Effect of the Side-Chain Structure of Perfluoro-Sulfonic Acid Ionomers on the Oxygen Reduction Reaction on the Surface of Pt

Development and application of ordered membrane electrode assemblies for water electrolysis

With the development of hydrogen energy, there has been increasing attention toward fuel cells and water electrolysis. Among them, the zero-gap membrane electrode assembly (MEA) serves as an important triple-phase reaction site that determines the performance and efficiency of the reaction system. The development of efficient and durable MEAs plays a crucial role in the development of hydrogen energy. Consequently, a great deal of effort has been devoted to developing ordered MEAs that can effectively increase catalyst utilization, maximize triple-phase boundaries, enhance mass transfer and improve stability. The research progress of ordered MEAs in recent advances is highlighted, involving hydrogen fuel cells and low temperature water electrolysis technology. Firstly, the fundamental scientific understanding and structural characteristics of MEAs based on one-dimensional nanostructures such as nanowires, nanotubes and nanofibers are summarized. Then, the classification, preparation and development of ordered MEAs based on three-dimensional structures are summarized. Finally, this review presents current challenges and proposes future research on ordered MEAs and offers potential solutions to overcome these obstacles.

Spatially Confined Alloying of Pt Accelerates Mass Transport for Fuel Cell Oxygen Reduction

Pt-based alloy with high mass activity and durability is highly desired for proton exchange membrane fuel cells, yet a great challenge remains due to the high mass transport resistance near catalysts with lowering Pt loading. Herein, an extensible approach employing atomic layer deposition to accurately introduce a gas-phase metal precursor into platinum nanoparticles (NPs) pre-filled mesoporous channels is reported, achieved by controlling both the deposition site and quantity. Following the spatially confined alloying treatment, the prepared PtSn alloy catalyst within mesopores demonstrates a small size and homogeneous distribution (2.10 ± 0.53 nm). The membrane electrode assembly with mesoporous carbon-supported PtSn alloy catalyst achieves a high initial mass activity of 0.85 Amg Pt - 1 ${\mathrm{mg}}_{\mathrm{Pt}}^{-1}$ at 0.9 V, which is attributed to the smallest local oxygen transport resistance (3.68 S m-1) ever reported. The mass activity of the catalyst only decreases by 11% after 30000 cycles of accelerated durability test, representing superior full-cell durability among the reported Pt-based alloy catalysts. The enhanced activity and durability are attributed to the decreased adsorption energy of oxygen intermediates on Pt surface and the strong electronic interaction between Pt and Sn inhibiting Pt dissolution.

Unravel-engineer-design: a three-pronged approach to advance ionomer performance at interfaces in proton exchange membrane fuel cells

Proton exchange membrane fuel cells (PEMFCs), which use hydrogen as fuel, present an eco-friendly alternative to internal combustion engines (ICEs) for powering low-to-heavy-duty vehicles and various devices. Despite their promise, PEMFCs must meet strict cost, performance, and durability standards to reach their full potential. A key challenge lies in optimizing the electrode, where a thin ionomer layer is responsible for proton conduction and binding catalyst particles to the electrode. Enhancing ion transport within these sub-μm thick films is critical to improving the oxygen reduction reaction (ORR) at the cathodes of PEMFCs. For the past 15 years, our research has targeted this limitation through a comprehensive "Unravel - Engineer - Design" approach. We first unraveled the behavior of ionomers, gaining deeper insights into both the average and distributed proton conduction properties within sub-μm thick films and at interfaces that mimic catalyst binder layers. Next, we engineered ionomer-substrate interfaces to gain control over interfacial makeup and boost proton conductivity, essential for PEMFC efficiency. Finally, we designed novel nature-derived or nature-inspired, fluorine-free ionomers to tackle the ion transport limitations seen in state-of-the-art ionomers under thin-film confinement. Some of these ionomers even pave the way to address cost and sustainability challenges in PEMFC materials. This feature article highlights our contributions and their importance in advancing PEMFCs and other sustainable energy conversion and storage technologies.

Overcoming the Limitation of Ionomers on Mass Transport and Pt Activity to Achieve High-Performing Membrane Electrode Assembly

The membrane electrode assembly (MEA) is one of the critical components in proton exchange membrane fuel cells (PEMFCs). However, the conventional MEA cathode with a covered-type catalyst/ionomer interfacial structure severely limits oxygen transport efficiency and Pt activity, hardly achieving the theoretical performance upper bound of PEMFCs. Here, we design a noncovered catalyst/ionomer interfacial structure with low proton transport resistance and high oxygen transport efficiency in the cathode catalyst layer (CL). This noncovered interfacial structure employs the ionomer cross-linked carbon particles as long-range and fast proton transport channels and prevents the ionomer from directly covering the Pt/C catalyst surface in the CL, freeing the oxygen diffusion process from passing through the dense ionomer covering layer to the Pt surface. Moreover, the structure improves oxygen transport within the pores of the CL and achieves more than 20% lower pressure-independent oxygen transport resistance compared to the covered-type structure. Fuel-cell diagnostics demonstrate that the noncovered catalyst/ionomer interfacial structure provides exceptional fuel-cell performance across the kinetic and mass transport-limited regions, with 77% and 67% higher peak power density than the covered-type interfacial structure under 0 kPagauge of oxygen and air conditions, respectively. This alternative interfacial structure provides a new direction for optimizing the electrode structure and improving mass-transport paths of MEA.

