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

Effect of Electro-Sprayed Porous Electrodes on the Performance and Stability of Water Electrolysis

The efficiency of proton exchange membrane water electrolysis (PEMWE) is a critical issue in realizing the production of green hydrogen. The coexistence of three phases in the catalyst layer of PEMWE causes mass transport limitation at the interfaces between them. In particular, the vigorous production of gaseous hydrogen and oxygen derived from liquid water is generated in the form of bubbles that seriously deactivate the membrane electrode assembly (MEA). In this study, we investigated the effect of porous structure in the electrode on the efficiency of hydrogen production at a high current density, which is highly related to the mass transport limitation. A widely used commercial catalyst (IrO2) was directly coated on the membrane by the electro-spray method. Porous electrodes on the membrane were formed by the charged catalyst particles that repulsed each other due to their electrostatic forces. Our membrane electrode assembly (MEA) exhibited outstanding electrolysis performances such as 5.3 A cm-2 and 3.2 A cm-2 at 2.0 and 1.8 V, respectively, which are the highest values compared with the results published in the current studies. In addition to porosity, it was confirmed that optimum binder contents positively affect the hydrophobicity and contact resistance of MEA. Through a simple porosity-controlled technique, the performance of PEMWE, in which three phases coexist, can be improved by more than 60 %. Accordingly, we expect that our systematic study on the role of porosity in the electrodes opens a new era to efficiently produce green hydrogen.

Revealing the Oxygen Transport Challenges in Catalyst Layers in Proton Exchange Membrane Fuel Cells and Water Electrolysis

Urgent requirements of the renewable energy boost the development of stable and clean hydrogen, which could effectively displace fossil fuels in mitigating climate changes. The efficient interconversion of hydrogen and electronic is highly based on polymer electrolyte membrane fuel cells (PEMFCs) and water electrolysis (PEMWEs). However, the high cost continues to impede large-scale commercialization of both PEMFC and PEMWE technologies, with the expense primarily attributed to noble catalysts serving as a major bottleneck. The reduction of Pt loading in PEMFCs is essential but limited by the oxygen transport resistance in the cathode catalyst layers (CCLs), while the oxygen transport in anode catalyst layers (ACLs) in PEMWEs also being focused as the Ir/IrOx catalyst reduced. The pore structure and the catalyst-ionomer agglomerates play important roles in the oxygen transport process of both PEMFCs and PEMWEs due to the similarity of membrane electrode assembly (MEA). Herein, the oxygen transport mechanism of PEMFCs in pore structure and ionomer thin films in CCLs is systematically reviewed, while state-of-the-art strategies are presented for enhancing oxygen transport and performance through materials and structural design. The deeply research opens avenues for exploring similar key scientific problems in oxygen transport process of PEMWEs and their further development.

Integration Construction of Hybrid Electrocatalysts for Oxygen Reduction

There is notable progress in the development of efficient oxygen reduction electrocatalysts, which are crucial components of fuel cells. However, these superior activities are limited by imbalanced mass transport and cannot be fully reflected in actual fuel cell applications. Herein, the design concepts and development tracks of platinum (Pt)-nanocarbon hybrid catalysts, aiming to enhance the performance of both cathodic electrocatalysts and fuel cells, are presented. This review commences with an introduction to Pt/C catalysts, highlighting the diverse architectures developed to date, with particular emphasis on heteroatom modification and microstructure construction of functionalized nanocarbons based on integrated design concepts. This discussion encompasses the structural evolution, property enhancement, and catalytic mechanisms of Pt/C-based catalysts, including rational preparation recipes, superior activity, strong stability, robust metal-support interactions, adsorption regulation, synergistic pathways, confinement strategies, ionomer optimization, mass transport permission, multidimensional construction, and reactor upgrading. Furthermore, this review explores the low-barrier or barrier-free mass exchange interfaces and channels achieved through the impressive multidimensional construction of Pt-nanocarbon integrated catalysts, with the goal of optimizing fuel cell efficiency. In conclusion, this review outlines the challenges associated with Pt-nanocarbon integrated catalysts and provides perspectives on the future development trends of fuel cells and beyond.

