GoreGore’’s Development Path to a Commercial s Development Path to a Commercial Automotive Membrane Electrode AssemblyAutomotive Membrane Electrode Assembly
Simon Cleghorn, Matthew Griffith, Wen Liu, Jacquelyn Pires,
Jeff Kolde
October 17, 2007
GORE CONFIDENTIAL
A company with an unrelenting commitment to fitness-for-use of our products and a culture thatdrives continuous innovation to deliver productsthat make a difference in peoples’ lives.
“Our products will do what we say they will do”.Bob Gore former CEO, current Chairman of the Board
W. L. Gore & Associates
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Gore Fuel Cell Technologies
• Supplying advanced MEA products to the industry since 1995– Technology Leadership– Strong Partnerships– Broad Experience
• Committed to enabling commercialization of fuel cells– Application-specific MEA
products
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Global Gore Fuel Cell Team
Japan
USA
Germany
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China
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Internal Combustion Engine
BatteriesElectric Grid
Fuel Cells
Zero emissions (environmental)
More efficient (fuel savings)
Fuel Flexible (energy security)
Less moving parts (reliability)
Quieter, lower heat signal (military uses)
Lower weight/volume
Rapid “recharging”
Environmental benefits
Lower lifecycle costs
Distributed generation (Reliability, cost)
Low emissions (environmental)
High efficiency (fuel savings)
GORE CONFIDENTIAL
Internal Combustion Engine
BatteriesElectric Grid
Fuel Cells
Zero emissions (environmental)
More efficient (fuel savings)
Fuel Flexible (energy security)
Less moving parts (reliability)
Quieter, lower heat signal (military uses)
Lower weight/volume
Rapid “recharging”
Environmental benefits
Lower lifecycle costs
Distributed generation (Reliability, cost)
Low emissions (environmental)
High efficiency (fuel savings)
GORE CONFIDENTIAL
High PowerOperation
Stop / StartRapid PowerTransients
Cold StartFreeze Survivability
• Most demanding technically
• Most cost-sensitive
• Highest quality expectations
• Highest volume potential
Automotive sets the standard
GORE CONFIDENTIAL
0.001
0.01
0.1
1
10
100
1985 1990 1995 2000 2005 2010 2015 2020 2025
$/kW
-hr s
yste
m c
ost
$/kW-hr system cost
ICE Equivalence
GORE CONFIDENTIAL
0.001
0.01
0.1
1
10
1985 1990 1995 2000 2005 2010 2015 2020 2025
$/kW
-hr s
yste
m c
ost,
mas
s pr
oduc
tion
Projected $/kW-hr system cost, assuming mass production
ICE Equivalence
GORE CONFIDENTIAL
0.001
0.01
0.1
1
10
1985 1990 1995 2000 2005 2010 2015 2020 2025
$/kW
-hr s
yste
m c
ost,
mas
s pr
oduc
tion
Projected $/kW-hr system cost, assuming mass production
ICE Equivalence
~4x reduction needed
How can we close this gap? ….from an MEA supplier’s perspective…
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Fixed CostVariable Cost
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Variable Cost Reduction
• Membrane costs are projected to meet the most aggressive automotive cost targets in volume– Perfluorinated membranes (Mathias, et al. ECS Interface, Fall 2005)
• Largest MEA Variable Cost: Catalyst– Today’s typical loadings are ~2-5x the long-term targets
– Need to improve durability and reduce loadings
– Largest remaining “materials” challenge
GORE CONFIDENTIAL
Electrode Development Trends
Performance / LoadingPower Density (150%RHexit) * Power Density (50%RHexit) / mg precious metal
Durab
ility(V
oltag
e Loss in
1.4
V h
old
test * V
oltag
e Loss in
Voltag
e Cyclin
g P
roto
col)
Series 5000 (1995) Series 5710 (2001)
High Surface Area Carbon Supports, highly dispersed Pt
Series 5720 (2006)
Graphitized Supports
Pt Alloys
GOAL
GORE CONFIDENTIAL
Electrode Development Trends
Performance / LoadingPower Density (150%RHexit) * Power Density (50%RHexit) / mg precious metal
Durab
ility(V
oltag
e Loss in
1.4
V h
old
test * V
oltag
e Loss in
Voltag
e Cyclin
g P
roto
col)
GOAL
Series 5000 (1995) Series 5710 (2001)