Influence of the Pt/ionomer/water interface on the oxygen reduction reaction: insights into the micro-three-phase interface

Understanding the Pt/ionomer/water interface structure and its impact on the oxygen reduction reaction (ORR) activity is essential for enhancing catalyst utilization and performance of fuel cells. This study aimed to investigate the influence of sulfonic acid groups on the Pt/ionomer/water interface and the ORR mechanism. By using a combination of DFT, AIMD, and microkinetic simulations, the results showed that when the sulfonic acid group is located at the edge of the Helmholtz plane, it creates an optimal three-phase interface, providing more available active sites, a stronger interfacial electric field, and a more continuous H-bond network. This configuration results in the *OOH dissociation becoming the rate-determining step, demonstrating significantly higher intrinsic ORR activity with a much lower theoretical overpotential of 0.11 V. Conversely, when the sulfonic acid group is in contact with the Pt surface, it causes the Pt surface's d-band center to shift down, weakens the interfacial electric field, and disrupts the H-bond network, resulting in a blocking effect on the ORR with an overpotential of 0.23 V. These insights shed light on the role of solid-solid-liquid interfaces in the ORR performance and provide valuable information for the rational design of catalyst interfaces.

Evolution of the network structure and voltage loss of anode electrode with the polymeric dispersion in PEM water electrolyzer

Exploring the intrinsic relationship between the network structure and the performance of catalyst layer (CL) by rational design its structure is of paramount importance for proton exchange membrane (PEM) electrolyzers. This study reveals the relative effect of polymeric dispersion evolution on oxygen evolution reaction (OER) performance and cell voltage loss and linked to CL network structure. The results show that although the dispersed particle size of the ionomer and ink increases with increasing the solubility parameter (δ) difference between the mixed solvent and the ionomer, MeOH-cat (ink from MeOH aqueous solution) has the largest ionomer and ink particle size resulting in the poorest stability, but has comparable OER overpotential to that of IPA-cat (249 mV@10 mA cm-2), which has the smallest dispersed size. While at 100 mA cm-2, the overpotential of the ink rises as the particle size increases, suggesting that the electrode structure becomes more influential as the current density increases. Quantitatively analyzed the electrolyzers' voltage losses and determined that the CL from MeOH-cat has the lowest kinetic overpotential. However, its performance is the worst because of the insufficient network structure of CL, resulting in an output of 1.96 V at 1.5 A cm-2. Comparatively, the CL from IPA-cat has the highest kinetic overpotential yet can achieve the greatest performance of 1.76 V at 2 A cm-2 due to its homogeneous network structure and optimal mass transport. Furthermore, the performance variation becomes more pronounced as current density rises. Hence, this study highlights the significant impact of CL structure on electrolyzer's performance. To improve performance in PEM water electrolysis technology, especially for large work current density, it is crucial to enhance the CL's network structure.

Resolving optimal ionomer interaction in fuel cell electrodes via operando X-ray absorption spectroscopy

To bridge the gap between oxygen reduction electrocatalysts development and their implementation in real proton exchange membrane fuel cell electrodes, an important aspect to be understood is the interaction between the carbon support, the active sites, and the proton conductive ionomer as it greatly affects the local transportations to the catalyst surface. Here we show that three Pt/C catalysts, synthesized using the polyol method with different carbon supports (low surface area Vulcan, high surface area Ketjenblack, and biomass-derived highly ordered mesoporous carbon), revealed significant variations in ionomer-catalyst interactions. The Pt/C catalysts supported on ordered mesoporous carbon derived from biomass showed the best performance under the gas diffusion electrode configuration. Through a unique approach of operando X-ray Absorption Spectroscopy combined with gas sorption analysis, we were able to demonstrate the beneficial effect of mesopore presence for optimal ionomer-catalyst interaction at both molecular and structural level.

