Analysis of Low Platinum Loading Thin Polymer Electrolyte Fuel Cell Electrodes Prepared by Inkjet Printing

Structure, Property, and Performance of Catalyst Layers in Proton Exchange Membrane Fuel Cells

Catalyst layer (CL) is the core component of proton exchange membrane (PEM) fuel cells, which determines the performance, durability, and cost. However, difficulties remain for a thorough understanding of the CLs' inhomogeneous structure, and its impact on the physicochemical and electrochemical properties, operating performance, and durability. The inhomogeneous structure of the CLs is formed during the manufacturing process, which is sensitive to the associated materials, composition, fabrication methods, procedures, and conditions. The state-of-the-art visualization and characterization techniques are crucial to examine the CL structure. The structure-dependent physicochemical and electrochemical properties are then thoroughly scrutinized in terms of fundamental concepts, theories, and recent progress in advanced experimental techniques. The relation between the CL structure and the associated effective properties is also examined based on experimental and theoretical findings. Recent studies indicated that the CL inhomogeneous structure also strongly affects the performance and degradation of the whole fuel cell, and thus, the interconnection between the fuel cell performance, failure modes, and CL structure is comprehensively reviewed. An analytical model is established to understand the effect of the CL structure on the effective properties, performance, and durability of the PEM fuel cells. Finally, the challenges and prospects of the CL structure-associated studies are highlighted for the development of high-performing PEM fuel cells.

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Spectroscopic Investigation of Catalyst Inks and Thin Films Toward the Development of Ionomer Quality Control

As the production of polymer electrolyte fuel cells expands, novel quality control methods must be invented or adapted in order to support expected rates of production. Ensuring the quality of deposited catalyst layers is an essential step in the fuel cell manufacturing process, as the efficiency of a fuel cell is reliant on the catalyst layer being uniform at both the target platinum loading and the target ionomer content. Implementing a quality control method that is sensitive to these aspects is imperative, as wasting precious metals and other catalyst materials is expensive, and represents a potential barrier to entry into the field for manufacturers experimenting with novel deposition processes. In this work, we analyzed catalyst inks to determine if their ionomer content could be quantized spectroscopically. Attenuated total reflection (ATR) Fourier transform infrared spectroscopic technique was investigated producing a signal proportional to the ionomer content. ATR spectroscopy was able to quantitatively differentiate samples in which the ionomer to carbon mass ratio (I/C) varied between 0.9 and 3.0. The I/C ratio was correlated to the measured ATR signal near the CF₂ vibrational bands located between 1100 cm^-1 and 1400 cm^-1. The experimental results obtained constitute a step toward the development of novel quality control methodologies for catalyst inks utilized by the fuel cell industry.

Electrospray Deposition of Catalyst Layers with Ultralow Pt Loading for Cost-Effective H2 Production by SO2 Electrolysis

The hybrid sulfur (HyS) thermochemical cycle has been considered as a promising approach for the massive production of clean hydrogen without CO2 emissions. The key to advance this technology and to enhance the cycle efficiency is to improve the electrocatalytic oxidation of SO2, which is the pivotal reaction within this process. Hence, this paper investigates, for the first time, the effect of electrospray and air gun deposition techniques and the influence of very low Pt loadings (<0.3 mg Pt/cm2) on catalyst durability and activity. The variation of electrochemical active surface area (ECSA) with the number of cycles demonstrates the significant impact of the electrode fabrication method and catalyst loading on the catalyst durability with considerable ECSA values for electrosprayed electrodes. Electrodes prepared with low platinum loadings (0.05 mg Pt/cm2) exhibit elevated catalyst activity and stability under sulfuric acid conditions and maintain a crucial current density after 5 h of electrolysis. This work extends the understanding of the SO2-depolarized electrolysis (SDE) process and gives suggestions for further improvements in the catalyst layer fabrication, which provides potential support for the large-scale research and application of the HyS cycle.

