Impact of the Composition of Alcohol/Water Dispersion on the Proton Transport and Morphology of Cast Perfluorinated Sulfonic Acid Ionomer Thin Films

Colloidal Stability of PFSA-Ionomer Dispersions Part II: Determination of Suspension pH Using Single-Ion Potential Energies

Perfluorosulfonic acid (PFSA) ionomers serve a vital role in the performance and stability of fuel-cell catalyst layers. These properties, in turn, depend on the colloidal processing of precursor inks. To understand the colloidal structure of fuel-cell catalyst layers, we explore the aggregation of PFSA ionomers dissolved in water/alcohol solutions and relate the predicted aggregation to experimental measurements of solution pH. Not all side chains contribute to measured pH because of burying inside particle aggregates. To account for the measured degree of dissociation, a new description is developed for how PFSA aggregates interact with each other. The developed single-counterion electrostatic repulsive pair potential from Part I is incorporated into the Smoluchowski collision-based kinetics of interacting aggregates with buried side chains. We demonstrate that the surrounding solvent mixture affects the degree of aggregation as well as the pH of the system primarily through the solution dielectric permittivity, which drives the strength of the interparticle repulsive energies. Successful pH prediction of Nafion ionomer dispersions in water/n-propanol solutions validates the numerical calculations. Nafion-dispersion pH measurements serve as a surrogate for Nafion particle-size distributions. The model and framework can be leveraged to explore different ink formulations.

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.

Elucidating the Roles of Nafion/Solvent Formulations in Copper-Catalyzed CO2 Electrolysis

Nafion ionomer, composed of hydrophobic perfluorocarbon backbones and hydrophilic sulfonic acid side chains, is the most widely used additive for preparing catalyst layers (CLs) for electrochemical CO₂ reduction, but its impact on the performance of CO₂ electrolysis remains poorly understood. Here, we systematically investigate the role of the catalyst ink formulation on CO₂ electrolysis using commercial CuO nanoparticles as the model pre-catalyst. We find that the presence of Nafion is essential for achieving stable product distributions due to its ability to stabilize the catalyst morphology under reaction conditions. Moreover, the Nafion content and solvent composition (water/alcohol fraction) regulate the internal structure of Nafion coatings, as well as the catalyst morphology, thereby significantly impacting CO₂ electrolysis performance, resulting in variations of C₂₊ product Faradaic efficiency (FE) by >3×, with C₂₊ FE ranging from 17 to 54% on carbon paper substrates. Using a combination of ellipsometry and in situ Raman spectroscopy during CO₂ reduction, we find that such selectivity differences stem from changes to the local reaction microenvironment. In particular, the combination of high water/alcohol ratios and low Nafion fractions in the catalyst ink results in stable and favorable microenvironments, increasing the local CO₂/H₂O concentration ratio and promoting high CO surface coverage to facilitate C₂₊ production in long-term CO₂ electrolysis. Therefore, this work provides insights into the critical role of Nafion binders and underlines the importance of optimizing Nafion/solvent formulations as a means of enhancing the performance of electrochemical CO₂ reduction systems.

Correlation between Nafion Morphology in Various Dispersion Liquids and Properties of the Cast Membranes

Nafion is a perfluorosulfonic acid polymer that is most commonly used in proton-exchange membrane fuel cells. The processes of pretreatment and formation of such membranes strongly affect their properties. In this work, dispersions of Nafion in various ionic forms and dispersing liquids (ethylene glycol, N,N-dimethylformamide, N-methyl-2-pyrrolidone and isopropyl alcohol-water mixtures in different ratios) were obtained and studied. Membranes fabricated by casting of the various dispersions were also studied. The effect of the nature of the dispersing liquid and the counterion on the properties of Nafion dispersions, the morphology of the polymer in the dispersions and the characteristics of the membranes obtained from them has been shown. Based on the overall results, it can be concluded that the use of perfluorosulfonic acid dispersions in aprotic polar solvents is advisable for obtaining membranes by the casting procedure. This is because it provides optimal polymer morphology in the dispersion, which leads to the formation of films with good selectivity, mechanical and transport properties. The performed investigations show the relationship between the composition of dispersions, the morphology of the polymer and the properties of the membranes formed from them by the casting procedure.