Ionomer and Membrane Designs for Low-temperature CO2 and CO Electrolysis

Low-temperature electroreduction of CO2 and CO (CO(2)RR) into valuable chemicals and fuels offers a promising pathway to reduce greenhouse gas emissions and achieve carbon neutrality. Today's low-temperature CO(2)RR technology relies on the use of ionomers, polymers with ionized groups, primarily as catalyst layer (CL) additives. In the meantime, ionomers can assemble into ion-exchange membranes (IEMs), serving as important components of electrolyzers. According to the ion-exchange functions, ionomer additives are classified as cation-exchange ionomers (CEIs) and anion-exchange ionomers (AEIs); similarly, IEMs are divided into cation-exchange membranes (CEMs) and anion-exchange membranes (AEMs), as well as the multilayer polymer electrolytes (MPEs). Recent studies show that ionomer additives can regulate the catalytic microenvironment and thereby enhance performance towards desired products. This Review discusses the roles of ionomer additives and IEMs in CO2 and CO reduction reactions, highlighting the latest mechanistic insights and performance advances. It outlines challenges in designing ionomer additives and IEMs to improve product selectivity, energy efficiency (EE), and operational lifetime of CO(2)RR electrolyzers, while also providing perspectives on future research directions. The aim is to connect the current status of ionomer and membrane development with performance metrics analysis, offering insights for the advancement of commercially relevant low-temperature CO(2)RR electrolyzers.

Transport-Friendly Microstructure in SSC-MEA: Unveiling the SSC Ionomer-Based Membrane Electrode Assemblies for Enhanced Fuel Cell Performance

The significant role of the cathodic binder in modulating mass transport within the catalyst layer (CL) of fuel cells is essential for optimizing cell performance. This investigation focuses on enhancing the membrane electrode assembly (MEA) through the utilization of a short-side-chain perfluoro-sulfonic acid (SSC-PFSA) ionomer as the cathode binder, referred to as SSC-MEA. This study meticulously visualizes the distinctive interpenetrating networks of ionomers and catalysts, and explicitly clarifies the triple-phase interface, unveiling the transport-friendly microstructure and transport mechanisms inherent in SSC-MEA. The SSC-MEA exhibits advantageous microstructural features, including a better-connected ionomer network and well-organized hierarchical porous structure, culminating in superior mass transfer properties. Relative to the MEA bonded by long-side-chain perfluoro-sulfonic acid (LSC-PFSA) ionomer, noted as LSC-MEA, SSC-MEA exhibits a notable peak power density (1.23 W cm-2), efficient O2 transport, and remarkable proton conductivity (65% improvement) at 65 °C and 70% relativity humidity (RH). These findings establish crucial insights into the intricate morphology-transport-performance relationship in the CL, thereby providing strategic guidance for developing highly efficient MEA.

Oxygen- and proton-transporting open framework ionomer for medium-temperature fuel cells

Medium-temperature proton exchange membrane fuel cells (MT PEMFCs) operating at 100° to 120°C have improved kinetics, simplified thermal and water management, and broadened fuel tolerance compared with low-temperature PEMFCs. However, high temperatures lead to Nafion ionomer dehydration and exacerbate gas transportation limitations. Inspired by osmolytes found in hyperthermophiles, we developed α-aminoketone-linked covalent organic framework (COF) ionomers, interwoven with Nafion, to act as "breathable" proton conductors. This approach leverages synergistic hydrogen bonding to retain water, enhancing hydration and proton transport while reducing oxygen transport resistance. For commercial Pt/C, the MT PEMFCs achieved peak and rated power densities of 18.1 and 9.5 Watts per milligram of Pt at the cathode at 105°C fueled with H2 and air, marking increases of 101 and 187%, respectively, compared with cells lacking the COF.

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.

Boosting Oxygen Reduction at Pt(111)|Proton Exchange Ionomer Interfaces through Tuning the Microenvironment Water Activity

A proton exchange ionomer is one of the most important components in membrane electrode assemblies (MEAs) of polymer electrolyte membrane fuel cells (PEMFCs). It acts as both a proton conductor and a binder for nanocatalysts and carbon supports. The structure and the wetting conditions of the MEAs have a great impact on the microenvironment at the three-phase interphases in the MEAs, which can significantly influence the electrode kinetics such as the oxygen reduction reaction (ORR) at the cathode. Herein, by using the Pt(111)|X ionomer interface as a model system (X = Nafion, Aciplex, D72), we find that higher drying temperature lowers the onset potential for sulfonate adsorption and reduces apparent ORR current, while the current wave for OHad formation drops and shifts positively. Surprisingly, the intrinsic ORR activity is higher after properly correcting the blocking effect of Pt active sites by sulfonate adsorption and the poly(tetrafluoroethylene) (PTFE) skeleton. These results are well explained by the reduced water activity at the interfaces induced by the ionomer/PTFE, according to the mixed potential effect. Implications for how to prepare MEAs with improved ORR activity are provided.

