Fuel Cell Advances

Los Alamos National Laboratory (LANL), was selected by 3M for evaluation of its early work in fuel cells based on its 20 years of experience in this area. The 3M fuel cell effort began with a novel, 3M proprietary, nanostructured thin film (NSTF) catalyst system for use in proton exchange membrane (PEM) fuel cells. LANL evaluated the first set of membrane electrode assembly (MEA) samples fabricated by 3M with NSTF catalysts in March 1995. This led to a two-year CRADA between 3M and LANL for testing 3M NSTF catalyst electrodes in LANL-developed MEAs, which were put into LANL’s PEM fuel cells and evaluated as possible direct methanol fuel cells (DMFC). This CRADA was performed in conjunction with the Defense Advanced Research Projects Agency -sponsored DMFC program for military portable power applications.

Using a variety of 3M technologies, 3M established a fuel cell commercialization program, including PEMs, dispersed catalyst electrodes, and gas diffusion electrode backing layers, and became a leading supplier of 5-layer MEAs for PEM fuel cells. Concurrently, 3M partnered with DOE in five cost-sharing CRADA projects with Los Alamos, Lawrence Berkeley, Brookhaven, and Argonne National Laboratories, and collaborated with six universities and four systems manufacturers under what is now the DOE Hydrogen, Fuel Cells, and Infrastructure Technologies Program.

Direct methanol fuel cell stacks using advanced membrane technology.

These projects have focused on issues that must be addressed for PEM fuel cells to be commercially viable for automotive and distributed stationary applications including performance (efficiency and peak power), durability, and cost. Under these projects, DOE goals for the year 2010 for fuel cells in automotive applications have been met in the areas of precious group metal loading and cost, with significant progress made toward the 2010 fuel cell MEA durability goal. Laboratory results have been verified in fuel cell stack testing by 3M and systems manufacturers. The feasibility of high volume MEA and component fabrication processes has been demonstrated and the fundamental understanding of factors affecting performance and lifetime has increased.