Investigating Electrode-Ionomer Interface Phenomena for Electrochemical Energy Applications

The endeavor to develop high-performance electrochemical energy applications has underscored the growing importance of comprehending the intricate dynamics within an electrode's structure and their influence on overall performance. This review investigates the complexities of electrode-ionomer interactions, which play a critical role in optimizing electrochemical reactions. Our examination encompasses both microscopic and meso/macro scale functions of ionomers at the electrode-ionomer interface, providing a thorough analysis of how these interactions can either enhance or impede surface reactions. Furthermore, this review explores the broader-scale implications of ionomer distribution within porous electrodes, taking into account factors like ionomer types, electrode ink formulation, and carbon support interactions. We also present and evaluate state-of-the-art techniques for investigating ionomer distribution, including electrochemical methods, imaging, modeling, and analytical techniques. Finally, the performance implications of these phenomena are discussed in the context of energy conversion devices. Through this comprehensive exploration of intricate interactions, this review contributes to the ongoing advancements in the field of energy research, ultimately facilitating the design and development of more efficient and sustainable energy devices.

Solvent Effects on the Catalyst Ink and Layer Microstructure for Anion Exchange Membrane Fuel Cells

Understanding the complex solvent effects on the microstructures of ink and catalyst layer (CL) is crucial for the development of high-performance anion exchange membrane fuel cells (AEMFCs). Herein, we study the solvent effects within the binary solvent ink system composed of water, isopropyl alcohol (IPA), commercial anion exchange ionomer, and Pt/C catalyst. The results show that the Pt/C particles and ionomer tend to form large aggregates wrapped with a thick ionomer layer in IPA-rich ink and promote the formation of large mesopores within the CL. With the increase of the water content in the ink, Pt/C particles are more likely to bridge to each other through wrapped FAA to form a well-connected three-dimensional network. The CL fabricated using water-rich ink shows smaller pores, higher porosity, and a more homogeneous ionomer network without the formation of large aggregates. Based on these results, we propose that the properties of the solvent mixture, including dielectric constant (ε) and solubility parameter (δ), affect the coulomb interaction of charged particles and surface tension at interfaces, which in turn affects the microstructure of ink and CL. By leveraging the solvent effects, we optimize the CL microstructures and improve the performance of AEMFC. These results may guide the rational design and fabrication of AEMFCs.

Hydrocarbon Ionomeric Binders for Fuel Cells and Electrolyzers

Ionomeric binders in catalyst layers, abbreviated as ionomers, play an essential role in the performance of polymer-electrolyte membrane fuel cells and electrolyzers. Due to environmental issues associated with perfluoroalkyl substances, alternative hydrocarbon ionomers have drawn substantial attention over the past few years. This review surveys literature to discuss ionomer requirements for the electrodes of fuel cells and electrolyzers, highlighting design principles of hydrocarbon ionomers to guide the development of advanced hydrocarbon ionomers.

Customizing Catalyst/Ionomer Interface for High-Durability Electrode of Proton Exchange Membrane Fuel Cells

Commercialization applications of proton exchange membrane fuel cells (PEMFCs) are throttled by the durability issues of the electrodes prepared by using catalyst inks. Probing into a desirable catalyst/ionomer interface by adjusting the catalyst inks is an effective way for obtaining high-durability electrodes. The present study investigated quantitatively the catalyst/ionomer interfaces based on the viscosity (η) property of the isopropyl alcohol (IPA) and dipropylene glycol (DPG) nonaqueous mixture solvent for the first time. Accelerated stress test (AST) showed that η as one of the characteristic parameters of the solvent had a threshold effect on the durability of electrodes. The electrodes in the half-cell and single cell all exhibited the highest durability using IPA:DPG = 2:6 (η = 27.00 cP) as the dispersion solvent in this work, embodied by its ECSA loss rate, and the cell potential loss was minimum after AST. The ECSA loss mechanism showed that a fine catalyst/ionomer interface structure was created for the highest durability electrode by regulating the η values of the solvent, and the carbon corrosion loss (le) and Pt particle dissolution loss (ld) were weakened. Based on the molecular dynamics (MD) simulation and 19F NMR spectra results, the solvent ratio (various η and similar ε and δ) affected the dispersion states of the ionomer. For the catalyst inks with the highest durability (IPA:DPG = 2:6), the Nafion backbone and side chain presented a higher mobility behavior in the solvent and tended to show the structure of extension separation and the respective aggregation of hydrophilic/hydrophobic phases. Meanwhile, Pt slab models suggested that the side chain of Nafion more easily adhered to the Pt interface zone, while the backbone was pushed toward the carbon support interface zone as more DPG molecules distributed on the Pt surface, which reduced the dissolution of Pt particles and the corrosion of the carbon support. These catalyst/ionomer interface structures tailored by regulating the solvent η values provide insights into improving the electrode durability.