Potential-Dependent Ionomer Rearrangement on the Pt Surface in Polymer Electrolyte Membrane Fuel Cells

The interface between the catalyst and the ionomer in the catalyst layer of polymer electrolyte membrane fuel cells (PEMFCs) has been a subject of keen interest, but its effect on durability has not been fully understood due to the complexity of the catalyst layer structure. Herein, we utilize a Pt nanoparticle (NP) array electrode fabricated using a block copolymer template as the platform for a focused investigation of the interfacial change between the Nafion thin film and the Pt NP under a constant potential. A set of analyses for the electrodes treated with various potentials reveals that the Nafion thin film becomes densely packed at the intermediate potentials (0.4 and 0.7 V), indicating an increased ionomer-catalyst interaction due to the positive charges formed at the Pt surface at these potentials. Even for a practical PEMFC single cell, we demonstrate that the potential holding at the intermediate potentials increases ionomer adsorption to the Pt surface and the oxygen transport resistance, negatively impacting its power performance. This work provides fresh insight into the mechanism behind the performance fade in PEMFCs caused by potential-dependent ionomer rearrangement.

Comprehensive Molecular Dynamics Study of Oxygen Diffusion in Carbon Mesopores: Insights for Designing Fuel-Cell Catalyst Supports

Mesoporous carbon is often used as a support for platinum catalysts in polymer electrolyte fuel-cell catalyst layers. Mesopores in the carbon support improve the performance of fuel cells by inhibiting the adsorption of ionomer onto the catalyst particles. However, the mesopores may impair mass transport. Hence, understanding molecular behaviors in the pores is essential to optimizing the mesopore structures. Specifically, it is crucial to understand the oxygen transport in the high-current region. In this study, the diffusion coefficients of oxygen molecules in carbon mesopores were calculated for various pore lengths, pore diameters, filling rates, and water contents in the ionomer via molecular dynamics simulations. The results show that oxygen diffusion slows by 2 orders of magnitude because of pore occlusion, and it slows down by an additional 1 or 2 orders of magnitude if ionomers are present in the pores. The occlusion can be theoretically predicted by considering the surface free energy. This theory provides some insight into mesoporous carbon designs; for instance, the theory suggests that narrow pores should be shortened to prevent occlusion. Slow diffusion in the presence of ionomers was attributed to the localization of oxygen at the dense ionomer-carbon interface. Thus, to improve oxygen transport properties, carbon surfaces and ionomer structures may be designed in such a manner as to prevent densification at the interface.

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.

Materials Strategies Tackling Interfacial Issues in Catalyst Layers of Proton Exchange Membrane Fuel Cells

The most critical challenge for the large-scale commercialization of proton exchange membrane fuel cells (PEMFCs), one of the primary hydrogen energy technologies, is to achieve decent output performance with low usage of platinum (Pt). Currently, the performance of PEMFCs is largely limited by two issues at the catalyst/ionomer interface, specifically, the poisoning of active sites of Pt by sulfonate groups and the extremely sluggish local oxygen transport toward Pt. In the past few years, emerging strategies are derived to tackle these interface problems through materials optimization and innovation. This perspective summarizes the latest advances in this regard, and in the meantime unveils the molecule-level mechanisms behind the materials modulation of interfacial structures. This paper starts with a brief introduction of processes and structures of catalyst/ionomer interfaces, which is followed by a detailed review of progresses in key materials toward interface optimization, including catalysts, ionomers, and additives, with particular emphasis on the role of materials structure in regulating the intermolecular interactions. Finally, the challenges for the application of the established materials and research directions to broaden the material library are highlighted.

Effect of Blended Perfluorinated Sulfonic Acid Ionomer Binder on the Performance of Catalyst Layers in Polymer Electrolyte Membrane Fuel Cells

In this study, blended perfluorinated sulfonic acid (PFSA) ionomers with equivalent weights (EWs, g/mol) of ~1000, 980, and 830 are prepared. Catalyst layers (CLs), using blended PFSA ionomers, with different side chain lengths and EWs are investigated and compared to CLs using single ionomers. The ion exchange capacity results confirm that blended ionomers have the target EWs. As a result, blended ionomers exhibit higher ion conductivity than single ionomers at all temperatures due to the higher water uptake of the blended ionomers. This implies that blended ionomers have a bulk structure to form a competent free volume compared to single ionomers. Blended ionomers with short side chains and low EWs can help reduce the activation energy in proton conduction due to enhanced hydrophobic and hydrophilic segregation. In addition, when using the blended ionomer, the CLs form a more porous microstructure to help reduce the resistance of oxygen transport and contributes to lower mass transfer loss. This effect is proven in fuel cell operations at not a lower temperature (70 °C) and full humidification (100%) but at an elevated temperature (80 °C) and lower relative humidity (50 and 75%). Blended ionomer-based CLs with a higher water uptake and porous CL structure result in improved fuel cell performance with better mass transport than single ionomer-based CLs.

