SBIR-STTR Award

The goal of this Phase I SBIR project (under AREA 3) is to develop the next generation of Protonex' low cost, reliable polymer electrolyte membrane (PEM) fuel cell stacks by incorporating rolled good type membrane and electrode assemblies (MEAs) during manufacture. Such an achievement would further reduce the cost of fabricating PEM fuel cells while simultaneously improving manufacturing yield. Protonex has already demonstrated the capability to produce low cost, reliable fuel cells utilizing our proprietary (patent pending) technology. The stack technology adapted to the rolled good MEAs will be applied to develop 20Watt fuel cell system (during phase II) that will be safe, rugged, highly efficient and easy to manufacture. Furthermore, the system will be compact and lightweight, allowing the DoD to achieve truly "man portable" power. To accomplish these objectives, Protonex has teamed with Albany International Techniweave (AIT) to capitalize on their advanced low cost, high performance rolled good type MEA technology. Our other teaming partner, Northeastern University (Dr. Sanjeev Mukerjee) will assist the development effort by characterizing the novel MEAs and corresponding gas diffusion layers (GDLs). In addition to military applications, developments in fuel cell power sources will have an immediate impact on a wide range of commercial power sources including battery chargers, laptop computers, emergency power and light (medical), recreational power (camping) and uninterruptible power supplies (UPS)

The goal of this Phase II SBIR project is to develop the next generation of Protonex' low cost, reliable polymer electrolyte membrane (PEM) fuel cell stacks for hydrogen and direct methanol fuels. Protonex has already demonstrated the capability to produce low cost, reliable fuel cells utilizing our proprietary (patent pending) technology. In the phase I, our stack technology was adapted to utilize rolled good MEAs, compatible with high volume production techniques under development by most major MEA producers. Stack prototypes from Phase I are already being incorporated into portable power systems by our teaming partners. These systems represent a significant advantage in solider power over both traditional batteries and other likely portable power technologies. Phase II of this program will advance Protonex state of the art stacks, further reducing the size, weight and cost of these units. In addition, Protonex will extend the stack designs and manufacturing to direct methanol fuel cells. The result will be best-in-class, manufacturable, reliable, DMFC and hydrogen fueled PEM stacks. In addition to military applications, developments in fuel cell power sources will have impact on a wide range of commercial power sources including battery chargers, portable medical devices, laptops, and emergency power and lighting

Keywords:
proton exchange membrane fuel cells, soldier power, fuel cell manufacturing, fuel cell stacks, direct methanol fuel cells, portable power devices