Structure and conductivity of ionomer in PEM fuel cell catalyst layers: a model-based analysis

Efforts in design and optimization of catalyst layers for polymer electrolyte fuel cells hinge on mathematical models that link electrode composition and microstructure with effective physico-chemical properties. A pivotal property of these layers and the focus of this work is the proton conductivity, which is largely determined by the morphology of the ionomer. However, available relations between catalyst layer composition and proton conductivity are often adopted from general theories for random heterogeneous media and ignore specific features of the microstructure, e.g., agglomerates, film-like structures, or the hierarchical porous network. To establish a comprehensive understanding of the peculiar structure-property relations, we generated synthetic volumetric images of the catalyst layer microstructure. In a mesoscopic volume element, we modeled the electrolyte phase and calculated the proton conductivity using numerical tools. Varying the ionomer morphology in terms of ionomer film coverage and thickness revealed two limiting cases: the ionomer can either form a thin film with high coverage on the catalyst agglomerates; or the ionomer exists as voluminous chunks that connect across the inter-agglomerate space. Both cases were modeled analytically, adapting relations from percolation theory. Based on the simulated data, a novel relation is proposed, which links the catalyst layer microstructure to the proton conductivity over a wide range of morphologies. The presented analytical approach is a versatile tool for the interpretation of experimental trends and it provides valuable guidance for catalyst layer design. The proposed model was used to analyze the formation of the catalyst layer microstructure during the ink stage. A parameter study of the initial ionomer film thickness and the ionomer dispersion parameter revealed that the ionomer morphology should be tweaked towards well-defined films with high coverage of catalyst agglomerates. These implications match current efforts in the experimental literature and they may thus provide direction in electrode materials research for polymer electrolyte fuel cells.

Construction of catalyst layer network structure for proton exchange membrane fuel cell derived from polymeric dispersion

A rational design of the structure of catalyst layer (CL) is required for proton exchange membrane fuel cells to attain outstanding performance and excellent stability. It is crucial to have a profound comprehension of the correlations existing between the properties (catalyst ink), network structures of CL and proton exchange membrane fuel cells' performance for the rational design of the structure of CL. This study deeply investigates the effects of a series of alcohol solvents on the properties and network structure of CL. The results demonstrate that the CL aggregates in higher ε solution show smaller particle sizes, and the sulfonic acid groups (∼SO3H) tend to extend more outward due to the strong dissociation. A more continuous and homogeneous ionomer distribution around Pt/C aggregates is observed in the CL, which improves the electrochemically active surface area (ECSA) and performance of the electrode. But, the electrode has a poor performance at high current density regions due to the mass transfer resistance. Based on this, a two-step solvent control strategy is proposed to maintain uniform ionomer and aggerates distribution and optimize the mass transfer for CL. The performance of the cell improves from 0.555 V to 0.615 V at 2000 mA·cm-2.

Nanosized Proton Conductor Array with High Specific Surface Area Improves Fuel Cell Performance at Low Pt Loading

The use of ordered catalyst layers, based on micro-/nanostructured arrays such as the ordered Nafion array, has demonstrated great potential in reducing catalyst loading and improving fuel cell performance. However, the size (diameter) of the basic unit of the most existing ordered Nafion arrays, such as Nafion pillar or cone, is typically limited to micron or submicron sizes. Such small sizes only provide a limited number of proton transfer channels and a small specific area for catalyst loading. In this work, the ordered Nafion array with a pillar diameter of only 40 nm (D40) was successfully prepared through optimization of the Nafion solvent, thermal annealing temperature, and stripping mode from the anode alumina oxide (AAO) template. The density of D40 is 2.7 × 10¹⁰ pillars/cm², providing an abundance of proton transfer channels. Additionally, D40 has a specific area of up to 51.5 cm²/cm², which offers a large area for catalyst loading. This, in turn, results in the interface between the catalyst layer and gas diffusion layer becoming closer. Consequently, the peak power densities of the fuel cells are 1.47 (array as anode) and 1.29 W/cm² (array as cathode), which are 3.3 and 2.9 times of that without array, respectively. The catalyst loading is significantly reduced to 17.6 (array as anode) and 61.0 μg/cm² (array as cathode). Thus, the nanosized Nafion array has been proven to have high fuel cell performance with low Pt catalyst loading. Moreover, this study also provides guidance for the design of a catalyst layer for water electrolysis and electrosynthesis.

Insights into Degradation of the Membrane-Electrode Assembly Performance in Low-Temperature PEMFC: the Catalyst, the Ionomer, or the Interface?

