Ionomer migration within PEMFC catalyst layers induced by humidity changes

Fundamental and Practical Aspects of Break-In/Conditioning of Proton Exchange Membrane Fuel Cells

Proton exchange membrane fuel cells (PEMFCs) have proven to be a promising power source for various applications ranging from portable devices to automotive and stationary power systems. The production of PEMFC involves numerous stages in the value chain, with each stage presenting unique challenges and opportunities to improve the overall performance and durability of the PEMFC stack. These include steps such as manufacturing the key components such as the platinum-based catalyst, processing these components into the membrane electrode assemblies (MEAs), and stacking the MEAs to ultimately produce a PEMFC stack. However, it is also known that the break-in or conditioning phase of the stack plays a crucial role in the final performance as well as durability. It involves several key phenomena such as hydration of the membrane, swelling of the ionomer, redistribution of the catalyst and the creation of suitable electrochemical interfaces - establishment of the triple phase boundary. These improve the proton conductivity, the mass transport of reactants and products, the catalytic activity of the electrode and thus the overall efficiency of the FC. The cruciality of break-in is demonstrated by the improvement in performance, which can even be over 50 % compared to the initial state. The state-of-the-art approach for the break-in of MEAs involves an electrochemical protocol, such as voltage cycling, using a PEMFC testing station. This method is time-consuming, equipment-intensive, and costly. Therefore, new, elegant, and cost-effective solutions are needed. Nevertheless, the primary aim is to achieve maximum/optimal performance so that it is fully operational and ready for the market. It is therefore essential to better understand and deconvolute these complex mechanisms taking place during break-in/conditioning. Strategies include controlled humidity and temperature cycling, novel electrode materials and other advanced break-in methods such as air braking, vacuum activation or steaming. In addition, it is critical to address the challenges associated with standardisation and quantification of protocols to enable interlaboratory comparisons to further advance the field.

Hydrophobic modification enhances the microstructure stability of the catalyst layer in alkaline polymer electrolyte fuel cells

Alkaline polymer electrolyte fuel cells (APEFCs) have achieved notable advancements in peak power density, yet their durability during long-term operation remains a significant challenge. It has been recognized that increasing the hydrophobicity of the catalyst layer can effectively alleviate the performance degradation. However, a microscopic view of how hydrophobicity contributes to the stability of the catalyst layer microstructure is not clear. Here, we construct a membrane electrode assembly (MEA) with enhanced structural stability and durability by incorporating polytetrafluoroethylene (PTFE) particles into the catalyst layer. MEAs modified by this approach exhibit stabilized voltage platforms in current step tests and reduced hysteresis in current-voltage polarization curves during operation, indicating the critical role of PTFE in the removal of the excess water within the catalyst layer. Fuel cells with PTFE modification show more than 45% increase in electrochemical durability. By characterizing with field-emission scanning electron microscopy (FE-SEM) the surface and the internal microstructures of MEAs after durability tests, we find that the catalyst layers modified by PTFE experience much less reduction in porosity and less agglomeration of the solid components. These findings elucidate the microscopic mechanisms by which hydrophobicity promotes a more stable catalyst layer structure, thereby enhancing the durability of APEFCs. This research advances our understanding of hydrophobicity's impact on catalyst layer stability and offers a practical method to enhance the durability of APEFCs.

Boosting Bulk Oxygen Transport with Accessible Electrode Nanostructure in Low Pt Loading PEMFCs

Despite the high potential for reducing carbon emissions and contributing to the future of energy utilization, polymer electrolyte membrane fuel cells (PEMFCs) face challenges such as high costs and sluggish oxygen transport in cathode catalyst layers (CCLs). In this study, the impact of pore size distribution on bulk oxygen transport behavior is explored by introducing nano calcium carbonate of varying particle sizes for pore-forming. Physicochemical characterizations for are employed to examine the electrode structure, while in situ electrochemical measurements are used to scrutinize bulk oxygen transport resistance, effective oxygen diffusivity (D O 2 eff $D_{{{\mathrm{O}}}_2}^{{\mathrm{eff}}}$ ) and fuel cell performance. Additionally, the CCLs are constructed with aid of Lattice Boltzmann method (LBM) simulations andD O 2 eff $D_{{{\mathrm{O}}}_2}^{{\mathrm{eff}}}$ for CCLs with different pore size distribution are calculated. The findings reveal thatD O 2 eff $D_{{{\mathrm{O}}}_2}^{{\mathrm{eff}}}$ initially increases and then decreases as the most probable pore size increases. A "sphere-pipe" model is proposed to describe practical bulk oxygen transport in CCLs, highlighting the significant role of not only the pore size of secondary pores but also the number of primary pores in bulk oxygen transport.

