Gores Development Path to a Commercial Automotive Membrane Electrode Assembly

Simon Cleghorn, Matthew Griffith, Wen Liu, Jacquelyn Pires, Jeff Kolde

October 17, 2007

W. L. Gore & Associates

A company with an unrelenting commitment to fitness-for-use of our products and a culture that drives continuous innovation to deliver products that 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

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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

China USA

Germany Japan

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Internal Combustion Engine

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

Fuel Cells

Distributed generation (Reliability, cost) Low emissions (environmental) High efficiency (fuel savings)

Batteries
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Electric Grid

Internal Combustion Engine

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

Fuel Cells

Distributed generation (Reliability, cost) Low emissions (environmental) High efficiency (fuel savings)

Batteries
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Electric Grid

Automotive sets the standard

Most demanding technically Most cost-sensitive Highest quality expectations Highest volume potential

Cold Start Freeze Survivability

High Power Operation

Rapid Power Transients

Stop / Start

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$/kW-hr system cost

100 10 1 1985 0.1 0.01 0.001

$/kW-hr system cost

1990

1995

2000

2005

2010

2015

2020

2025

ICE Equivalence

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Projected $/kW-hr system cost, assuming mass production

$/kW-hr system cost, mass production 10

1 1985 0.1 1990 1995 2000 2005 2010 2015 2020 2025

0.01

ICE Equivalence
0.001

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Projected $/kW-hr system cost, assuming mass production

$/kW-hr system cost, mass production 10

1 1985 0.1 1990 1995 2000 2005 2010 2015 2020 2025

~4x reduction needed

0.01

ICE Equivalence
0.001

How can we close this gap?

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.from an MEA suppliers perspective

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Variable Cost

Fixed 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

Todays typical loadings are ~2-5x the long-term targets Need to improve durability and reduce loadings Largest remaining materials challenge

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Electrode Development Trends

(Voltage Loss in 1.4V hold test * Voltage Loss in Voltage Cycling Protocol)

Graphitized Supports

GOAL

Series 5720 (2006)

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Durability

Pt Alloys

Series 5000 (1995)

Series 5710 (2001)

High Surface Area Carbon Supports, highly dispersed Pt

Performance / Loading
Power Density (150%RHexit) * Power Density (50%RHexit) / mg precious metal

Electrode Development Trends

(Voltage Loss in 1.4V hold test * Voltage Loss in Voltage Cycling Protocol)

GOAL
Series 5720 (2006)

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Durability

Series 5000 (1995)

Series 5710 (2001)

High Surface Area Carbon Supports, highly dispersed Pt

Performance / Loading
Power Density (150%RHexit) * Power Density (50%RHexit) / mg precious metal

Electrode Development Trends

(Voltage Loss in 1.4V hold test * Voltage Loss in Voltage Cycling Protocol)

Graphitized Supports

GOAL

Series 5720 (2006)

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Durability

Pt Alloys

Series 5000 (1995)

Series 5710 (2001)

High Surface Area Carbon Supports, highly dispersed Pt

Performance / Loading
Power Density (150%RHexit) * Power Density (50%RHexit) / mg precious metal

Electrode Development Trends

(Voltage Loss in 1.4V hold test * Voltage Loss in Voltage Cycling Protocol)

0.8 mg/cm2

GOAL

0.5 mg/cm2

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Durability

0.15 mg/cm2

Performance / Loading
Power Density (150%RHexit) * Power Density (50%RHexit) / mg precious metal

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)
0.30

Current Gore Ionomer

Through-Plane Conductivity (S/cm)
0.25

New Gore Ionomer 1 New Gore Ionomer 2 New Gore Ionomer 3

0.20

0.15

0.10

0.05

0.00 20%

30%

40%

50%

60%

70%

80%

90%

Relative Humidity

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Gore Ionomer Development

95 C (N2/N2, 20 kHz)
0.30

Current Gore Ionomer

Through-Plane Conductivity (S/cm)
0.25

New Gore Ionomer 1 New Gore Ionomer 2 New Gore Ionomer 3

0.20

0.15

0.10

GM Goal

0.05

0.00 20%

30%

40%

50%

60%

70%

80%

90%

Relative Humidity

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System Simplification

Longer Lifetime
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System Simplification / Durability

Reduce / Eliminate Humidification Reduce Radiator Size (Higher T) Membrane Dehydration Accelerate Chemical Attack

Simplify Start-up / Shut-down Simplify Voltage Controls

Carbon Corrosion Platinum Dissolution

Lower Fuel Purity Requirements Lower Air Purity Requirements

Anode Catalyst Poisoning Cathode Catalyst Poisoning

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System Simplification / Durability

Reduce / Eliminate Humidification Reduce Radiator Size (Higher T) Membrane Dehydration Accelerate Chemical Attack

Can the MEA Operate in Hot, Dry Conditions? Can the MEA Survive in Hot, Dry Conditions?