Here, we report a study on the structural characteristics of membrane electrode assembly (MEA) samples obtained from a low-temperature (LT) polymer electrolyte membrane (PEM) fuel cell (FC) stack subjected to long-term durability testing for ∼18,500 h of nominal operation along with ∼900 on/off cycles accumulated over the operation time, with the total power production being 3.39 kW h/cm2 of MEA and the overall degradation being 87% based on performance loss. The chemical and physical states of the degraded MEAs were investigated through structural characterizations aiming to probe their different components, namely the cathode and anode electrocatalysts, the Nafion ionomer in the catalyst layers (CLs), the gas diffusion layers (GDLs), and the PEM. Surprisingly, X-ray diffraction and electron microscopy studies suggested no significant degradation of the electrocatalysts. Similarly, the cathode and anode GDLs exhibited no significant change in porosity and structure as indicated by BET analysis and helium ion microscopy. Nevertheless, X-ray fluorescence spectroscopy, elemental analysis through a CHNS analyzer, and comprehensive investigations by X-ray photoelectron spectroscopy suggested significant degradation of the Nafion, especially in terms of sulfur content, that is, the abundance of the -SO3- groups responsible for H+ conduction. Hence, the degradation of the Nafion, in both of the CLs and in the PEM, was found to be the principal mechanism for performance degradation, while the Pt/C catalyst degradation in terms of particle size enlargement or mass loss was minimal. The study suggests that under real-life operating conditions, ionomer degradation plays a more significant role than electrocatalyst degradation in LT-PEMFCs, in contrast to many scientific studies under artificial stress conditions. Mitigation of the ionomer degradation must be emphasized as a strategy to improve the PEMFC's durability.

Perspective: Morphology and ion transport in ion-containing polymers from multiscale modeling and simulations

Ion-containing polymers are soft materials composed of polymeric chains and mobile ions. Over the past several decades they have been the focus of considerable research and development for their use as the electrolyte in energy conversion and storage devices. Recent and significant results obtained from multiscale simulations and modeling for proton exchange membranes (PEMs), anion exchange membranes (AEMs), and polymerized ionic liquids (polyILs) are reviewed. The interplay of morphology and ion transport is emphasized. We discuss the influences of polymer architecture, tethered ionic groups, rigidity of the backbone, solvents, and additives on both morphology and ion transport in terms of specific interactions. Novel design strategies are highlighted including precisely controlling molecular conformations to design highly ordered morphologies; tuning the solvation structure of hydronium or hydroxide ions in hydrated ion exchange membranes; turning negative ion-ion correlations to positive correlations to improve ionic conductivity in polyILs; and balancing the strength of noncovalent interactions. The design of single-ion conductors, well-defined supramolecular architectures with enhanced one-dimensional ion transport, and the understanding of the hierarchy of the specific interactions continue as challenges but promising goals for future research.

Effect of Catalyst Ink and Formation Process on the Multiscale Structure of Catalyst Layers in PEM Fuel Cells

The structure of a catalyst layer (CL) significantly impacts the performance, durability, and cost of proton exchange membrane (PEM) fuel cells and is influenced by the catalyst ink and the CL formation process. However, the relationship between the composition, formulation, and preparation of catalyst ink and the CL formation process and the CL structure is still not completely understood. This review, therefore, focuses on the effect of the composition, formulation, and preparation of catalyst ink and the CL formation process on the CL structure. The CL structure depends on the microstructure and macroscopic properties of catalyst ink, which are decided by catalyst, ionomer, or solvent(s) and their ratios, addition order, and dispersion. To form a well-defined CL, the catalyst ink, substrate, coating process, and drying process need to be well understood and optimized and match each other. To understand this relationship, promote the continuous and scalable production of membrane electrode assemblies, and guarantee the consistency of the CLs produced, further efforts need to be devoted to investigating the microstructure of catalyst ink (especially the catalyst ink with high solid content), the reversibility of the aged ink, and the drying process. Furthermore, except for the certain variables studied, the other manufacturing processes and conditions also require attention to avoid inconsistent conclusions.

Multiscale simulation approach to investigate the binder distribution in catalyst layers of high-temperature polymer electrolyte membrane fuel cells

