2007fuel cell seminar j kolde,0

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

GORE CONFIDENTIAL

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

GORE CONFIDENTIAL

Global Gore Fuel Cell Team

Japan

USA

Germany

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China

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

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…

GORE CONFIDENTIAL

GORE CONFIDENTIAL

Fixed CostVariable Cost

GORE CONFIDENTIAL

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

GORE CONFIDENTIAL

Higher Power Density

GORE CONFIDENTIAL

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?

GORE CONFIDENTIAL

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

GORE CONFIDENTIAL

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

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/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

GORE CONFIDENTIAL

System Simplification

Longer Lifetime

GORE CONFIDENTIAL

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

GORE CONFIDENTIAL

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?

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

GORE CONFIDENTIAL

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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

GORE CONFIDENTIAL

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

GORE CONFIDENTIAL

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

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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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Cro

ssov

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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

GORE CONFIDENTIAL

Thank You!

GORE and PRIMEA are trademarks of W.L. Gore and Associates, Inc.