Ultra Lightweight/High Performance Structural PEM Fuel Cell Electrodes

This program will demonstrate the fabrication of ultra lightweight/high performance composite annular electrodes incorporating the reliability, via strength and toughness, necessary to facilitate efficient, simple assembly of low cost PEM fuel cells for lightweight extended duty cycle portable power sources. New and innovative composite manufacturing techniques will be employed which offer a low cost, net shape automated fabrication process. The design concept incorporates methods to affect more efficient electrocatalyst reactions through enhanced electrolyte/catalyst/electrode interface and reactant dispersion. Techniques will be demonstrated to optimize the electrode electrical/thermal conductivity properties and provide a highly reliable method of structurally encapsulating the PEM and achieving optimal water management. These techniques provide mechanical mechanisms which maintain the integrity/stability of the reaction region interface and insure that thermal fatigue, vibration and shock loadings do not decouple the constituent materials/ components. A lightweight multidirectional pitch carbon fiber reinforced composite electrode will be fabricated which incorporates a controlled porosity to affect optimal gaseous reactant and reaction product flow. This electrode will function as the primary structural component of the fuel cell system by accommodating internal/external loading, contain high pressure forced reactant flow and perform indefinitely in a hydrated environment.