Durable High Efficiency Membrane and Electrode Assemblies for Heavy Duty Fuel Cell Vehicles

Heavy-duty fuel cell vehicles operate under more stringent conditions, including longer driving distance, higher thermal stress, and unique driving cycles. Therefore, they require membrane and electrode assemblies (MEAs) with high efficiency and long durability to be commercially viable. In this project, we will first develop low platimum group metal (low-PGM) cathode catalyst that may demonstrate remarkable activity and durability for heavy duty applications. The novel catalyst will be integrated with high O2 permeability ionomer to achieve durable MEAs simultaneously with high efficiency and high power. First, we will design innovative low-PGM catalysts by incorporating highly active and stable PtCo intermetallic nanoparticles with the PGM-free single Mn active site-rich Mn-N-C catalyst as support. We will achieve superior ORR activity and outstanding durability by maximizing the synergistic effects between PGM and PGM-free single metal sites. Second, the above novel PtCo/Mn-N-C low-PGM catalyst will be integrated with fluorinated ionomer with high O2 permeability. Finally, we design and fabricate high-performance low-PGM MEAs for heavy- duty fuel cell applications. The developed MEAs will be first designed for heavy-duty fuel cell vehicle applications. Besides, the developed high-performance catalysts, ionomers, and MEAs can be used for light- and medium-duty vehicles too. Furthermore, the high-performance MEAs can apply to other fuel cell systems for residential/stationary and portable applications.