High Surface Area Carbon Supports, highly dispersed Pt
Series 5720 (2006)
GORE CONFIDENTIAL
Electrode Development Trends
Performance / LoadingPower Density (150%RHexit) * Power Density (50%RHexit) / mg precious metal
Durab
ility(V
oltag
e Loss in
1.4
V h
old
test * V
oltag
e Loss in
Voltag
e Cyclin
g P
roto
col)
GOAL
Series 5000 (1995) Series 5710 (2001)
High Surface Area Carbon Supports, highly dispersed Pt
Series 5720 (2006)
Graphitized Supports
Pt Alloys
GORE CONFIDENTIAL
Electrode Development Trends
Performance / LoadingPower Density (150%RHexit) * Power Density (50%RHexit) / mg precious metal
Durab
ility(V
oltag
e Loss in
1.4
V h
old
test * V
oltag
e Loss in
Voltag
e Cyclin
g P
roto
col)
GOAL
0.5 mg/cm2
0.15 mg/cm2
0.8 mg/cm2
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Higher Power Density
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Higher Power Density
• Designing stacks to run at higher rated current density can result in significant cost savings / stack– Lower number of cells– Smaller cells, less MEA / stack
• Typically, this results in an efficiency tradeoff, as lower voltages are reached at higher current density
How much of a tradeoff is this for automotive applications?
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Calculations provided by Nuvera
• Demonstration of large impact of cell count reduction from higher current density operation, and relatively small efficiency impact on actual driving cycle
• Upon request by Nuvera, these calculations are not included for broad dissemination.
• To request a copy, contact James Cross at Nuvera
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Gore Ionomer Development 95 °C (N2/N2, 20 kHz)
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Relative Humidity
Thro
ugh-
Plan
e C
ondu
ctiv
ity (S
/cm
)
Current Gore Ionomer
New Gore Ionomer 1
New Gore Ionomer 2
New Gore Ionomer 3
GORE CONFIDENTIAL
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Relative Humidity
Thro
ugh-
Plan
e C
ondu
ctiv
ity (S
/cm
)
Current Gore Ionomer
New Gore Ionomer 1
New Gore Ionomer 2
New Gore Ionomer 3
Gore Ionomer Development95 °C (N2/N2, 20 kHz)
GM Goal
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System Simplification
Longer Lifetime
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System Simplification / Durability
Reduce / Eliminate HumidificationReduce Radiator Size (Higher T)
Membrane DehydrationAccelerate Chemical Attack
Simplify Start-up / Shut-downSimplify Voltage Controls
Carbon CorrosionPlatinum Dissolution
Lower Fuel Purity RequirementsLower Air Purity Requirements
Anode Catalyst PoisoningCathode Catalyst Poisoning
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System Simplification / Durability
Reduce / Eliminate HumidificationReduce Radiator Size (Higher T)
Membrane DehydrationAccelerate Chemical Attack
Can the MEA Operate in Hot, Dry Conditions?
Can the MEA Survive in Hot, Dry Conditions?
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70 75 80 85 90 95 100 105 110Cell Temp (°C)
Cel
l Pot
entia
l (V)
RHinlet 50% 33% 22% 15% 10%RHoutlet 110% 73% 50% 34% 24%
RH sensitivity at 1200 mA/cm2
GORE CONFIDENTIAL
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70 75 80 85 90 95 100 105 110Cell Temp (°C)
Cel
l Pot
entia
l (V)
RHinlet 50% 33% 22% 15% 10%RHoutlet 110% 73% 50% 34% 24%
RH sensitivity at 1200 mA/cm2
Benchmark (NRE-211 DuPont®)
GORE CONFIDENTIAL
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70 75 80 85 90 95 100 105 110Cell Temp (°C)
Cel
l Pot
entia
l (V)
RHinlet 50% 33% 22% 15% 10%RHoutlet 110% 73% 50% 34% 24%
RH sensitivity at 1200 mA/cm2
Benchmark (NRE-211 DuPont®) New Gore Membrane
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Pressure =7 psig, RH inlet = 30 / 30%, RH out = 46%
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Current Density [mA/cm2]
Vol
tage
[V]
110°C Cell Temperature
Benchmark (NRE-211 DuPont®) New Gore Membrane
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Can it Survive?
