1. TD Aiken March 31, 2008 1 Developing a Safety Sensor for Fuel Cell Vehicles Thomas Aiken Marketing and Business Development AppliedSensor, Inc. (908) 222-1477 tom.aiken@appliedsensor.com

2. TD Aiken March 31, 2008 2 AppliedSensor provides gas sensing solutions for safety, quality, comfort and control.

3. TD Aiken March 31, 2008 3 The Challenge Design and develop a selective safety sensor to detect hydrogen gas leaking within the confines of a hydrogen or fuel cell powered vehicle and do so –within LEL, –to automotive standards, –using high volume manufacturing processes –and, oh by the way, make it cheap

4. TD Aiken March 31, 2008 4 Why hydrogen but not gasoline sensing? Association of hydrogen and explosions runs deep with the consumer. Gasoline vapor is heavy and will lie low while hydrogen will rise quickly to fill a space. Low molecular weight allows hydrogen leaks to be a constant safety issue.

5. TD Aiken March 31, 2008 5 Hurdles – Automotive Standards –Detection Range0-4.4% in air –Startup time1 second –Speed of response< 2 seconds –Accuracy+/- 3,000 ppm –Temperature range-40 º to +110 º –Voltage supply variation9-16 volts –Electrical interfaceCAN communication Also…Vibration, shock, EMC - automotive

6. TD Aiken March 31, 2008 6 Hurdles – Customer Expectations –10,000 modules/year capability –Thousands of units for testing –Security/safety standards –Operating hours –Operate when the vehicle is turned off –ISO certification –Meet ATEX Zone 2 standard

7. TD Aiken March 31, 2008 7 ISO/TS 16949 Project ISO/TS 16949 is ISO 9001:2000 with particular requirements for automotive production and service organizations. AppliedSensor to be ISO/TS certified in 2008. IEC 60079 specifies the general requirements for construction, testing and marking of an electrical apparatus and explosive components intended for use in explosive gas atmospheres

8. TD Aiken March 31, 2008 8 How does ATEX work - intrinsic safety A security concept is determined The security concept drives requirements on design –Minimum distance between conductors (air, solid) –Maximum temperature –Power limitation –Housing durability, strength, electric insulation and capacitance

9. TD Aiken March 31, 2008 9 ATEX Zone 2 Zone 0 – flammable vapor exists Zone 1 – flammable vapor likely to exist Zone 2 – an explosive atmosphere consisting of a mixture of air and flammable gas vapor or mist is not likely to occur in normal operation but if it does occur will persist for a period of time.

10. TD Aiken March 31, 2008 10 Standards in general Significant standarization efforts going on worldwide –ISO/CD 26142 - Hydrogen detection apparatus (ISO/TC 197 WG 13 ) –EU projects –UL standards, etc.…

11. TD Aiken March 31, 2008 11 Sensor Development History Early sensing technology relied on field effect principle to detect hydrogen at low levels. Various metals investigated for sensing layer Levels below 1,000 ppm were achieved but this is far below the LEL of 4% in air. Standards and customer requirements dictated an integrated solution. Combination of field effect and thermal conductivity achieved the goal. Wafer sub-suppliers could only be required to meet heater and temperature measurement performance. But gas characterization fell on us and is carried at our risk.

12. TD Aiken March 31, 2008 12 How we met the challenge - technology 1.Integrated solution –Combine field effect with thermal conductivity –Cross sensitivity – FE principle

13. TD Aiken March 31, 2008 13 Field Effect Operating Principle SiO 2 p-Si nn I V nn H2H2 H H H - + VV H - + H 2 dissociates H-atoms transport through metal layer H-atoms trapped at metal- insulator interface

14. TD Aiken March 31, 2008 14 Field Effect Selectivity to H 2 25, 75 and 250 ppm of respective gas

15. TD Aiken March 31, 2008 15 Thermal conductivity – selectivity to H 2 at 273 K (10 -3 W/mK) 0 40 80 120 160 200 Hydrogen (H2) Air Nitrogen (N2) Oxygen (O2) Methane (CH4) Carbondioxide (CO2) Helium (He) Argon (Ar) Ethane (C2H6) Water (H2O)

16. TD Aiken March 31, 2008 16 How we met the challenge - Production 2. Establish a production process –Class 1,000 clean room –A-B-C sample development (automotive standard) –Design validation tests

17. TD Aiken March 31, 2008 17 How we met the challenge – Scale up 3. Scale production –Supplier/partners with large volume capabilities –Robust and well established NMOS basic silicon technology –Wafer level clean room production Deposition, annealing, dicing –Automation – chip on board mounting, wire bonding

18. TD Aiken March 31, 2008 18 How we met the challenge - Performance 4. Testing and Validation –Repeatability (one sensor, time-to-time variation) –Reproducibility (sensor-to-sensor variation) –Accuracy –Selectivity –Etc…..

19. TD Aiken March 31, 2008 19 Repeatability – same module

20. TD Aiken March 31, 2008 20 Repeatability - same module

21. TD Aiken March 31, 2008 21 Reproducibility – different modules

22. TD Aiken March 31, 2008 22 Reproducibility – different modules

23. TD Aiken March 31, 2008 23 Response Dynamic 1.2% H 2 pulse

24. TD Aiken March 31, 2008 24 Accuracy - Module

25. TD Aiken March 31, 2008 25 Humidity Effect, ~60 º C in 1% H2

26. TD Aiken March 31, 2008 26 Hydrogen Safety Module HSS-440

27. TD Aiken March 31, 2008 27 BMW Hydrogen 7

28. TD Aiken March 31, 2008 28 Locations of the HSS-440 Filling port Engine compartment Hydrogen tank Trunk Cabin

29. TD Aiken March 31, 2008 29 GENERAL MOTORS Chevrolet Equinox Fuel Cell Chevrolet is committed to bringing you drivable and practical vehicles that decrease our energy dependence and reduce our emissions.

30. TD Aiken March 31, 2008 30 Mercedes- Benz B-Class F-Cell Launch of the first series-production fuel cell The engine for this innovative vehicle will be a new generation of fuel-cell engine that is much more compact and yet at the same time more powerful and completely practicable for everyday use. Source – Daimler AG

31. TD Aiken March 31, 2008 31 Ramping up Commercialization Designing for H 2 gas leaks is critical in product development. Ability to detect leaks rapidly is now commercially available for automotive and non- automotive applications. Tough automotive standards have been met and may exceed other application requirements.

32. TD Aiken March 31, 2008 32 Developing a Safety Sensor for Fuel Cell Vehicles AppliedSensor, Inc. Booth 510