Investigation of Effect of Platinum Nanoparticle Shape on Oxygen Transport in PEMFC Catalyst Layer Using Molecular Dynamics Simulation

For the widespread adoption of polymer electrolyte membrane fuel cells, it is compelling to investigate the influence of the Pt nanoparticle shapes on the electrocatalytic activity. In this study, a catalyst layer was modeled by incorporating four types of Pt nanoparticles: tetrahedron, cube, octahedron, and truncated octahedron, to investigate the relationship between the shapes of the nanoparticles and their impact on the oxygen transport properties using molecular dynamics simulations. The results of our study reveal that the free volume, which has a substantial impact on the oxygen transport properties, exhibited higher values in the sequence of the tetrahedron, cube, octahedron, and truncated octahedron model. The difference in free volume following the formation of less dense ionomers was also related to the surface adsorption of Pt nanoparticles. Consequently, this led to an improved facilitation of oxygen transport. To clarify the dependence of the oxygen transport on the shape of the Pt nanoparticles in detail, we analyzed the structural properties of different Pt shapes by dividing the Pt nanoparticle regions into corners, edges, and facets. Examination of the structural properties showed that the structure of the ionomer depended not only on the shape of the Pt nanoparticles but also on the number of corners and edges in the upper and side regions of the Pt nanoparticles.

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.

Alternative and facile production pathway towards obtaining high surface area PtCo/C intermetallic catalysts for improved PEM fuel cell performance

The design of catalysts with stable and finely dispersed platinum or platinum alloy nanoparticles on the carbon support is key in controlling the performance of proton exchange membrane (PEM) fuel cells. In the present work, an intermetallic PtCo/C catalyst is synthesized via double-passivation galvanic displacement. TEM and XRD confirm a significantly narrowed particle size distribution for the catalyst particles compared to commercial benchmark catalysts (Umicore PtCo/C). Only about 10% of the mass fraction of PtCo particles show a diameter larger than 8 nm, whereas this is up to or even more than 35% for the reference systems. This directly results in a considerable increase in electrochemically active surface area (96 m² g^-1 vs. >70 m² g^-1), which confirms the more efficient usage of precious catalyst metal in the novel catalyst. Single-cell tests validate this finding by improved PEM fuel cell performance. Reducing the cathode catalyst loading from 0.4 mg cm^-2 to 0.25 mg cm^-2 resulted in a power density drop at an application-relevant 0.7 V of only 4% for the novel catalyst, compared to the 10% and 20% for the commercial benchmarks reference catalysts.

Interfacial Distribution of Nafion Ionomer Thin Films on Nitrogen-Modified Carbon Surfaces

Chemically modified carbon supports for the cathode catalyst layers of polymer electrolyte fuel cells (PEFCs) show considerable promise for boosting the oxygen reduction reaction. This study evaluated the ionomer distribution of Nafion ionomer thin films on nitrogen (N)-modified carbon surfaces along their depth direction. Neutron reflectivity (NR) measurements performed using the double-contrast technique with H2O and D2O revealed that the introduction of N functional groups to carbon thin films promoted ionomer adsorption onto the surface under wet conditions (22 °C, 85% relative humidity). Molecular dynamics (MD) simulations conducted to verify the origin of the robust contact between the ionomer and N-modified carbon surface revealed an ionomer adsorption mechanism on the N-modified carbon surfaces, which involved Coulomb interactions between the positively charged carbon surface and the ionomer side chains with negatively charged sulfonic acid groups. The positive surface charge, which was determined using the contents of the N functional groups estimated by X-ray photoelectron spectroscopy, was found to be sufficient as an impetus for ionomer adsorption. This strategy involving NR measurements and MD simulations can provide insights into the solid-ionomer interfacial structures in a cathode catalyst layer and can therefore be extensively employed in studies on PEFCs.

Humidity-Dependent Hydration and Proton Conductivity of PFSA Ionomer Thin Films at Fuel-Cell-Relevant Temperatures: Effect of Ionomer Equivalent Weight and Side-Chain Characteristics

Studies on the hydration properties, proton conductivity, and water content of perfluorinated ionomer thin films at temperatures relevant to fuel cell operation temperatures (around 80 °C) and the effect of ionomer chemistry are scarce. In this work, we report the water content and proton conductivity properties of thin-film ionomers (30 nm) at 80 °C over a wide range of relative humidity (0-90%) for seven different ionomers differing in the side-chain structure, including the number of protogenic groups, with the equivalent weight ranging from 620 to 1100 g/mol of sulfonic acid. The results show that the acid content or equivalent weight of the ionomer is the strongest determinant of both the swelling and the proton conductivity of ionomer films at a given relative humidity. The molar water content (λ) of ionomer films normalized to the molar protogenic group is observed to be equivalent-weight-dependent, implying that the affinity for water is acid-content-dependent. At high relative humidity conditions (>70%) pertinent to fuel cell operations, the proton conductivity of low-equivalent-weight ionomers was higher than that of higher-equivalent-weight ionomers. However, upon correlating the proton conductivity with molar water content (λ), the differences reduce dramatically, highlighting that water content is the controlling factor for proton conduction. Significantly higher values of both water content and proton conductivity are observed at 80 °C compared to those at 30 °C, implying that room temperature data are not reliable for estimating ionomer properties in the fuel cell catalyst layer.

