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GM’s work on a car that combines a hydrogen fuel cell with a plug-in battery could see a validated, cost-effective hydrogen version of the Chevrolet Volt ready for production by 2010-2012.

GM sees the development as an important part of its plans to replace hydraulic and mechanical systems with electrics.
It believes battery-only vehicles are no longer credible. Its own all-electric EV1 had a limited range and was withdrawn in the 1990s.

Combining lithium-ion cells with a hydrogen fuel cell in the Volt should give the car a 480km range, with more than 60km in battery-only zero-emission mode.

GM’s director of advanced technology vehicle concepts, Dr Christopher Borroni-Bird, said: “A battery vehicle is not viable for mass production. Plug-in hybrids and fuel cell vehicles will allow us to electrify our vehicles. No other OEM is talking about using current from a fuel cell to power brakes, steering and vehicle systems.”

Having the Volt ready on time is contingent on battery technology advancing at the pace GM expects. The investment and development of Li-ion within the consumer electronics industry is making an important contribution.

“There is no successor battery on the radar screen that could overtake our progress with Li-ion,” said Borroni-Bird. “We don’t see it as the interim solution.”

Development battery contracts have been awarded to Continental and LG Chem subsidiary Compact Power. Cobasys and Johnson Controls-Saft are already developing Li-ion for the plug-in Saturn Vue hybrid.

GM needs to overcome two issues: durability and cost. It says it should cost the same as a conventional diesel engine and transmission, quoting a target of $50/kW.

Borroni-Bird said: “We need to reach 100,000 miles or 10 years. Improving the thermal management and cooling is critical. A zero emissions car that can go 480km should be the limit of our responsibilities.”