A multiscale approach involving both density functional theory (DFT) and molecular dynamics (MD) simulations was used to deduce an appropriate binder for Pt/C in the catalyst layers of high-temperature polymer electrolyte membrane fuel cells. The DFT calculations showed that the sulfonic acid (SO₃⁻) group has higher adsorption energy than the other functional groups of the binders, as indicated by its normalized adsorption area on Pt (− 0.1078 eV/Ų) and carbon (− 0.0608 eV/Ų) surfaces. Consequently, MD simulations were performed with Nafion binders as well as polytetrafluoroethylene (PTFE) binders at binder contents ranging from 14.2 to 25.0 wt% on a Pt/C model with H₃PO₄ at room temperature (298.15 K) and operating temperature (433.15 K). The pair correlation function analysis showed that the intensity of phosphorus atoms in phosphoric acid around Pt (\documentclass[12pt]{minimal} \usepackage{amsmath} \usepackage{wasysym} \usepackage{amsfonts} \usepackage{amssymb} \usepackage{amsbsy} \usepackage{mathrsfs} \usepackage{upgreek} \setlength{\oddsidemargin}{-69pt} \begin{document}$${\rho }_{\mathrm{P}}{g}_{\mathrm{Pt}-\mathrm{P}}\left(r\right)$$\end{document}ρPgPt-Pr) increased with increasing temperature because of the greater mobility and miscibility of H₃PO₄ at 433.15 K than at 298.15 K. The coordination numbers (CNs) of Pt–P(H₃PO₄) gradually decreased with increasing ratio of the Nafion binders until the Nafion binder ratio reached 50%, indicating that the adsorption of H₃PO₄ onto the Pt surface decreased because of the high adsorption energy of SO₃⁻ groups with Pt. However, the CNs of Pt–P(H₃PO₄) gradually increased when the Nafion binder ratio was greater than 50% because excess Nafion binder agglomerated with itself via its SO₃⁻ groups. Surface coverage analysis showed that the carbon surface coverage by H₃PO₄ decreased as the overall binder content was increased to 20.0 wt% at both 298.15 and 433.15 K. The Pt surface coverage by H₃PO₄ at 433.15 K reached its lowest value when the PTFE and Nafion binders were present in equal ratios and at an overall binder content of 25.0 wt%. At the Pt (lower part) surface covered by H₃PO₄ at 433.15 K, an overall binder content of at least 20.0 wt% and equal proportions of PTFE and Nafion binder are needed to minimize H₃PO₄ contact with the Pt.

Pt utilization in proton exchange membrane fuel cells: structure impacting factors and mechanistic insights

It is essential to realize an expected low usage of platinum (Pt) in proton exchange membrane fuel cells (PEMFCs) for the large-scale market penetration of PEMFC-powered vehicles. As well as seeking Pt-based catalysts with a high specific activity, improving Pt utilization through structure optimization of the catalyst layer (CL) has been the main route and apparently a more practical way so far to develop high-performance low-Pt PEMFCs. Despite the significant progress achieved in the past 2-3 decades, a visible gap remains between the current Pt demand of automobile PEMFCs and the target value. To further increase Pt utilization, insights from previous studies are necessary. This review analyzes the structural factors that impact the current-generation efficiency of Pt in PEMFC electrodes in great detail, with emphasis particularly put on the mechanistic and molecule-level insights into the structural effects. The contents include the so-called local transport resistance associated with the permeation and diffusion of oxygen molecules in the ionomer film covering the Pt surface, regulation of ionomer aggregation through molecular interactions between ink components, modulation of ionomer distribution through pore size exclusion and surface electrostatic interaction of the carbon support, optimization of the coupling between the reaction and transport processes through graded composition, and the formation of highways of protons, electrons, and gas molecules through component alignment. We provide a critical analysis of the measurement methods and theoretical models assessing the local transport resistance, which is considered as a crucial issue in the current-generation efficiency of Pt in ultralow-Pt CL. Finally, new opportunities toward the further promotion of Pt utilization are proposed. These subjects and discussions should be of great significance in the rational design and precise fabrication of PEMFC electrodes, and may also inspire similar subjects in other electrochemical energy technologies such as water electrolysis, CO₂ reduction, and batteries.

Electrocatalysis in Alkaline Media and Alkaline Membrane-Based Energy Technologies

