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Flexible Barrier Coatings for Harsh Environments

Award Information
Agency: Department of Energy
Branch: N/A
Contract: DE-SC0011339
Agency Tracking Number: 0000217411
Amount: $998,833.65
Phase: Phase II
Program: SBIR
Solicitation Topic Code: 13b
Solicitation Number: DE-FOA-0001193
Timeline
Solicitation Year: 2015
Award Year: 2015
Award Start Date (Proposal Award Date): 2015-04-06
Award End Date (Contract End Date): 2017-04-05
Small Business Information
45 Spinelli Pl
CAMBRIDGE, MA 02138-1046
United States
DUNS: 085502958
HUBZone Owned: No
Woman Owned: No
Socially and Economically Disadvantaged: No
Principal Investigator
 William O'Shaughnessy
 Dr.
 (617) 661-0060
 soshaughnessy@gvdcorp.com
Business Contact
 William O'Shaughnessy
Title: Dr.
Phone: (617) 661-0060
Email: soshaughnessy@gvdcorp.com
Research Institution
N/A
Abstract

There is a need to reduce the cost and improve the reliability of hydrogen fuel cell electric vehicles (FCEVs) and their supporting infrastructure to enable FCEV competitiveness. Many reliability problems stem from plastic and elastomer seals employed in hydrogen systems that leak and degrade as a result of the extreme temperature and high pressure hydrogen environments. There is a critical need for improved materials are needed that can enable seals to operate reliably at both extreme temperatures (-40T200C) and high hydrogen pressures (>875 bar). GVD Corporation proposes to utilize hydrogen gas barrier coatings deposited on such seals to shield them from hydrogen permeation and enable reliable, long-term operation. These barrier coatings are based on GVDs novel thin film vapor deposition technology. In GVDs process an inorganic-organic multilayer barrier coatings are fabricated from the vapor-phase and is grown directly on the surface of the elastomer seal. The coating deposits uniformly and conformally over three-dimensional seals and gaskets. Further these coatings are highly flexible and stable at 200C. In Phase I, GVD demonstrated technical feasibility of the concept by depositing flexible, well adhered barrier coating stacks on elastomeric substrates. These coatings survived temperatures up to 200oC while reducing permeability to helium by >50% (equivalent to a 70-90% reduction in hydrogen permeability). During Phase II, GVD will optimize these materials for ease of manufacturing. Demonstration of resistance to high-pressure hydrogen permeability will be shown directly. The deposition process will be scaled up and a production tool designed to handle significant product volumes. In addition, prototype seals will be coated and tested at the bench level by a hydrogen compressor manufacturer and in the field by an industrial user of FCEVs. GVD has also already secured commitment from a commercial partner to bring this technology to market through an existing sales and marketing agreement. Commercial Applications and other Benefits. FCEVs have the potential to significantly reduce US dependence on foreign oil and lower harmful emissions that contribute to climate change. Successful commercialization of GVD barrier coatings for polymer seals will help improve reliability and reduce cost of hydrogen systems employed in FCEVs and their supporting infrastructure. GVD barrier-coated seals developed during this project may also be useful for equipment used in the oil and gas industry and for organic electronic devices such as organic light emitting diodes (OLEDs) and organic photovoltaics (OPVs).

* Information listed above is at the time of submission. *

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