October 10, 2003 — Honda Motor Co., Ltd. today announced the development of the Honda FC Stack, a remarkably compact, next-generation fuel cell stack that delivers high performance, yet operates at temperatures as low as –20ºC (-４ºF). It is the world’s first fuel stack to feature a stamped metal separator structure and newly developed electrolyte membranes. The FCX equipped with the Honda FC Stack was certified September 24, by the Minister of Land, Infrastructure and Transport.
Honda will begin public testing of the vehicle’s cold start and driving performance capabilities to advance more widespread use of fuel cell vehicles. Honda FC Stack-equipped FCX will take the role of a lead car in the 80th Tokyo-Hakone Ekiden relay race in January 2004.
Conventional fuel cell stacks have a complex structure in which carbon separators are fastened together with bolts. The Honda FC Stack, however, has a simplified structure composed of stamped metal separators, with rubber seals that are attached in a unique molding process and enclosed by panels. This reduces the number of components by almost 50% (compared to a conventional unit*1) and more than doubles the output density*2, resulting in world-leading high performance. Further, use of newly developed aromatic electrolyte membranes greatly improves durability and allows for power generation at temperatures ranging from -20ºC(-4ºF) to +95ºC(+203 ºF)— a difficult achievement for stacks that employ conventional fluorine electrolyte membranes. The driving range of the FCX with a Honda FC Stack also has increased by 40 km*3, from 355 km to 395 km, while fuel economy has improved by over 10%*4.
Honda began fuel cell technology research in the 1980s. Tests of Honda fuel cell stacks were conducted under a range of driving conditions using the 1999 FCX-V2 and the 2001 FCX-V3. Developed with a view to volume production and the ultimate need to recycle fuel cell vehicles, this next generation Honda FC Stack significantly reduces the use of special materials and offers excellent driving performance and low-temperature starts.
Honda FC Stack
FCX equipped with the Honda FC Stack
Key Features of the Honda FC Stack
| (1) | Compact, high output | |
| ・ | The number of components is reduced by almost 50% through use of the world’s first stamped metal separators and a panel-type structure, while the output density is almost double that of a conventional fuel cell stack. | |
| (2) | Low-temperature starts | |
| ・ | Ion conductivity at low temperatures is double that of a conventional stack thanks to use of aromatic electrolyte membranes. | |
| ・ | Use of stamped metal separators improves conductivity. | |
| ・ | Thermal capacity is reduced because the unit is more compact. Warm-up time is 20% that of a conventional stack. | |
| (3) | Durable even at high temperatures | |
| ・ | Power can be generated at up to +95ºC(203ºF). | |
| (4) | Next-generation fuel cell stack developed in consideration of mass production and recycling. | |
| ・ | Some special materials have been replaced by more readily-available materials. | |
- *1Honda fuel cell stack on the FCX-V3
- *2output/volume, output/weight
- *3LA4 mode Honda in-house calculations
- *4Compared with an FCX equipped with a Ballard fuel cell stack
Specifications of the Honda FC Stack-equipped FCX
| Name | FCX | |
| Number of occupants | 4 | |
| Max・speed | 150km/h | |
| Motor | Max. output | 80kW (109PS) |
| Max. drive torque | 272N・m (27.5 kg・m) | |
| Type | AC synchronous electric motor (manufactured by Honda) | |
| Fuel cell stack (2units) |
Type | PEMFC (proton exchange membrane fuel cell, manufactured by Honda) |
| Output | 86kW | |
| Fuel | Type | Compressed hydrogen |
| Storage | High-pressure hydrogen tank (350 atmospheres) | |
| Capacity | 156.6L | |
| Dimensions (L x W x H, mm) | 4,165 x 1,760 x 1,645 | |
| Energy storage | UltraCapacitor (manufactured by Honda) | |
| Vehicle range(LA4 mode) | 395 km | |