Open Competition 1 - Chemistry and Materials

'Free Standing' Single-Wall Carbon-Nanotube Fuel Cell Electrode

Sponsor: Carbon Nanotechnologies, Inc.

• Project Performance Period: 10/1/2004 - 9/30/2007
• Total project (est.): $7,379,707.00
• Requested ATP funds: $3,616,054.00

Hand-held electronic devices are increasing in sophistication with their demands for electrical power seemingly rising exponentially. Rechargeable battery technology is mature, and unlikely to satisfy the demands of future portable electronics. Small fuel cells have the potential to provide the power required, but this potential has not yet been realized. In the longer term, success of the "hydrogen economy" including fuel cells for distributed power generation and automotive applications is critically contingent upon increasing performance and durability, while decreasing associated manufacturing costs of present-day proton exchange membrane (PEM) fuel cells. Presently the major shortcomings of polymer-membrane-based fuel cells include the inefficiencies of the membrane-electrode assembly (MEA), unacceptably short service lifetimes, and manufacturing complexities. Carbon Nanotechnologies, Inc. (CNI) in a joint-venture partnership with Johnson Matthey Fuel Cells, Inc. (JMFCI) (West Chester, Pa.) and Motorola Labs (Tempe, Ariz.), propose to exploit the unique properties of single wall carbon-nanotubes (SWNTs) in order to achieve major breakthroughs in PEM fuel cell performance, durability and manufacturability. The nanometer scale and novel chemical characteristics of SWNTs give them profound advantages as electro-catalyst supports and enable the fabrication of "free standing" fuel cell electrodes. "Free standing" electrodes have the potential to be considerably more powerful than those currently in use and greatly simplify fabrication of membrane electrode assemblies (MEA), the heart of a PEM fuel cell. The electrode is "free-standing" in that it does not require a binder to provide mechanical integrity, and it can be fabricated independently of other fuel cell elements. SWNT electrodes should also significantly extend the service life of the MEA. One of the main causes of electrode failure in MEAs is corrosion of the catalyst support material. SWNTs have almost no exposed "graphite-like" edges, the location where corrosion typically begins. SWNT production and manipulation, along with the fabrication of "free standing" electrodes will be performed by CNI, building on their strong position in SWNT technology and intellectual property. JMFCI will develop technology associated with deposition of precious-metal catalyst on SWNT, fabrication of SWNT-based MEAs, and assessment of associated performance in direct methanol and hydrogen PEM fuel cells. Motorola Labs intends to test SWNT-based direct methanol fuel cells and high temperature reformate micro-fuel cell prototypes with MEAs fabricated by PEMEAS (formerly known as Celanese Ventures), a major sub-contractor to the project. Several aspects of the project entail considerable technical risk, including manipulating the SWNTs to enhance catalyst deposition while achieving superior electrical and proton conductivity, in addition to fabricating thin films of SWNTs (approximately 1 micron) that will form the fuel cell electrodes. Because of the technical risks and relatively long-term payback period, the partners are unable to support the project without ATP assistance. If successful, the technology would enable not only dramatically improved compact PEM fuel cells for a host of current hand-held electronic devices, but would also enable the design and commercialization of more powerful next generation "wireless" devices. The new technology has the potential to place the United States in a commanding position in the portable electronics power market, which now is dominated by foreign firms.

For project information:

T.J. Wainerdi, (281) 492-5719
twainerdi@cnanotech.com

Active Project Participants

• Johnson Matthey Fuel Cells, Inc. (West Chester, PA)
  [Original, Active Member]
  
• Motorola, Inc. (Tempe, AZ)
  [Original, Active Member]
  

ATP Project Manager

Richard Bartholomew, (301) 975-4786
richard.bartholomew@nist.gov