The polymer electrolyte membrane (PEM) remains one of the most significant cost components of the fuel cell (FC) stack. Development of a low-cost PEM suitable for rapid commercialization of FCs, with a wide range of desired characteristics meeting the DOE performance targets is the subject of this project. This Small Business Innovation Research Phase I project aims to design, develop, and produce a new low-cost proton conducting polymer electrolyte membrane employing nanofiber electrospinning technology. The proton exchange membrane will be produced using low cost non-fluorinated polymers. This ultra-thin membrane will be composed of a robust ionomer having inorganic backbone embedded in a reinforcing network of sub-micron diameter fibers co-electrospun from a thermally and chemically stable polymer. During Phase I, the ionically conducting hydrocarbon polymer will be synthesized and process for membrane production will be fully developed; the resultant membranes will be characterized in terms of microstructural features, mechanical, thermal and chemical stability, proton transport characteristics and fuel cell performance. The prospective Phase II work shall address long-term fuel cell durability and development of manufacturing processes to meet the cost targets.The proposed electrospinning project will lead to a potential commercial product that may not only accelerate deployment of automotive fuel cells but can also have a significant environmental impact. From technical point of view, the subject polymer electrolyte membrane will have the major physicochemical characteristics (specific resistance, mechanical strength and lateral swelling) similar or better than those of the currently available PFSA (perfluorinated!) fuel cell membranes but with the advantage of significantly increased thermal stability, lower hydrogen and oxygen crossover rates and lower production cost. Additionally, the use of the proposed membrane will lead to simplification of the fuel cell hydration subsystem and will eliminate the threat of dangerous releases of fluorine compounds inherent to the operation of fuel cells with PFSA-based PEMs. If funded and successfully completed, the project might help reversing the erosion of manufacturing in the US.
