Fuel cell systems are considered forward-thinking power generators that produce electrical energy by reversing the process of water electrolysis. This energy can be used to power vehicles, buildings, and other applications. Due to their low emissions and good efficiency, there are numerous international efforts to further develop fuel cell technology.
High power densities, high energy conversions, and short start-up times (cold start) at low operating temperatures of approximately 60-80 °C often put the focus on the PEM fuel cell (Polymer Electrolyte Membrane Fuel Cell, PEMFC or Proton Exchange Membrane Fuel Cell). A hydrogen fuel cell stack uses pure hydrogen and normal ambient air as an oxidizing agent, making them particularly suitable for stationary power generation systems, battery replacement devices, or fuel cell powered transportation systems.
The optimisation of efficiency through the adjustment of systems and components is central to the further development of fuel cell stacks. Critical factors include operating conditions and potential cost reductions through materials and manufacturing processes. Engineering thermoplastics play a key role in fuel cells. Their easy processability and low weight contribute to significant cost savings, and their very long service life makes them ideal for use in fuel cell systems.
As a leading manufacturer and processor of engineering thermoplastics, we offer comprehensive solutions for fuel cell stacks - from material to component.
As a leading manufacturer and processor of engineering thermoplastics, Ensinger specialises in the development and production of hydrogen fuel cell materials and fuel cell components.
From production to performance - we are your partner for fuel cell technology. For durable, sustainable, and innovative solutions
Bipolar plates in fuel cells separate and distribute gases and coolants. While metal and thermoset plates are common, durable high performance plastic plates are becoming increasingly important. Ensinger offers innovative solutions with bipolar plates made from graphitic thermoplastic materials, offering numerous benefits:
End plates in fuel cells clamp and fix the fuel cell stack. The contact pressure is crucial for uniform force distribution and leak-free operation of the stack. Insufficient contact pressure between the electrode and the bipolar plate can impair performance due to high contact resistance and losses or even lead to component failure. As stack size increases, so do the requirements for contact pressure. End plates also form the anode and cathode side terminations of the stack, allowing the connection of pipes, cables, and connections for gas, electrolyte, or cooling lines. The performance of the fuel cell stack is significantly influenced by the geometry of the end plate, the connection method, and the materials used.
Metals were primarily used for end plates in the past, despite complex manufacturing processes and high costs. Metal plates also corrode faster, allowing metal ions to diffuse into the electrolyte, which negatively affects conductivity and output voltage. The high thermal conductivity of metallic materials leads to heat loss, requiring more time to reach operating temperature and the use of additional thermal insulators.
Ensinger offers a beneficial alternative with thermoplastic end plates. Our end plates made from glass fiber-reinforced PPS TECATRON GF40 natural or black (semi-finished product) are characterised by excellent chemical resistance, low water absorption, and a low risk of ion leaching. The high mechanical strength and stiffness allow the required contact pressure to be built up in the stack. The high dimensional stability and creep resistance result in very low deformation, even over longer periods under load and at higher temperatures. TECATRON GF40 black also meets the flame resistance requirements of UL94 V-0. Through our established extrusion process, we can significantly reduce stress in materials such as TECATRON GF40 black or natural (PPS GF40), which offers extreme advantages, especially in the machining of end plates.
The complex geometry typical of end plates, with many breakthroughs, pockets, and edge-near holes, poses high demands on machining. Larger components over half a meter in length and significant deviations in the width/length to thickness ratio are not uncommon, posing additional challenges for tools, machines, and expertise. Precision in manufacturing is essential, especially in the prototyping phase, with a view to scaling production towards injection molding.
With high expertise and decades of experience in processing fiber-reinforced plastics, we offer ready-to-install, low-distortion, and high-precision end plates. If you zoom in and rotate, you can take a closer look at Ensinger's end plate made from TECATRON GF40 black: AR Application
Insulation plates are seemingly simple components whose true complexity is often underestimated. Besides the enormous pressure load due to stack compression, they must withstand all media required in the stack at the same time with media pressure and high temperatures.
One of the biggest challenges in manufacturing insulation plates, however, is the dimensions of the stack, which often exceed the dimensions of common thermoplastics. Ensinger manufactures insulation plates according to customer-specific requirements and the highest quality standards, precisely tailored to the end application. We offer insulation plates for fuel cells, electrolysis stacks, or redox flow batteries.
The media supply unit (MSU) is a key component in the fuel cell that ensures a reliable supply of hydrogen, oxygen, and coolant. Ensinger has extensive experience in manufacturing media supply units with dimensions up to 500 x 700 mm, both machined and injection-molded.
To ensure optimal performance and reliability of the MSU, we offer filling simulations, FEM analyses, and other simulations for the design of injection-molded parts. Our advantage lies in a strong network and close cooperation with leading European institutes specialising in fuel cell technologies. These partnerships enable us to stay at the forefront of technology and develop innovative solutions for the challenges in hydrogen technology. Through these synergies and our technical expertise, we ensure that our media supply units meet the highest standards and contribute to the efficiency and longevity of modern fuel cell systems.
