Autoworld.com - Joey Ho - TH!NK, an enterprise of Ford Motor Company, today unveiled a family size sedan powered by the latest generation methanol reformer fuel cell electric powertrain.

Based on the 2000 Ford Focus, the TH!NK FC5 (Fuel Cell - 5th generation) offers a realistic vision of what a four-door family sedan could be in the near future. With electric power from the latest generation fuel cell technology, this engineering prototype will deliver exceptional fuel efficiency and ultra low emissions, while providing similar range, top speed and performance to today's gasoline models.

"Ford is a world leader in the development of fuel cell technology and the FC5 is built around the most advanced fuel cell installation yet developed," said John Wallace, executive director of TH!NK Group.


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"By locating most of the fuel cell installation beneath the vehicle floor, our engineers have given the design team the freedom to create space for a family-size vehicle," Wallace added.

Fuel Cell Technology: Driving the Future Currently, fuel cells offer the most promising solution for next generation family vehicles. Fuel cells generate electricity by electrochemically combining oxygen with hydrogen. The process is efficient, silent and without combustion. In the TH!NK FC5, the hydrogen is extracted from methanol, which is readily available, easily stored and handled and produces very low emissions. Utilizing methanol, the fuel cell system reduces emissions dramatically compared to a conventional gasoline vehicle. Moreover, there are virtually no carbon monoxide, nitrogen oxides or particulates, which are major contributors to urban smog.

Methanol is also a highly practical source of hydrogen. It is comparable in cost to gasoline and diesel, though Ford Motor Company's objective is to make fuel cell powertrains 50 percent more efficient than either of those fuels.

In addition, methanol is liquid under normal conditions, so refueling is identical to filling up with gasoline. Adding methanol capacity to existing fuel stations is relatively simple. Therefore, the necessary infrastructure could be developed swiftly and economically.

Finally, while methanol is most commonly derived from natural gas, it can also be produced from plant material such as seaweed, wood pulp and organic waste (known as biomass sources). These biomass sources are renewable resources, which would help preserve earth's finite fossil fuel stocks.

TH!NK FC5 Utilitizes Methanol Reformer On the FC5, the methanol is stored in an onboard tank. From there, the fuel passes through a 'reformer', which extracts the pure hydrogen required to react with oxygen.

The hydrogen, as the gaseous fuel, and oxygen, supplied in the form of compressed air, flow separately into the latest generation compact fuel cell stack, manufactured by Ballard Power Systems of Vancouver, Canada. The stack comprises several hundred individual fuel cells, in which the hydrogen and oxygen are combined, producing electricity, heat and water.

Each cell generates about one volt. The direct current (DC) from the fuel cells is then converted into alternating current (AC), powering the electric motor.

"We are convinced that fuel cells have tremendous potential as a vehicle power source for the 21st century, helping protect the environment without compromising personal mobility," Wallace said.

"But there are still some significant technical challenges," he continued. "Current fuel cell systems are heavy, bulky and expensive, although we've made significant progress in reducing their size. The TH!NK FC5 represents another major step forward. Cost is the other major problem, but as economies of scale come into play, the cost will come down to affordable levels - as we've seen with major consumer products from the Ford Model T to the personal computer," Wallace added.

The TH!NK FC5 has been designed to maximize interior space and ergonomics. Driver and passenger comfort are not compromised in order to accommodate the fuel cell system and there is usable rear storage.

TH!NK - Driving the Future TH!NK Technologies is the team within the TH!NK Group assigned the responsibility for leading Ford's fuel cell research and development.

In addition to the FC5, TH!NK already has a road-going hydrogen fuel cell (HFC) under intensive evaluation with the Mondeo-based P2000 vehicle.

Unlike the FC5, the P2000's fuel is pure gaseous hydrogen. The vehicle produces only electricity and pure water and there is no need for the added fuel reforming process. However, there are major barriers to developing a hydrogen fueling infrastructure, so methanol-based vehicles like the TH!NK FC5 look much more viable in the immediate future. Ford Motor Company plans to begin low volume commercial production of fuel cell electric vehicles by 2004.

Ford is among the leaders of the first long-term, real-world testing program for fuel cell-powered passenger cars in California. Partners in the project include Ballard Power Systems, DaimlerChrysler AG, Honda, Volkswagen, ARCO, Shell, Texaco, the California Air Resources Board and the California Energy Commission.

The California Fuel Cell partnership will test the technology and market readiness for fuel cell vehicles, along with researching infrastructure issues, by placing about 45 fuel cell-powered cars and buses on California roads over the next several years.

TH!NK Group, an enterprise of Ford Motor Company, is comprised of TH!NK Mobility (battery electric vehicles) and TH!NK Technologies (fuel cell electric vehicles), and provides innovative environmentally responsible solutions for personal mobility.

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