High Efficiency Fuel Cell Stack and Key Technologies of Power Module

In this paper, the development of key technologies in fuel cell stacks and fuel cell power modules are reported, with emphasis on high-volume production (>10,000 units/year). Fuel cell stack design is focused on the development of high-efficiency membrane electrode assemblies (≧300 mA/cm2 @0.8 V) suitable for continuous roll-to-roll manufacturing and high volumetric efficiency stacks (1.5 kW/L) with power rating of at least 10 kW. Power module design focuses on the union of liquid-cooled fuel cell stack, smart power conditioning technology, battery, hydrogen storage system and balance-of-plant into a fully-integrated, drop-in unit for MHE (Material Handling Equipment) systems. Technical verification was conducted by integrating the fuel cell power module into an automated guided vehicle as a turn-key replacement for the original power system. Power module performance was demonstrated with continuous current loading up to 240 A and peak current loading of 300 A. All core technologies of the fuel cell power module are deliverable as a free-standing total solution, expanding the potential applications beyond vehicle systems, and allowing rapid commercialization of related technologies.