smooth and homogenous surfaces and very tight thickness control. It means the coating process can be optimized during the DTM, resulting in very thin catalyst layers, improving the efficiency of the MEA and the overall stack. The used surface energies allow both wettability and release.

Benefits of VERSIV™ films in hydrogen fuel cell and electrolyzer infrastructure

VERSIV™ films provide an important set of properties that make them ideal for use in hydrogen application infrastructure, helping to improve the efficiency, safety, and reliability of fuel cells.

Benefits include:

  • High chemical resistance: PTFE-coated films are highly resistant to chemicals, making them ideal for use in the harsh chemical environment of hydrogen fuel cells and electrolyzers. It can withstand exposure to aggressive chemicals such as strong acids and bases, which are commonly used in the manufacturing of fuel cells and electrolyzers.
  • Low permeability to gases: Our films have extremely low permeability to gases, including hydrogen, which is a key component in fuel cells and electrolyzers. This property ensures that hydrogen gas is contained within the cell and does not leak out, which is essential for the safe and efficient operation of the application.
  • Excellent electrical insulation: VERSIV™ films are an excellent electrical insulator, which is important in hydrogen applications where electrical current must be conducted through the fuel cell or electrolyzer without shorting out. These fluoropolymer-based films can be used as separators between the cell layers, preventing electrical contact between the anode and cathode.
  • High-temperature resistance: Our films have excellent high-temperature resistance, which is important in such applications where high temperatures are generated during operation. PTFE-based films can withstand temperatures up to 260°C without degradation, ensuring long-term performance and reliability.

Read more about our solutions in our brochure Improving Performance in Fuel Cells and Electrolyzers.

What is a VERSIV™ film?

VERSIV™ is a Saint-Gobain Composite Solutions tradename describing a variety of high-performance, flexible, transparent films typically used as a barrier layer in various applications, including fuel cells. VERSIV™ films are engineered to provide a range of properties, such as high gas and moisture barrier, chemical resistance, thermal stability, and optical clarity. They can be tailored to meet specific performance requirements based on the intended use and application. These films are customizable to meet the specific needs of fuel cell and electrolyzer applications. 
 

What are VERSIV™ films made of?

We have different products in use in hydrogen applications. These hydrogen-oriented films include: 

PTFE-coated Polyimides (e.g., VERSIV™ DF2919) 

Mod. PTFE and virgin PTFE (e.g., VERSIV™ 0200) 

PTFE-coated glass fabric such as VERSIV™ CF205 or VERSIV™ SRF205 

ETFEs, PFAs, PVDFs 

How are VERSIV™ films used in improving fuel cell and electrolyzer performance?

Our films are used in the manufacturing or assembly process of fuel cell and electrolyzer components or in the production of membranes used to separate the anode and cathode of the cell. In this context, films play a role in improving the performance or durability of fuel cell systems. 

When should I use a VERSIV™ film?

Monolayer films have many potential applications, including electronic devices, sensors, catalysis, and surface coatings. Specific uses include: 

Surface coatings: Our films can be used as surface coatings to modify the properties of a material. For example, a monolayer film of a hydrophobic material makes a surface water-repellent. 
Lubricants: VERSIV™™ films can be used to reduce friction between surfaces.  

Process aid for Decal Transfer Method (DTM): Our films can be used as a substrate/carrier during the Decal Transfer Method. Our materials are ideal for the process as they provide smooth and homogenous surfaces and very tight thickness control. It means the coating process can be optimized during the DTM, resulting in very thin catalyst layers, improving the efficiency of the MEA and the overall stack. The used surface energies also allow both wettability and release. 
 

How do you improve membrane electrode assembly (MEA) efficiency?

The efficiency of an MEA refers to the ability of the fuel cell to convert the chemical energy stored in a fuel (such as hydrogen) into electrical energy. Improving an MEA requires optimizing the materials used, the operating conditions, and the fuel cell design, all helping make fuel cell technology more efficient and cost-effective. 

The thinner the catalyst layer, the easier the gas transfer in the fuel cell and, thus, the higher the efficiency of the MEA itself. The material minimizes the potential for a short. Our materials used as substrates for Decal Transfer Method (DTM) show smooth and homogenous surfaces and very tight thickness control. It means the coating process can be optimized during the DTM, resulting in very thin catalyst layers, improving the efficiency of the MEA and the overall stack. 

How do VERSIV™ films decrease stack size? 

The thinner and tighter tolerance thickness of VERSIV™ gasket materials makes for tighter tolerance chains and supports a decrease in overall stack size. 

Are VERSIV™ decal substrate release films compatible with all catalyst ink chemistries and solvents? 

There is plentiful variety of catalyst inks in use in the market today and under development for future use. Our substrates are compatible with all known formulations so far.

How rigid are VERSIV™ gaskets and how easily are they assembled into a fuel cell stack?

Rigidity and assembly depend on customer stack, gasket design, and used materials and thicknesses. In general, we have non-rigid and very thin materials in use but also materials in mm thickness which are very stiff. Regarding assembly, we can support kiss-cut processes and adopt customer packing requirements. As well as that, we can make the gaskets slightly tacky or even coat them with pressure or temperature-sensitive adhesives to support customer stack assembly and serial production processes. 

How do VERSIV™ fuel cell products withstand leak testing, thermal cycling, and creep testing?

We do not test in stacks/systems internally, but customer durability tests show we meet customer requirements. These requirements differ from customer to customer and vary mainly between 5,000 hours and 25,000 hours running time. 

Usually, there is a trade-off between efficiency and durability. For example, the thicker the membrane, the more durable the system is, but the lower the efficiency, as the gas transfer is better with thinner membranes. In terms of creep, we have good results as we have materials in our portfolio using, for example, glass fabric or polyimide (PI) as reinforcement which decreases creep significantly. 

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