Hydrogen energy-based electrochemical energy conversion technologies offer the promise of enabling a transition of the global energy landscape from fossil fuels to renewable energy. Here, we present a comprehensive review of the fundamentals of electrocatalysis in alkaline media and applications in alkaline-based energy technologies, particularly alkaline fuel cells and water electrolyzers. Anion exchange (alkaline) membrane fuel cells (AEMFCs) enable the use of nonprecious electrocatalysts for the sluggish oxygen reduction reaction (ORR), relative to proton exchange membrane fuel cells (PEMFCs), which require Pt-based electrocatalysts. However, the hydrogen oxidation reaction (HOR) kinetics is significantly slower in alkaline media than in acidic media. Understanding these phenomena requires applying theoretical and experimental methods to unravel molecular-level thermodynamics and kinetics of hydrogen and oxygen electrocatalysis and, particularly, the proton-coupled electron transfer (PCET) process that takes place in a proton-deficient alkaline media. Extensive electrochemical and spectroscopic studies, on single-crystal Pt and metal oxides, have contributed to the development of activity descriptors, as well as the identification of the nature of active sites, and the rate-determining steps of the HOR and ORR. Among these, the structure and reactivity of interfacial water serve as key potential and pH-dependent kinetic factors that are helping elucidate the origins of the HOR and ORR activity differences in acids and bases. Additionally, deliberately modulating and controlling catalyst-support interactions have provided valuable insights for enhancing catalyst accessibility and durability during operation. The design and synthesis of highly conductive and durable alkaline membranes/ionomers have enabled AEMFCs to reach initial performance metrics equal to or higher than those of PEMFCs. We emphasize the importance of using membrane electrode assemblies (MEAs) to integrate the often separately pursued/optimized electrocatalyst/support and membranes/ionomer components. Operando/in situ methods, at multiscales, and ab initio simulations provide a mechanistic understanding of electron, ion, and mass transport at catalyst/ionomer/membrane interfaces and the necessary guidance to achieve fuel cell operation in air over thousands of hours. We hope that this Review will serve as a roadmap for advancing the scientific understanding of the fundamental factors governing electrochemical energy conversion in alkaline media with the ultimate goal of achieving ultralow Pt or precious-metal-free high-performance and durable alkaline fuel cells and related technologies.

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.

Distinguishing Adsorbed and Deposited Ionomers in the Catalyst Layer of Polymer Electrolyte Fuel Cells Using Contrast-Variation Small-Angle Neutron Scattering

The ionomers distributed on carbon particles in the catalyst layer of polymer electrolyte fuel cells (PEFCs) govern electrical power via proton transport and oxygen permeation to active platinum. Thus, ionomer distribution is a key to PEFC performance. This distribution is characterized by ionomer adsorption and deposition onto carbon during the catalyst-ink coating process; however, the adsorbed and deposited ionomers cannot easily be distinguished in the catalyst layer. Therefore, we identified these two types of ionomers based on the positional correlation between the ionomer and carbon particles. The cross-correlation function for the catalyst layer was obtained by small-angle neutron scattering measurements with varying contrast. From fitting with a model for a fractal aggregate of polydisperse core-shell spheres, we determined the adsorbed-ionomer thickness on the carbon particle to be 51 Å and the deposited-ionomer amount for the total ionomer to be 50%. Our technique for ionomer differentiation can be used to optimally design PEFC catalyst layers.

Low-PGM and PGM-Free Catalysts for Proton Exchange Membrane Fuel Cells: Stability Challenges and Material Solutions

Fuel cells as an attractive clean energy technology have recently regained popularity in academia, government, and industry. In a mainstream proton exchange membrane (PEM) fuel cell, platinum-group-metal (PGM)-based catalysts account for ≈50% of the projected total cost for large-scale production. To lower the cost, two materials-based strategies have been pursued: 1) to decrease PGM catalyst usage (so-called low-PGM catalysts), and 2) to develop alternative PGM-free catalysts. Grand stability challenges exist when PGM catalyst loading is decreased in a membrane electrode assembly (MEA)-the power generation unit of a PEM fuel cell-or when PGM-free catalysts are integrated into an MEA. More importantly, there is a significant knowledge gap between materials innovation and device integration. For example, high-performance electrocatalysts usually demonstrate undesired quick degradation in MEAs. This issue significantly limits the development of PEM fuel cells. Herein, recent progress in understanding the degradation of low-PGM and PGM-free catalysts in fuel cell MEAs and materials-based solutions to address these issues are reviewed. The key factors that degrade the MEA performance are highlighted. Innovative, emerging material concepts and development of low-PGM and PGM-free catalysts are discussed.

The threshold method in the analysis of catalyst layer porosity towards oxygen transport resistance in PEMFCs

The threshold method is used for the analysis of catalyst layer porosity towards oxygen transport resistance at different ionomer content levels.

Solvent-Dependent Adsorption of Perfluorosulfonated Ionomers on a Pt(111) Surface Using Atomic Force Microscopy