Effect of Double-Sided 3D Patterned Cathode Catalyst Layers on Polymer Electrolyte Fuel Cell Performance

Optimization of the structure of cathode catalyst layers (CCLs) for promoting the transfer of reactants and products in polymer electrolyte fuel cells (PEFCs) is important for improving the cell performance. In this study, using theoretical equations, we confirmed that the shortened proton conduction path in the ionomer layer (IL) with a 3D-patterned structure, compared to that in the IL with a flat-patterned structure, can improve the cell performance. We experimentally investigated the effect of the IL with a 3D-patterned structure included in the CCLs on the cell performance. Based on the combination of the flat- or 3D-pattern of the IL and the catalyst layer (CL), the samples were categorized as Str. 1 (3D-patterned CL without IL), Str. 2 (flat-patterned IL and CL), Str. 3 (3D-patterned IL and flat-patterned CL), and Str. 4 (3D-patterned IL and CL). All of the samples had different morphologies. According to the I–V curves and impedance spectra data acquired at 80 °C and 40% relative humidity, Str. 4 showed superior cell performance relative to those of the other CCLs. These results indicate that the structure of Str. 4 enhanced the proton conductivity at a low humidity at which proton conduction is usually poor, thereby resulting in improved cell performance.

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.

Influence of the Catalyst Layer Structure Formed by Inkjet Coating Printer on PEFC Performance

In this study, we investigated the influence of the Catalyst-Layer (CL) structure on Polymer Electrolyte Fuel Cell (PEFC) performance using an inkjet coating printer, and we especially focused on the CL thickness and the electrode area. In order to evaluate the influence of CL thickness, we prepared four Membrane Electrode Assemblies (MEAs), which have one, four, five and six CLs, respectively, and evaluated it by an overpotential analysis. As a result, the overpotentials of an activation and a diffusion increased with the increase of thickness of CL. From Energy Dispersive X-ray spectroscopy (EDX) analysis, because platinum twines most ionomers and precipitates, the CL separates into a layer of platinum with a big grain aggregate ionomer and the mixing layer of platinum and ionomer during the catalyst ink drying process. Consequently, the activation overpotential increased because the three-phase interface was not able to be formed sufficiently. The gas diffusivity of the multilayer catalyst electrode was worse than that of a single layer MEA. The influence of the electrode area was examined by two MEAs with 1 and 9 cm² of electrode area. As a result, the diffusion overpotential of 9 cm² MEA was worse than 1 cm² MEA. The generated condensate was multiplied and moved to the downstream side, and thereafter it caused the flooding/plugging phenomena.

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.

Multigrid hierarchical simulated annealing method for reconstructing heterogeneous media

A reconstruction methodology based on different-phase-neighbor (DPN) pixel swapping and multigrid hierarchical annealing is presented. The method performs reconstructions by starting at a coarse image and successively refining it. The DPN information is used at each refinement stage to freeze interior pixels of preformed structures. This preserves the large-scale structures in refined images and also reduces the number of pixels to be swapped, thereby resulting in a decrease in the necessary computational time to reach a solution. Compared to conventional single-grid simulated annealing, this method was found to reduce the required computation time to achieve a reconstruction by around a factor of 70-90, with the potential of even higher speedups for larger reconstructions. The method is able to perform medium sized (up to 300(3) voxels) three-dimensional reconstructions with multiple correlation functions in 36-47 h.

Modification for Uniform Surface of Nafion Ultrathin Film Deposited by Inkjet Printing

A lack of knowledge about the features of Nafion confined to ultrathin films at the interface has motivated additional examinations to promote the performance of polymer electrolyte membrane fuel cells (PEMFCs). In this work, we demonstrated the utilization of practical film-forming technique inkjet printing to fabricate a Nafion ultrathin film less than 10 nm thickness. However, the well-known "coffee-ring" effect caused poor quality of the printed pattern, which has restricted its application. This report describes a systematic investigation of necessary parameters such as ink concentration, substrate type, pitch, and offset for printing processes. Furthermore, post-treatment in an ethanol vapor atmosphere exhibited a significant effect on flattening and homogenizing the film surface morphology. Results show that the well-distributed Nafion ultrathin film modified by ethanol vapor annealing manifested much-improved proton conductivity.