A fuel cell is an electrochemical device that converts hydrogen fuel into electricity without using combustion. This technology has a spectrum of uses, from providing primary or backup power for buildings and plants, to powering mobile phones, laptop computers and other portable electronics. But the most publicized use of fuel cells is in automobiles, partly driven by strong government endorsement in the U.S., the EU and Japan.

While this industry is developing at a slow pace, the growth potential is significant. The market for fuel cells could attain levels of US$35 billion by 2013, according to a report by market researcher Allied Business Intelligence. Growth is dependent on technological improvements, as also on availability of hydrogen and methanol; fuels used by fuel cells in the automotive and portable electronics fields, respectively. By 2006, new products using fuel cells are expected to deliver performance gains and sell in larger numbers.

There are, however, considerable performance and cost issues to overcome. ABI predicts automotive fuel-cell penetration will be limited in addition to cost concerns, by strict technological challenges, infrastructure challenges and lack of certainty over fuel choice in the near term. Stationary fuel cells for power generation and portable fuel cells for high-end electronic products will generate early revenues.

There are several fuel-cell types, such as phosphoric acid and proton exchange membrane (PEM), each offering different power efficiencies and applicability. The components holding the most promise for plastics application, experts say, are bipolar plates, end plates, plate assemblies, manifolds and peripheral system components used in fuel-cell stacks. Bipolar plates can be fabricated from thermoplastic or thermoset resins with electrically conductive fillers and have elastomeric seals pressed in place, overmolded, or dispensed onto them for plate/seal assemblies. Much research is being carried out to advance the technology of polymer membranes, the heart of the PEM fuel cell. Plastics will make fuel cells affordable, efficient and effective. In addition, they are more reliable when specific requirements have to be met. The biggest challenge with a lot of materials is electrical conductivity as materials have to be rigid and conductive.

The development is still at an embryonic stage. Only time will determine how successful the electrically conductive plastics; whether thermoplastic or thermoset, will be in this application.