Anion Exchange Ionomers: Design Considerations and Recent Advances - An Electrochemical Perspective

Alkaline-based electrochemical devices, such as anion exchange membrane (AEM) fuel cells and electrolyzers, are receiving increasing attention. However, while the catalysts and membrane are methodically studied, the ionomer is largely overlooked. In fact, most of the studies in alkaline electrolytes are conducted using the commercial proton exchange ionomer Nafion. The ionomer provides ionic conductivity; it is also essential for gas transport and water management, as well as for controlling the mechanical stability and the morphology of the catalyst layer. Moreover, the ionomer has distinct requirements that differ from those of anion-exchange membranes, such as a high gas permeability, and that depend on the specific electrode, such as water management. As a result, it is necessary to tailor the ionomer structure to the specific application in isolation and as part of the catalyst layer. In this review, an overview of the current state of the art for anion exchange ionomers is provided, summarizing their specific requirements and limitations in the context of AEM electrolyzers and fuel cells.

The Application of a Self-Made Integrated Three-in-One Microsensor and Commercially Available Wind Speed Sensor to the Cold Air Pipe of the Heating, Ventilation, and Air Conditioning in a Factory for Real-Time Wireless Measurement

In this study, the integrated three-in-one (temperature, humidity, and wind speed) microsensor was made through the technology of the Micro-electro-mechanical Systems (MEMS) to measure three important physical quantities of the internal environment of the cold air pipe of the Heating, Ventilation and Air Conditioning (HVAC) in the factory, plan the installation positions of the integrated three-in-one microsensor and commercially available wind speed sensor required by the internal environment of the cold air pipe, and conduct the actual 310-h long term test and comparison. In the experiment, it was also observed that the self-made micro wind speed sensor had higher stability compared to the commercially available wind speed sensor (FS7.0.1L.195). The self-made micro wind speed sensor has a variation range of ±200 mm/s, while the commercially available wind speed sensor a variation range of ±1000 mm/s. The commercially available wind speed sensor (FS7.0.1L.195) can only measure the wind speed; however, the self-made integrated three-in-one microsensor can conduct real-time measurements of temperature and humidity according to the environment at that time, and use different calibration curves to know the wind speed. As a result, it is more accurate and less costly than commercially available wind speed sensors. The material cost of self-made integrated three-in-one microsensor includes chemicals, equipment usage fees, and wires. In the future, factories may install a large number of self-made integrated three-in-one microsensors in place of commercially available wind speed sensors. Through real-time wireless measurements, the self-made integrated three-in-one microsensors can achieve the control optimization of the HVAC cold air pipe's internal environment to improve the quality of manufactured materials.

High-Pressure-Resistant Flexible Seven-in-One Microsensor Embedded in High-Pressure Proton Exchange Membrane Water Electrolyzer for Real-Time Microscopic Measurement

The high-pressure proton exchange membrane water electrolyzer (PEMWE) used for hydrogen production requires a high-operating voltage, which easily accelerates the decomposition of hydrogen molecules, resulting in the aging or failure of the high-pressure PEMWE. As the high-pressure PEMWE ages internally, uneven flow distribution can lead to large temperature differences, reduced current density, flow plate corrosion, and carbon paper cracking. In this study, a new type of micro hydrogen sensor is developed with integrated flexible seven-in-one (voltage; current; temperature; humidity; flow; pressure; and hydrogen) microsensors.

