Angus Dickinson – Johnson Matthey Making an MEA for future power train – the challenges
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Angus Dickinson – Johnson Matthey
Making an MEA for future power
train – the challenges
Alternative PowertrainWorldwide Locations
APT Sonning Common, UK. Research on materials and next generation technologies
APT Moosburg, DEMaterials product development
APT Sales, Shanghai, China
APT Changzhou ChinaManufacturing site.
APT Sales , Tokyo Japan
APT Sales, Seoul Korea
APT Candiac, CA Manufacturing site
APT Sales East Coast
APT Sales West Coast
APT Sales UKSwindon/Royston
APT Swindon, UKResearch, Application & Manufacturing site
APT Billingham, UKResearch & Material Scale-up site
APT Oxford, UK Application testing site
APT Gliwice, PLSystems series production
Proprietary Information 2
The Membrane Electrode Assembly (MEA)
Proprietary Information 3
XM
X0MX00M
X00k
Different volumes may require different manufacturing methods
2015
2013-14
2020
2025
Manual process
Roll to roll Process
Mass production
X00 cars
X0 k cars
million cars
= 300
Proprietary Information 4
Manufacturing challenge
Future manufacturing
This project has received funding from the FCH JU andEuropean Union’s Horizon2020 research andinnovation programme under Grant Agreement no.779591. Proprietary Information 5
The quality demand
Single point failure for whole stack
1ppm escape rate = 300ppm customer event rate
In line vision systems
Defect marking systems Defect tracking systems? Potential in line rework
Proprietary Information 6
Near surface strain for PtCo alloys
Proprietary Information 7
1. L. Jones, Measurement and visualization of picometre-scale displacements on the surface of Pt3Co nanoparticles, EMCat, Berlin 2016
Acknowledgements to Don Ozkaya (JMTC-Microscopy)
Picometre-scale displacements,
Done at Oxford University (Lewys Jones)1
JMFC Pt3Co/C
Bulk Pt, 3.912 A
Bulk Pt3Co, 3.835 A
Direct imaging of near-surface compressive strain in d-PtCo alloy
Non cell reversal tolerant MEA shows performance decay after 6s reversal
events (62 mV after x9 events)
Cell reversal tolerant MEA shows a significantly more stable performance after
6s reversal events (10 mV after x9 events)
Non Cell Reversal Tolerant MEA Cell Reversal Tolerant MEA
Proprietary Information 8
Effect of 6s reversal event on MEA performance
Non Cell Reversal Tolerant MEA Cell Reversal Tolerant MEA
Inclusion of the cell reversal catalyst has significantly reduced carbon
corrosion at the anode during reversal events evidenced by CO2 anode
exhaust monitoring
Proprietary Information 9
200mAcm-2 Reversal Holds - Anode CO2
Membrane durability
In combined OCV + RH cycling AST new membrane options can exceed 20,000 cycles.
Proprietary Information 10
Roll to roll and automated production processes in place for near-
medium term capacity requirements for automotive MEA’s
(10’s of 000’s of cars)
• Focus on quality assurance with cleanroom manufacturing, web cleaning and
process air cleanliness
• In-line process monitoring of critical to quality parameters loading, visual
quality and dimensions
Processes designed to support both current and future product
development
• Short run capability to make initial prototypes
• Alternative part constructions and range of material sets
• Will steer future investment for processes capable of producing 10’s of
millions of MEAs
Proprietary Information 11
Summary
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