Highly Robust Low-PGM MEAs based on Composite Supports

This Small Business Innovation Research Phase I project will develop high performance, highly durable supports for low Platinum Group Metal (PGM) fuel cells using low-cost techniques to achieve the 2020 targets for cost ($40/kW at the system level, $14/kW at the MEA level), start- up/shutdown durability (5,000 cycles), and less than 10% loss in power after 5,000 hours. Fuel cells for transportation and stationary applications (including distributed power and combined heat and power, CHP) remain a DOE priority for achieving reduced energy and petroleum consumption, as well as an important route to addressing the challenge of reducing carbon emissions. Tremendous progress in PEM fuel cell technology has been made over the last two decades in addressing key DOE milestones for cost reduction, Pt loading and overall performance. Indeed, this progress has manifested itself as PEM fuel cells have made inroads in commercial applications, most notably the initial introduction of light-duty vehicles in California (e.g., Toyota, Hyundai), as well as the forklift market where thousands of units have been fielded and projections for continued market growth remain high. Although progress has been made, additional improvements to fuel cell stack durability are needed. This program will apply a recently developed low-cost Atomic Layer Deposition (ALD) technique to apply ultra-thin conductive barrier coatings onto carbon particles to prepare drop-in ready materials suitable for use in highly robust Membrane Electrode Assemblies (MEAs), without sacrificing cost or performance, and while extending system durability shortcomings. In addition, the high-throughput ALD technology developed by PneumatiCoat is very low cost, and may even lower the cost of the electrode by enabling further reductions in PGM catalyst loading. These attributes promise to facilitate use of the current inexpensive carbon material, yet solving the durability issues experienced today, which will further accelerate commercial adoption.