• Two key aspects to membrane durability:– Mechanical durability
• RH Cycling
– Chemical durability• OCV Hold testing
GORE CONFIDENTIAL
02468
10121416
0 200 400 600 800 1000Time (hrs)
H2
XO (m
L/m
in)
Relative Humidity Cycling (N2)
Benchmark (NRE-211 DuPont®) New Gore Membrane
No Failure after 1000 hrs (60,000 cycles)
F A I L U R E C R I T E R I A
GORE CONFIDENTIAL
1.0E-08
1.0E-07
1.0E-06
1.0E-05
1.0E-04
0.0025 0.0026 0.0027 0.0028 0.0029 0.0030 0.0031 0.00321/T (1/K)
5700
FRR
(g o
f F- /c
m2 .h
r)
Rate of Chemical Degradation(OCV Hold Test)
50 °C
60 °C
70 °C80 °C
95 °C
110 °C120 °C
Series 5710 (2002)
GORE CONFIDENTIAL
1.0E-08
1.0E-07
1.0E-06
1.0E-05
1.0E-04
0.0025 0.0026 0.0027 0.0028 0.0029 0.0030 0.0031 0.00321/T (1/K)
5700
5720
BATES2
FRR
(g o
f F- /c
m2 .h
r)
Rate of Chemical Degradation(OCV Hold Test)
50 °C
60 °C
70 °C80 °C
95 °C
110 °C120 °C
Series 5710 (2002)
Series 5720 (2006)
Next Gen (2008)
GORE CONFIDENTIAL
0.0E+00
1.0E-08
2.0E-08
3.0E-08
4.0E-08
5.0E-08
6.0E-08
7.0E-08
8.0E-08
9.0E-08
1.0E-07
0 2000 4000 6000 8000 10000Life (hours)
Membrane Durability: 80 C Duty Cycle
170
Pressure(kPa)
50
Inlet RH(% )
60-12010-1.720-100080
Exit RH(% )
Stoic (A and C)
Load(m A/cm ²)T Cell (°C)
170
Pressure(kPa)
50
Inlet RH(% )
60-12010-1.720-100080
Exit RH(% )
Stoic (A and C)
Load(m A/cm ²)T Cell (°C)
• The test was stopped at 9,000 hrs and was far from failure• H2 crossover at 9000 hr: ≤ 0.017 cc/min.cm2
Fluo
ride
Rel
ease
Rat
e
Very little change in membrane thickness after 9,000 hrs on test
GORE CONFIDENTIAL
New Duty Cycle with Variable Cell Temperature
0100200300400500600700800900
1000
0 0.5 1 1.5 2
Time in Cycle (hr)
Cur
rent
Den
sity
(m
A/s
qcm
)
70
80
90
100
110
120
130
Cell
Tem
pera
ture
(C)
Includes RH cycles (RHexit 26% - 158%), Cell Temp. 80-120 C
GORE CONFIDENTIAL
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Volta
ge
0
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Cro
ssov
er
0.00E+00
1.00E-07
2.00E-073.00E-07
4.00E-07
5.00E-07
6.00E-07
7.00E-078.00E-07
9.00E-07
1.00E-06
0 1000 2000 3000 4000 5000
Fluo
ride
Rel
ease
Rat
e5500 Hours Achieved with Series 5720
Fluoride Release Rate
Gas Crossover
Voltage at 200mA/cm2
F A I L U R E C R I T E R I A
GORE CONFIDENTIAL
Leveraging Automotive Technology• MEA technologies developed for automotive
applications provide significant value in non-automotive applications
• Forklifts, stationary, back-up power, bus, etc.– Longer life
– Higher power density
– System Simplification
GORE CONFIDENTIAL
…the Final Piece of the Puzzle…• Commitment
– Gore remains highly committed to the success of this industry
– Experience: Supplying MEAs to the fuel cell industry for 12 years
– Long-standing partnerships with leading fuel cell developers
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Thank You!
GORE and PRIMEA are trademarks of W.L. Gore and Associates, Inc.
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