The adsorption behavior of perfluorosulfonated ionomers (PFSIs) on a Pt(111) surface in various solvents is investigated by in situ atomic force microscopy (AFM) and discussed on the basis of aggregation of PFSIs in the liquid phase. The AFM images show that, in an aqueous solution of PFSI (0.1 wt % Nafion + 99.9 wt % water), PFSI aggregates with a lateral size of 20-200 nm adsorb on the Pt(111) surface. In a PFSI solution containing a small amount of 1-propanol (0.1 wt % Nafion + 99.5 wt % water + 0.4 wt % 1-propanol), however, slightly smaller aggregates adsorb on the Pt(111) surface. Such solvent-dependent sizes of adsorbed aggregates are in reasonable agreement with apparent hydrodynamic radii of PFSIs in the corresponding solutions determined by dynamic light scattering (DLS) while assuming the formation of spherical aggregation. Interestingly, a step-terrace structure characteristic to a clean Pt(111) surface is observed in a propanol-rich PFSI solution (0.1 wt % Nafion + 44.45 wt % water + 55.45 wt % 1-propanol) but X-ray photoelectron spectroscopy clearly indicates the existence of fluorocarbon species at the Pt(111) surface, suggesting the formation of a smooth adsorbed layer of PFSIs in a lying down configuration. Absence of any features assignable to aggregates in DLS data suggests well-dispersion of PFSIs in such propanol-rich solution without aggregations. Thus, the adsorbed structure of PFSIs at Pt surfaces can be controlled by tuning the composition of mixed solvent, which affects the aggregation of PFSI in the liquid phase.

Defect structure evolution of polyacrylonitrile and single wall carbon nanotube nanocomposites: a molecular dynamics simulation approach

In this study, molecular dynamics simulations were performed to understand the defect structure development of polyacrylonitrile-single wall carbon nanotube (PAN-SWNT) nanocomposites. Three different models (control PAN, PAN-SWNT(5,5), and PAN-SWNT(10,10)) with a SWNT concentration of 5 wt% for the nanocomposites were tested to study under large extensional deformation to the strain of 100% to study the corresponding mechanical properties. Upon deformation, the higher stress was observed in both nanocomposite systems as compared to the control PAN, indicating effective reinforcement. The higher Young’s (4.76 ± 0.24 GPa) and bulk (4.19 ± 0.25 GPa) moduli were observed when the smaller-diameter SWNT_(5,5) was used, suggesting that SWNT_(5,5) resists stress better. The void structure formation was clearly observed in PAN-SWNT_(10,10), while the nanocomposite with smaller diameter SWNT_(5,5) did not show the development of such a defect structure. In addition, the voids at the end of SWNT_(10,10) became larger in the drawing direction with increasing deformation.

Modifying the Electrocatalyst-Ionomer Interface via Sulfonated Poly(ionic liquid) Block Copolymers to Enable High-Performance Polymer Electrolyte Fuel Cells

Polymer electrolyte membrane fuel cell (PEMFC) electrodes with a 0.07 mgPt cm-2 Pt/Vulcan electrocatalyst loading, containing only a sulfonated poly(ionic liquid) block copolymer (SPILBCP) ionomer, were fabricated and achieved a ca. 2× enhancement of kinetic performance through the suppression of Pt surface oxidation. However, SPILBCP electrodes lost over 70% of their electrochemical active area at 30% RH because of poor ionomer network connectivity. To combat these effects, electrodes made with a mix of Nafion/SPILBCP ionomers were developed. Mixed Nafion/SPILBCP electrodes resulted in a substantial improvement in MEA performance across the kinetic and mass transport-limited regions. Notably, this is the first time that specific activity values determined from an MEA were observed to be on par with prior half-cell results for Nafion-free Pt/Vulcan systems. These findings present a prospective strategy to improve the overall performance of MEAs fabricated with surface accessible electrocatalysts, providing a pathway to tailor the local electrocatalyst/ionomer interface.

Impact of Membrane Types and Catalyst Layers Composition on Performance of Polymer Electrolyte Membrane Fuel Cells

Performance of a low temperature polymer electrolyte membrane fuel cell (PEMFC) is highly dependent on the kind of catalysts, catalyst supports, ionomer amount on the catalyst layers (CL), membrane types and operating conditions. In this work, we investigated the influence of membrane types and CL compositions on MEA performance. MEA performance increases under all practically relevant load conditions with reduction of the membrane thickness from 50 to 15 μm, however further decrease in membrane thickness from 15 to 10 μm leads to reduction in cell voltage at high current loads. A thick anode CL is found to be beneficial under wet operating conditions assuming more pore space is provided to accommodate liquid water, whereas under dry operating conditions, an intermediate thickness of the anode CL is beneficial. When studying the impact of catalyst layer thickness, too thin a catalyst layer again shows reduced performance due to increased ohmic resistance ruled out the performance of the MEAs which have identical Pt crystallite sizes on the cathode CLs i. e. the thinnest the cathode CL, the highest the voltage were achieved at a defined current load. Adaptation of the operating conditions is highly anticipated to achieve the highest MEA performance.