Covalent organic framework-based porous ionomers for high-performance fuel cells

Lowering platinum (Pt) loadings without sacrificing power density and durability in fuel cells is highly desired yet challenging because of the high mass transport resistance near the catalyst surfaces. We tailored the three-phase microenvironment by optimizing the ionomer by incorporating ionic covalent organic framework (COF) nanosheets into Nafion. The mesoporous apertures of 2.8 to 4.1 nanometers and appendant sulfonate groups enabled the proton transfer and promoted oxygen permeation. The mass activity of Pt and the peak power density of the fuel cell with Pt/Vulcan (0.07 mg of Pt per square centimeter in the cathode) both reached 1.6 times those values without the COF. This strategy was applied to catalyst layers with various Pt loadings and different commercial catalysts.

Impact of Carbon N-Doping and Pyridinic-N Content on the Fuel Cell Performance and Durability of Carbon-Supported Pt Nanoparticle Catalysts

Cathode catalyst layers of proton exchange membrane fuel cells (PEMFCs) typically consist of carbon-supported platinum catalysts with varying weight ratios of proton-conducting ionomers. N-Doping of carbon support materials is proposed to enhance the performance and durability of the cathode layer under operating conditions in a PEMFC. However, a detailed understanding of the contributing N-moieties is missing. Here, we report the successful synthesis and fuel cell implementation of Pt electrocatalysts supported on N-doped carbons, with a focus on the analysis of the N-induced effect on catalyst performance and durability. A customized fluidized bed reduction reactor was used to synthesize highly monodisperse Pt nanoparticles deposited on N-doped carbons (N-C), the catalytic oxygen reduction reaction activity and stability of which matched those of state-of-the-art PEMFC catalysts. Operando high-energy X-ray diffraction experiments were conducted using a fourth generation storage ring; the light of extreme brilliance and coherence allows investigating the impact of N-doping on the degradation behavior of the Pt/N-C catalysts. Tests in liquid electrolytes were compared with tests in membrane electrode assemblies in single-cell PEMFCs. Our analysis refines earlier views on the subject of N-doped carbon catalyst supports: it provides evidence that heteroatom doping and thus the incorporation of defects into the carbon backbone do not mitigate the carbon corrosion during high-potential cycling (1-1.5 V) and, however, can promote the cell performance under usual PEMFC operating conditions (0.6-0.9 V).

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.

Lens-Shaped Carbon Particles with Perpendicularly-Oriented Channels for High-Performance Proton Exchange Membrane Fuel Cells

Two-dimensional sheet-like mesoporous carbon particles are promising for maximizing the number of active sites and the mass transport efficiency of proton exchange membrane fuel cells (PEMFCs). Herein, we develop a series of lens-shaped mesoporous carbon (LMC) particles with perpendicularly oriented channels (diameter = 60 nm) and aspect ratios (ARs) varying from 2.1 to 6.2 and apply them for the fabrication of highly efficient PEMFCs. The membrane emulsification affords uniform-sized, lens-shaped block copolymer particles, which are successfully converted into the LMC particles with well-ordered vertical channels through hyper-cross-linking and carbonization steps. Then, an ultralow amount (1 wt %) of platinum (Pt) is loaded into the particles. The LMC particles with higher ARs are packed with a higher density in the cathode and are better aligned on the cathode surface compared to the LMC particles with lower ARs. Thus, the well-ordered channels in the particles facilitate the mass transport of the reactants and products, significantly increasing the PEMFC performance. For example, the LMC particles with the AR of 6.2 show the highest initial single cell performance of 1135 mW cm^-2, and the cell exhibits high durability with 1039 mW cm^-2 even after 30 000 cycles. This cell performance surpasses that of commercial Pt/C catalysts, even at 1/20 of the Pt loading.