3D-Zipped Interface: In Situ Covalent-Locking for High Performance of Anion Exchange Membrane Fuel Cells

Polymer electrolyte membrane fuel cells can generate high power using a potentially green fuel (H2 ) and zero emissions of greenhouse gas (CO2 ). However, significant mass transport resistances in the interface region of the membrane electrode assemblies (MEAs), between the membrane and the catalyst layers remains a barrier to achieving MEAs with high power densities and long-term stabilities. Here, a 3D-interfacial zipping concept is presented to overcome this challenge. Vinylbenzyl-terminated bi-cationic quaternary-ammonium-based polyelectrolyte is employed as both the anionomer in the anion-exchange membrane (AEM) and catalyst layers. A quaternary-ammonium-containing covalently locked interface is formed by thermally induced inter-crosslinking of the terminal vinyl groups. Ex situ evaluation of interfacial bonding strength and in situ durability tests demonstrate that this 3D-zipped interface strategy prevents interfacial delamination without any sacrifice of fuel cell performance. A H2 /O2 AEMFC test demonstration shows promisingly high power densities (1.5 W cm-2 at 70 °C with 100% RH and 0.2 MPa backpressure gas feeds), which can retain performances for at least 120 h at a usefully high current density of 0.6 A cm-2 .

Recent Advances in Alkaline Exchange Membrane Water Electrolysis and Electrode Manufacturing

Water electrolysis to obtain hydrogen in combination with intermittent renewable energy resources is an emerging sustainable alternative to fossil fuels. Among the available electrolyzer technologies, anion exchange membrane water electrolysis (AEMWE) has been paid much attention because of its advantageous behavior compared to other more traditional approaches such as solid oxide electrolyzer cells, and alkaline or proton exchange membrane water electrolyzers. Recently, very promising results have been obtained in the AEMWE technology. This review paper is focused on recent advances in membrane electrode assembly components, paying particular attention to the preparation methods for catalyst coated on gas diffusion layers, which has not been previously reported in the literature for this type of electrolyzers. The most successful methodologies utilized for the preparation of catalysts, including co-precipitation, electrodeposition, sol-gel, hydrothermal, chemical vapor deposition, atomic layer deposition, ion beam sputtering, and magnetron sputtering deposition techniques, have been detailed. Besides a description of these procedures, in this review, we also present a critical appraisal of the efficiency of the water electrolysis carried out with cells fitted with electrodes prepared with these procedures. Based on this analysis, a critical comparison of cell performance is carried out, and future prospects and expected developments of the AEMWE are discussed.

Recent Insights on Catalyst Layers for Anion Exchange Membrane Fuel Cells

Anion exchange membrane fuel cells (AEMFCs) performance have significantly improved in the last decade (>1 W cm-2 ), and is now comparable with that of proton exchange membrane fuel cells (PEMFCs). At high current densities, issues in the catalyst layer (CL, composed of catalyst and ionomer), like oxygen transfer, water balance, and microstructural evolution, play important roles in the performance. In addition, CLs for AEMFCs have different requirements than for PEMFCs, such as chemical/physical stability, reaction mechanism, and mass transfer, because of different conductive media and pH environment. The anion exchange ionomer (AEI), which is the soluble or dispersed analogue of the anion exchange membrane (AEM), is required for hydroxide transport in the CL and is normally handled separately with the electrocatalyst during the electrode fabrication process. The importance of the AEI-catalyst interface in maximizing the utilization of electrocatalyst and fuel/oxygen transfer process must be carefully investigated. This review briefly covers new concepts in the complex AEMFC catalyst layer, before a detailed discussion on advances in CLs based on the design of AEIs and electrocatalysts. The importance of the structure-function relationship is highlighted with the aim of directing the further development of CLs for high-performance AEMFC.

Designing the next generation of proton-exchange membrane fuel cells

With the rapid growth and development of proton-exchange membrane fuel cell (PEMFC) technology, there has been increasing demand for clean and sustainable global energy applications. Of the many device-level and infrastructure challenges that need to be overcome before wide commercialization can be realized, one of the most critical ones is increasing the PEMFC power density, and ambitious goals have been proposed globally. For example, the short- and long-term power density goals of Japan's New Energy and Industrial Technology Development Organization are 6 kilowatts per litre by 2030 and 9 kilowatts per litre by 2040, respectively. To this end, here we propose technical development directions for next-generation high-power-density PEMFCs. We present the latest ideas for improvements in the membrane electrode assembly and its components with regard to water and thermal management and materials. These concepts are expected to be implemented in next-generation PEMFCs to achieve high power density.