High-productivity technology development for fuel cell separators using carbon and resin composite materials

Kenichi Kondou (Toyota Auto Body)

As fuel cells become more widespread, there is a demand for high-precision, high-speed molding of separators. Carbon resin composites are expected to be lightweight and highly durable for a wide variety of applications. However, productivity is poor because heating and cooling are required for molding. In this study, we aim to achieve a molding cycle with carbon resin composites equivalent to that of metal materials.

Effect of the cathode carbon structure and the distribution of Pt and ionomer on improving the performance and durability of polymer electrolyte fuel cells

Makoto Uchida (University of Yamanashi)

We report the effect of platinum and ionomer distribution in cathode catalysts with different carbon structures on the performance and durability of solid polymer electrolyte fuel cells. In particular, we discuss the effect of generated water on the adsorption state of ionomer on the Pt surface, and the impact of ionomer poisoning, which has been a problem in the past.

FC-Platform Activities and Post Analysis of Tested MEAs

Masaki Yamauchi･Norimitsu Takeuchi･Kazuhiko Shinohara･Hideto Imai (FC-Cubic)

We strengthened cooperation between industry, academia, and governmental parties and built the "PEFC Evaluation and Analysis Platform (PEFC-PF)" to evaluate fuel Cell materials. This PEFC-PF promoted collaboration between the materials research group of the Innovative FC Project and the platform groups. Improving the properties of materials and components is essential to achieving the 2030 targets. In particular, the "NEDO Innovative FC MEA," which combines each element that makes up the MEA (membrane electrode assembly), showed the achievement status and identified issues that arise when combining them and issues for high-temperature operation that are expected in the future.

Effect of catalyst layer and electrolyte membrane on high temperature and low humidity operation of PEFC

Sana Kawashita･Hiroyuki Kanesaka･Hiroki Kusakabe･Chunyan Li (FC-Cubic)

High-temperature, low-humidity operation was conducted at 120°C and 40% RH to investigate the effects on the catalyst layer and electrolyte membrane. It was found that in high-temperature environments, the softening of the electrolyte membrane can easily degrade its mechanical properties, potentially causing rapid membrane deterioration. Furthermore, continuous high-temperature operation was suggested to accelerate catalyst layer degradation, potentially leading to voltage drop.

Big-data analysis of Hyundai 2nd FCEVs for validation of optimal fuelcell system, study of integrated design and control for fuel cell-battery system and analysis of failure mode and life prediction: From Full-FCEV to FC-EREV

Wook Il (Woogil) JANG (Hyundai Motor)

This study used large-scale customer driving data from Hyundai's second-generation FCEVs to address durability and cost challenges in fuel cell systems. Data from 22,681 passenger cars, 25 buses, and 25 trucks were analyzed. Cluster analysis showed that the FC-EREV architecture, which maintains constant fuel cell power with reduced runtime, offers superior durability. Driving-pattern analysis informed the development of optimized power-control logic and fuel cell–battery capacity design. Failure mode analysis indicated predominantly accidental failures, suggesting that probabilistic life-prediction models are applicable for assessing fuel cell reliability.

Sensitivity Assessment of Fracture-Controlling Factors under High-Pressure Hydrogen
-Using the C-FaTH₂ Next-Generation Testing System and an Orthogonal Experimental Design-

Hirotada Fujiwara･Hiroaki Kondo･Tomohiro Shimada･Kazumi Nakayama･Takahiro Miyamoto (Chemicals Evaluation and Research Institute, Japan)

A dedicated facility (C-FaTH₂) and an advanced testing system capable of continuously reproducing high-pressure hydrogen pressurization–depressurization cycles for over 24 hours, faithfully simulating operational protocols, were established. This infrastructure enables long-term degradation assessments that were previously unattainable. In this study, an orthogonal experimental design was employed to systematically elucidate the protocol sensitivity of fracture-controlling factors governing the degradation behavior of polymer materials under high-pressure hydrogen exposure.