After decades of research and development, commercialization of proton-exchange membrane fuel cell (PEMFC) vehicles is now a reality, and several production scale vehicles have been launched. GORE-SELECT® Membranes (GSMs) enable the Toyota Mirai (2015), Honda Clarity (2016), and Hyundai Nexo (2018)¹. However, mass deployment of PEMFC vehicles is hindered by lack of hydrogen infrastructure and higher cost than internal combustion engines². W. L. Gore and Associates, Inc. (Gore) is committed to supplying the fuel cell market with the highest performance and most durable membranes to support the lowest $/kW system. One approach to simultaneously increase power density and decrease membrane cost (by reducing material content) is to use thinner membranes, ca. 10 µm or less.

Thin membranes facilitate high performance systems by means of higher proton conductance and faster water transport properties, yet durability remains a challenge. Gore is uniquely positioned to deliver high-strength reinforcement layers for the most mechanically durable thin membranes at high volume with superior uniformity. Expertise in engineering fluoropolymer composites has allowed Gore to develop thin membranes that mechanically outlast thicker membranes while exceeding performance, Figure 1. The remaining challenge to address is chemical durability. Higher gas permeance of thin membranes can result in increased radical generation through multiple mechanisms³. As shown in Figure 2, Gore is working to increase the selectivity of protons relative to gas crossover, which is critical for maintaining performance while extending chemical lifetime. Additionally, chemical degradation can be mitigated through advanced additive strategies.

In this talk we discuss Gore’s understanding and advancements of thin membrane technology culminating with the introduction of new state-of-the-art membranes that break the cost / performance trade-off.

ACKNOWLEDGMENTS

The authors gratefully acknowledge the contribution of the Electrochemical Products team of W. L. Gore and Associates, Inc.

REFERENCES

1. W. L. Gore & Associates, (2018) https://www.gore.com/news-events/press-release/gore-s-fuel-cell-technology-helps-power-latest-hyundai-fuel-cell-vehicle.
2. D. L. Greene and G. Duleep, Status and Prospects of the Global Automotive Fuel Cell Industry and Plans for Deployment of Fuel Cell Vehicles and Hydrogen Refueling Infrastructure, Oak Ridge, Tennessee, (2013).
3. M. Zaton, J. Rozière, and D. J. Jones, Sustain. Energy Fuels, 1, 409–438 (2017).