Modulated ionomer distribution in the catalyst layer of polymer electrolyte membrane fuel cells for high temperature operation

RF Sputtering of Gold Nanoparticles in Liquid and Direct Transfer to Nafion Membrane for PEM Water Electrolysis

Sputtering onto liquids is rapidly gaining attention for the green and controlled dry synthesis of ultrapure catalysts nanomaterials. In this study, we present a clean and single-step method for the synthesis of gold nanoparticles directly in polyethylene glycol (PEG) liquid using radio frequency (RF) magnetron sputtering and by subsequently transferring them to Nafion ionomer, fabricating a catalyst-coated membrane (CCM), an essential component of the proton exchange membrane water electrolyzer (PEMWE). The samples were systematically characterized at different stages of process development. The innovative transfer process resulted in a monodispersed homogeneous distribution of catalyst particles inside CCM while retaining their nascent nanoscale topography. The chemical analysis confirmed the complete removal of the trapped PEG through the process optimization. The electrochemical catalytic activity of the optimized CCM was verified, and the hydrogen evolution reaction (HER) in acidic media appeared outstanding, a vital step in water electrolysis toward H2 production. Therefore, this first study highlights the advantages of RF sputtering in liquid for nanoparticle synthesis and its direct application in preparing CCM, paving the way for the development of innovative membrane preparation techniques for water electrolysis.

Differences in the Electrochemical Performance of Pt-Based Catalysts Used for Polymer Electrolyte Membrane Fuel Cells in Liquid Half- and Full-Cells

A substantial amount of research effort has been directed toward the development of Pt-based catalysts with higher performance and durability than conventional polycrystalline Pt nanoparticles to achieve high-power and innovative energy conversion systems. Currently, attention has been paid toward expanding the electrochemically active surface area (ECSA) of catalysts and increase their intrinsic activity in the oxygen reduction reaction (ORR). However, despite innumerable efforts having been carried out to explore this possibility, most of these achievements have focused on the rotating disk electrode (RDE) in half-cells, and relatively few results have been adaptable to membrane electrode assemblies (MEAs) in full-cells, which is the actual operating condition of fuel cells. Thus, it is uncertain whether these advanced catalysts can be used as a substitute in practical fuel cell applications, and an improvement in the catalytic performance in real-life fuel cells is still necessary. Therefore, from a more practical and industrial point of view, the goal of this review is to compare the ORR catalyst performance and durability in half- and full-cells, providing a differentiated approach to the durability concerns in half- and full-cells, and share new perspectives for strategic designs used to induce additional performance in full-cell devices.

Tuning the Ionomer Distribution in the Fuel Cell Catalyst Layer with Scaling the Ionomer Aggregate Size in Dispersion

With the demands for better performance of polymer electrolyte membrane fuel cells, studies on controlling the distribution of ionomers have recently gained interest. Here, we present a tunable ionomer distribution in the catalyst layer (CL) with dipropylene glycol (DPG) and water mixtures as the ionomer dispersion medium. Dynamic light scattering and molecular dynamics simulation demonstrate that, by increasing the DPG content in the dispersion, the size of the ionomer aggregates in the dispersion is exponentially reduced because of the higher affinity of DPG for Nafion ionomers. The ionomer distribution of the resulting CLs dictates the dimensional feature of the ionomer dispersion. Although the ionomer distribution becomes more uniform with increasing the DPG content, an optimal power performance is obtained at a DPG content of 50 wt % regardless of feed humidity because of balanced proton and mass transports. As a guide for tuning the ionomer distribution, we suggest that the ionomer aggregates in the dispersion with a size close to that of the Pt/C aggregates form a highly connected ionomer network and maintain a porosity in the catalyst/ionomer aggregate, resulting in high power performance.

In-Plane Channel-Structured Catalyst Layer for Polymer Electrolyte Membrane Fuel Cells

In this study, we present a novel catalyst layer (CL) with in-plane flow channels to enhance the mass transports in polymer electrolyte membrane fuel cells. The CL with in-plane channels on its surface is fabricated by coating a CL slurry onto a surface-treated substrate with the inverse line pattern and transferring the dried CL from the substrate to a membrane. The membrane electrode assembly with the in-plane channel-patterned CL has superior power performances in high current densities compared with an unpatterned, flat CL, demonstrating a significant enhancement of the mass-transport property by the in-plane channels carved in the CL. The performance gain is more pronounced when the channel direction is perpendicular to the flow field direction, indicating that the in-plane channels increase the utilization of the CL under the rib area. An oxygen-transport resistance analysis shows that both molecular and Knudsen diffusion can be facilitated with the introduction of the in-plane channels. The direct CL patterning technique provides a platform for the fabrication of advanced CL structures with a high structural fidelity and design flexibility and a rational guideline for designing high-performance CLs.