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RH sensitivity at 1200 mA/cm2

RHinlet 50% RHoutlet 110%
0.800 0.700 0.600 Cell Potential (V) 0.500 0.400 0.300 0.200 0.100 0.000

33% 73%

22% 50%

15% 34%

10% 24%

70

75

80

85

90

95

100

105

110

Cell Temp (C)

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RH sensitivity at 1200 mA/cm2

RHinlet 50% RHoutlet 110%
0.800 0.700 Cell Potential (V) 0.600 0.500 0.400 0.300 0.200 0.100 0.000

33% 73%

22% 50%

15% 34%

10% 24%

70

75

80

85

90

95

100

105

110

Cell Temp (C)

Benchmark (NRE-211 DuPont)

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RH sensitivity at 1200 mA/cm2

RHinlet 50% RHoutlet 110%
0.800 0.700 0.600 Cell Potential (V) 0.500 0.400 0.300 0.200 0.100 0.000

33% 73%

22% 50%

15% 34%

10% 24%

70

75

80

85

90

95

100

105

110

Cell Temp (C)

Benchmark (NRE-211 DuPont)

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New Gore Membrane

110C Cell Temperature

Pressure =7 psig, RH inlet = 30 / 30%, RH out = 46%
1.000 0.900 0.800 0.700 Voltage [V] 0.600 0.500 0.400 0.300 0.200 0.100 0.000

1000

1100

Current Density [mA/cm2]

Benchmark (NRE-211 DuPont)

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New Gore Membrane

1200

100

200

300

400

500

600

700

800

900

Can it Survive?
Two key aspects to membrane durability:
Mechanical durability
RH Cycling

Chemical durability
OCV Hold testing

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Relative Humidity Cycling (N2)

16 14
H2 XO (mL/min)

12 10 8 6 4 2 0 0 200 400
Time (hrs)
FAILURE CRITERIA

No Failure after 1000 hrs (60,000 cycles)

600

800

1000

Benchmark (NRE-211 DuPont)

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New Gore Membrane

Rate of Chemical Degradation

(OCV Hold Test)
1.0E-04

Series 5710 (2002)

120 C

FRR (g of F-/cm2 .hr)

1.0E-05

110 C 95 C 80 C

5700

1.0E-06

70 C 60 C 50 C

1.0E-07

1.0E-08 0.0025

0.0026

0.0027

0.0028

0.0029

0.0030

0.0031

0.0032

1/T (1/K)
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Rate of Chemical Degradation

(OCV Hold Test)
1.0E-04

120 C

FRR (g of F /cm .hr)

1.0E-05

110 C 95 C 80 C

Series 5710 (2002) 5700 Series 5720 (2006) 5720 Next Gen (2008) BATES2
70 C 60 C 50 C

1.0E-06

1.0E-07

1.0E-08 0.0025 0.0026 0.0027 0.0028 0.0029 0.0030 0.0031 0.0032

1/T (1/K)
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Membrane Durability: 80 C Duty Cycle

1.0E-07 9.0E-08

Fluoride Release Rate

8.0E-08 7.0E-08 6.0E-08 5.0E-08 4.0E-08 3.0E-08 2.0E-08 1.0E-08 0.0E+00 0

The test was stopped at 9,000 hrs and was far from failure H2 crossover at 9000 hr: 0.017 cc/min.cm2

2000

4000

6000

8000

10000

Life (hours)

C ell

(C )

Lo ad (m A /cm )

S toic (A a nd C )

P ress ure (kP a)

In let R H (% )

E xit R H (% )

80

20 -100 0

10 -1.7

17 0

50

60 -120

Very little change in membrane thickness after 9,000 hrs on test

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New Duty Cycle with Variable Cell Temperature

1000 900 800 700 600 500 400 300 200 100 0 0 0.5 1 Time in Cycle (hr) 1.5 2 130 120 110 100 90 80 70 Cell Temperature (C)

Includes RH cycles (RHexit 26% - 158%), Cell Temp. 80-120 C

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Current Density (mA/sqcm)

1.00E-06

Fluoride Release Rate

5500 Hours Achieved with Series 5720

9.00E-07 8.00E-07 7.00E-07 6.00E-07 5.00E-07 4.00E-07 3.00E-07 2.00E-07 1.00E-07 0.00E+00

Fluoride Release Rate

0 1000 2000 3000 4000 5000

14 12

Crossover

10 8 6 4 2 0

Gas Crossover
FAILURE CRITERIA

0.9 0.8 Voltage 0.7 0.6 0.5 0.4 0.3

1000

2000

3000

4000

5000

Voltage at 200mA/cm2
1000 2000 3000 4000 5000 6000

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Leveraging Automotive Technology

MEA technologies developed for automotive applications provide significant value in nonautomotive applications Forklifts, stationary, back-up power, bus, etc.
Longer life Higher power density System Simplification

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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. GORE CONFIDENTIAL