Acid anion electrolyte effects on platinum for oxygen and hydrogen electrocatalysis

Platinum is an important material with applications in oxygen and hydrogen electrocatalysis. To better understand how its activity can be modulated through electrolyte effects in the double layer microenvironment, herein we investigate the effects of different acid anions on platinum for the oxygen reduction/evolution reaction (ORR/OER) and hydrogen evolution/oxidation reaction (HER/HOR) in pH 1 electrolytes. Experimentally, we see the ORR activity trend of HClO4 > HNO3 > H2SO4, and the OER activity trend of HClO4 [Formula: see text] HNO3 ∼ H2SO4. HER/HOR performance is similar across all three electrolytes. Notably, we demonstrate that ORR performance can be improved 4-fold in nitric acid compared to in sulfuric acid. Assessing the potential-dependent role of relative anion competitive adsorption with density functional theory, we calculate unfavorable adsorption on Pt(111) for all the anions at HER/HOR conditions while under ORR/OER conditions [Formula: see text] binds the weakest followed by [Formula: see text] and [Formula: see text]. Our combined experimental-theoretical work highlights the importance of understanding the role of anions across a large potential range and reveals nitrate-like electrolyte microenvironments as interesting possible sulfonate alternatives to mitigate the catalyst poisoning effects of polymer membranes/ionomers in electrochemical systems. These findings help inform rational design approaches to further enhance catalyst activity via microenvironment engineering.

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.

Preparation, Performance and Challenges of Catalyst Layer for Proton Exchange Membrane Fuel Cell

In this paper, the composition, function and structure of the catalyst layer (CL) of a proton exchange membrane fuel cell (PEMFC) are summarized. The hydrogen reduction reaction (HOR) and oxygen reduction reaction (ORR) processes and their mechanisms and the main interfaces of CL (PEM|CL and CL|MPL) are described briefly. The process of mass transfer (hydrogen, oxygen and water), proton and electron transfer in MEA are described in detail, including their influencing factors. The failure mechanism of CL (Pt particles, CL crack, CL flooding, etc.) and the degradation mechanism of the main components in CL are studied. On the basis of the existing problems, a structure optimization strategy for a high-performance CL is proposed. The commonly used preparation processes of CL are introduced. Based on the classical drying theory, the drying process of a wet CL is explained. Finally, the research direction and future challenges of CL are pointed out, hoping to provide a new perspective for the design and selection of CL materials and preparation equipment.

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.

Advancements in cathode catalyst and cathode layer design for proton exchange membrane fuel cells

Proton exchange membrane fuel cells have been recently developed at an increasing pace as clean energy conversion devices for stationary and transport sector applications. High platinum cathode loadings contribute significantly to costs. This is why improved catalyst and support materials as well as catalyst layer design are critically needed. Recent advances in nanotechnologies and material sciences have led to the discoveries of several highly promising families of materials. These include platinum-based alloys with shape-selected nanostructures, platinum-group-metal-free catalysts such as metal-nitrogen-doped carbon materials and modification of the carbon support to control surface properties and ionomer/catalyst interactions. Furthermore, the development of advanced characterization techniques allows a deeper understanding of the catalyst evolution under different conditions. This review focuses on all these recent developments and it closes with a discussion of future research directions in the field.

The high platinum loadings at the cathodes of proton exchange membrane fuel cells significantly contribute to the cost of these clean energy conversion devices. Here, the authors critically review and discuss recent developments on low- and non-platinum-based cathode catalysts and catalyst layers.

The Activity Enhancement Effect of Ionic Liquids on Oxygen Reduction Reaction Catalysts: From Rotating Disk Electrode to Membrane Electrode Assembly

Ionic liquids (ILs) have been explored as a surface modification strategy to promote the oxygen reduction reaction (ORR) on Pt/C and their chemical structures were identified to have strong influence on the ORR activities. To better understand the roles of anion and cation of ILs on the catalytic reaction, two cations ([MTBD]+ and [bmim]+) were paired with three anions ([TFSI]−, [beti]−, and [C4F9SO3]−) to form various IL structures. By systematically varying the IL combinations and studying their effects on the electrochemical behaviors, such as electrochemical surface area and specific ORR activities, it was found that cation structure had a higher influence than anion, and the impact of the [MTBD]+ series was stronger than the [bmim]+ series. In addition to the investigation in the half-cell, studies were also extended to the membrane electrode assembly (MEA). Considerable performance enhancements were demonstrated in both the kinetic region and high current density region with the aid of IL. This work suggests that IL modification can provide a complementary approach to improve the performance of proton exchange membrane fuel cells.