Possible scenario of forming a catalyst layer for proton exchange membrane fuel cells

Ionomer in the catalyst layer provides an ion transport channel which is essential for many electrochemical devices. As the ionomer and electrochemical catalyst are packed together in the catalyst layer, it is difficult to have a clear image of the ionomer distribution in the catalyst layer and how the ionomer is in contact with Pt or carbon. A highly dispersed catalyst was deposited on the TEM SiN grid directly using the same (ultrasonic spray) or a similar way as the catalyst was deposited on the membrane. By analyzing the distribution of various elements (C, F, S, Pt etc.), we found that the ionomer may coexist in the catalyst layer in three ways: ionomer covered Pt particles due to the relatively strong interaction between Pt and the ionomer; ionomer covered C particles; packed free ionomer in between the aggregated catalyst particles. The results show that the ionomer is prone to covering the surface of Pt particles as further evidenced by the accelerated degradation test (ADT).

Ionomer in the catalyst layer provides an ion transport channel which is essential for many electrochemical devices.

Enhancement of service life of polymer electrolyte fuel cells through application of nanodispersed ionomer

In polymer electrolyte fuel cells (PEFCs), protons from the anode are transferred to the cathode through the ionomer membrane. By impregnating the ionomer into the electrodes, proton pathways are extended and high proton transfer efficiency can be achieved. Because the impregnated ionomer mechanically binds the catalysts within the electrode, the ionomer is also called a binder. To yield good electrochemical performance, the binder should be homogeneously dispersed in the electrode and maintain stable interfaces with other catalyst components and the membrane. However, conventional binder materials do not have good dispersion properties. In this study, a facile approach based on using a supercritical fluid is introduced to prepare a homogeneous nanoscale dispersion of the binder material in aqueous alcohol. The prepared binder exhibited high dispersion characteristics, crystallinity, and proton conductivity. High performance and durability were confirmed when the binder material was applied to a PEFC cathode electrode.

High-Power Abiotic Direct Glucose Fuel Cell Using a Gold-Platinum Bimetallic Anode Catalyst

We developed a high-power abiotic direct glucose fuel cell system using a Au-Pt bimetallic anode catalyst. The high power generation (95.7 mW cm^-2) was attained by optimizing operating conditions such as the composition of a bimetallic anode catalyst, loading amount of the metal catalyst on a carbon support, ionomer/carbon weight ratio when the catalyst was applied to the anode, glucose and KOH concentrations in the fuel solution, and operating temperature and flow rate of the fuel solution. It was found that poly(N-vinyl-2-pyrrolidone)-stabilized Au₈₀Pt₂₀ nanoparticles (mean diameter 1.5 nm) on a carbon (Ketjen Black 600) support function as a highly active anode catalyst for the glucose electrooxidation. The ionomer/carbon weight ratio also greatly affects the cell properties, which was found to be optimal at 0.2. As for the glucose concentration, a maximum cell power was derived at 0.4-0.6 mol dm^-3. A high KOH concentration (4.0 mol dm^-3) was preferable for deriving the maximum power. The cell power increased with the increasing flow rate of the glucose solution up to 50 cm³ min^-1 and leveled off thereafter. At the optimal condition, the maximum power density and corresponding cell voltage of 58.2 mW cm^-2 (0.36 V) and 95.7 mW cm^-2 (0.34 V) were recorded at 298 and 328 K, respectively.

Zoom in Catalyst/Ionomer Interface in Polymer Electrolyte Membrane Fuel Cell Electrodes: Impact of Catalyst/Ionomer Dispersion Media/Solvent

Large-scale applications of polymer electrolyte membrane fuel cells (PEMFCs) are throttled primarily by high initial cost and durability issues of the electrodes, which essentially consist of the nanoparticulate catalysts (e.g., Pt) having accessibility to electrons (e^-), protons (H⁺), and fuel/oxidant through catalyst support, polymer electrolyte ionomer, and porous gas diffusion layer, respectively. Hence, to achieve high electrode performance in terms of activity and/or durability, understanding and optimization of the catalyst/support and catalyst/ionomer interfaces are of significant importance. Present study demonstrates an alternative route to inspect the catalyst/ionomer interface through an accelerated stress test combined with electrochemical impedance spectroscopy. Various interfaces are created through catalyst inks prepared using commercial Pt/C catalyst powder dispersed in different solvents. Electrode degradation pattern turns out to be a very useful tool to interpret a catalyst/ionomer interface structure. Variations of interfacial impedance, electrochemical surface area (ECSA), and double layer capacitance with the number of potential cycles suggested significant impact of catalyst/ionomer interface on the catalyst performance. A quantification of the degradation mechanisms responsible for ECSA loss during AST was employed to further understand the correlations between the electrochemical performance of the electrodes and their catalyst/ionomer interface structures. The knowledge may be implied to further optimize the electrode structure and hence to advance the PEMFC technology.