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In partial fulfillment of the U.S. Department of Energy Contract No. DE-ACO2-94CE50389, {open_quotes}Direct Hydrogen-Fueled Proton-Exchange-Membrane (PEM) Fuel Cell System for Transportation Applications{close_quotes}, this conceptual vehicle design report addresses the design and packaging of battery augmented fuel cell powertrain vehicles. This report supplements the {open_quotes}Conceptual Vehicle Design Report - Pure Fuel Cell Powertrain Vehicle{close_quotes} and includes a cost study of the fuel cell power system. The three classes of vehicles considered in this design and packaging exercise are the same vehicle classes that were studied in the previous report: the Aspire, representing the small vehicle class; the AIV (Aluminum Intensive Vehicle) Sable, representing the mid-size vehicle; and the E-150 Econoline, representing the van-size class. A preliminary PEM fuel cell power system manufacturing cost study is also presented. As in the case of the previous report concerning the {open_quotes}Pure Fuel Cell Powertrain Vehicle{close_quotes}, the same assumptions are made for the fuel cell power system. These assumptions are fuel cell system power densities of 0.33 kW/ka and 0.33 kW/l, platinum catalyst loading of less than or equal to 0.25 mg/cm{sup 2} total, and hydrogen tanks containing compressed gaseous hydrogen under 340 atm (5000 psia) pressure. The batteries considered for power augmentation of the fuel cell vehicle are based on the Ford Hybrid Electric Vehicle (HEV) program. These are state-of-the-art high power lead acid batteries with power densities ranging from 0.8 kW/kg to 2 kW/kg. The results reported here show that battery augmentation provides the fuel cell vehicle with a power source to meet instant high power demand for acceleration and start-up. Based on the assumptions made in this report, the packaging of the battery augmented fuel cell vehicle appears to be as feasible as the packaging of the pure fuel cell powered vehicle

Direct-hydrogen-fueled proton-exchange-membrane fuel cell system for transportation applications