The role of oxygen-permeable ionomer for polymer electrolyte fuel cells

In recent years, considerable research and development efforts are devoted to improving the performance of polymer electrolyte fuel cells. However, the power density and catalytic activities of these energy conversion devices are still far from being satisfactory for large-scale operation. Here we report performance enhancement via incorporation, in the cathode catalyst layers, of a ring-structured backbone matrix into ionomers. Electrochemical characterizations of single cells and microelectrodes reveal that high power density is obtained using an ionomer with high oxygen solubility. The high solubility allows oxygen to permeate the ionomer/catalyst interface and react with protons and electrons on the catalyst surfaces. Furthermore, characterizations of single cells and single-crystal surfaces reveal that the oxygen reduction reaction activity is enhanced owing to the mitigation of catalyst poisoning by sulfonate anion groups. Molecular dynamics simulations indicate that both the high permeation and poisoning mitigation are due to the suppression of densely layered folding of polymer backbones near the catalyst surfaces by the incorporated ring-structured matrix. These experimental and theoretical observations demonstrate that ionomer's tailored molecular design promotes local oxygen transport and catalytic reactions.

Direct Integration of Strained-Pt Catalysts into Proton-Exchange-Membrane Fuel Cells with Atomic Layer Deposition

The design and fabrication of lattice-strained platinum catalysts achieved by removing a soluble core from a platinum shell synthesized via atomic layer deposition, is reported. The remarkable catalytic performance for the oxygen reduction reaction (ORR), measured in both half-cell and full-cell configurations, is attributed to the observed lattice strain. By further optimizing the nanoparticle geometry and ionomer/carbon interactions, mass activity close to 0.8 A mgPt -1 @0.9 V iR-free is achievable in the membrane electrode assembly. Nevertheless, active catalysts with high ORR activity do not necessarily lead to high performance in the high-current-density (HCD) region. More attention shall be directed toward HCD performance for enabling high-power-density hydrogen fuel cells.

Effect of Dispersion Solvents and Ionomers on the Rheology of Catalyst Inks and Catalyst Layer Structure for Proton Exchange Membrane Fuel Cells

This study investigated the effects of the dielectric constant (ε) of a dispersion solvent and ionomer content on the rheology of graphitized carbon (GC)-supported Pt catalyst ink and the structure of catalyst layers (CLs). The ionomer dispersions and catalyst inks were tested using rheological techniques, zeta (ξ) potential, and dynamic light scattering measurements. Results showed that increases in the solvent ε or ionomer content increased the ξ-potential of catalyst particles in the ink, which reduced the catalyst agglomerate size. Steady-state and oscillation scans showed that the Pt/GC catalyst ink had shear-thinning properties and gel-like behavior. The ink with a solvent ε of 40 tended to be more Newtonian fluid, with low yield stress (σ_y). The ionomer content altered the rheology of the ink by changing the internal interaction of inks. Solvents with ε of 70 and 55 enhanced the adsorption of ionomers onto catalysts, thereby increasing the adhesion between ink particles and reducing the risk of CL cracking. As the ionomer content increased, the catalyst absorbed more ionomers in inks, increasing the fracture toughness of CLs, which reduced the crack width.

Effect of Hydrophobic Cations on the Inhibitors for the Oxygen Reduction Reaction on Anions and Ionomers Adsorbed on Single-Crystal Pt Electrodes

Weakening of the poisoning by the specifically adsorbed anions assists in developing next-generation electrocatalysts for use in low-temperature fuel cells. In this study, we evaluated how hydrophobic cations with different alkyl chain lengths affect the oxygen reduction reaction (ORR) activities on the single-crystal Pt surfaces in contact with sulfuric acid solution and Nafion ionomers. Interfacial tetraalkylammonium cations with longer alkyl chains activated the ORR on the Pt(111) surface. In a solution containing tetrahexylammonium cations (THA⁺), the ORR activities on Pt(111) in sulfuric acid solution and on Nafion-modified Pt(111) in perchloric acid solution were four and eight times higher than those in the solutions without THA⁺, respectively. Infrared spectroscopy revealed the reduction of the amount of (bi)sulfate anions and the sulfonate group of Nafion adsorbed on Pt(111) due to the presence of THA⁺. The hydrophobic cations weaken the noncovalent interactions between specifically adsorbed species and promote the ORR.

Challenges in applying highly active Pt-based nanostructured catalysts for oxygen reduction reactions to fuel cell vehicles

The past 30 years have seen progress in the development of Pt-based nanocatalysts for the oxygen reduction reaction, and some are now in production on a commercial basis and used for polymer electrolyte fuel cells (PEFCs) for automotives and other applications. Further improvements in catalytic activity are required for wider uptake of PEFCs, however. In laboratories, researchers have developed various catalysts that have much higher activities than commercial ones, and these state-of-the-art catalysts have potential to improve energy conversion efficiencies and reduce the usage of platinum in PEFCs. There are several technical issues that must be solved before they can be applied in fuel cell vehicles, which require a high power density and practical durability, as well as high efficiency. In this Review, the development history of Pt-based nanocatalysts and recent analytical studies are summarized to identify the origin of these technical issues. Promising strategies for overcoming those issues are also discussed.