Catalyst layers for proton exchange membrane fuel cells prepared by electrospray deposition on Nafion membrane

The electrospray deposition method has been used for preparation of catalyst layers for proton exchange membrane fuel cells (PEMFC) on Nafion membrane. Deposition of Pt/C + ionomer suspensions on Nafion 212 gives rise to layers with a globular morphology, in contrast with the dendritic growth observed for the same layers when deposited on the gas diffusion layer, GDL (microporous carbon black layer on carbon cloth) or on metallic Al foils. Such a change is discussed in the light of the influence of the Nafion substrate on the electrospray deposition process. Nafion, which is a proton conductor and electronic insulator, gives rise to the discharge of particles through proton release and transport towards the counter electrode, compared with the direct electron transfer that takes place when depositing on an electronic conductor. There is also a change in the electric field distribution in the needle to counter-electrode gap due to the presence of Nafion, which may alter conditions for the electrospray effect. If discharging of particles is slow enough, for instances with a low membrane protonic conductivity, the Nafion substrate may be charged positively yielding a change in the electric field profile and, with it, in the properties of the film. Single cell characterization is carried out with Nafion 212 membranes catalyzed by electrospray on the cathode side. It is shown that the internal resistance of the cell decreases with on-membrane deposited cathodic catalyst layers, with respect to the same layers deposited on GDL, giving rise to a considerable improvement in cell performance. The lower internal resistance is due to higher proton conductivity at the catalyst layer-membrane interface resulting from on-membrane deposition. On the other hand, electroactive area and catalyst utilization appear little modified by on-membrane deposition, compared with on-GDL deposition.     

Effects of Nafion loading in anode catalyst inks on the miniature direct formic acid fuel cell

Nafion, within the anode and cathode catalyst layers, plays a large role in the performance of fuel cells, especially during the operation of the direct formic acid fuel cell (DFAFC). Nafion affects the proton transfer in the catalyst layers of the fuel cell, and studies presented here show the effects of three different Nafion loadings, 10 wt.%, 30 wt.% and 50 wt.%. Short term voltage-current measurements using the three different loadings show that 30 wt.% Nafion loading in the anode shows the best performance in the miniature, passive DFAFC. Nafion also serves as a binder to help hold the catalyst nanoparticles onto the proton exchange membrane (PEM). The DFAFC anode temporarily needs to be regenerated by raising the anode potential to around 0.8 V vs. RHE to oxidize CO bound to the surface, but the Pourbaix diagram predicts that Pd will corrode at these potentials. We found that an anode loading of 30 wt.% Nafion showed the best stability, of the three Nafion loadings chosen, for reducing the amount of loss of electrochemically active area due to high regeneration potentials. Only 58% of the area was lost after 600 potential cycles in formic acid compared to 96 and 99% for 10 wt.% and 50 wt.% loadings, respectively. Lastly we present cyclic voltammetry data that suggest that the Nafion adds to the production of CO during oxidation of formic acid for 12 h at 0.3 V vs. RHE. The resulting data showed that an increase in CO coverage was observed with increasing Nafion content in the anode catalyst layer.     

The influence of anode gas diffusion layer on the performance of low-temperature DMFC

The influence of the anode gas diffusion layers (GDLs) on the performances of low-temperature DMFCs, and the properties of mass transport and CO₂ removal on these anode GDLs were investigated. The membrane electrode assembly (MEA) based on the hydrophilic anode GDL, which consisted of the untreated carbon paper and hydrophilic anode micro-porous layer (comprised carbon black and 10 wt.% Nafion), showed the highest power density of 13.4 mW cm⁻² at 30 °C and ambient pressure. The performances of the MEAs tended to decline with the increase of the PTFE content in the anode GDLs due to the difficulty of methanol transport. The contact angle measurements revealed that the wettabilities of the anode GDLs decreased as the increase of PTFE content. The wettabilities of the GDLs were improved by addition of hydrophilic Nafion ionomer to the GDLs. From the visualizations of CO₂ gas bubbles dynamics on the anodes using a transparent cell, it was observed that uniform CO₂ gas bubbles with smaller size formed on hydrophilic anode GDLs. And bubbles with larger size were not uniform over the hydrophobic anode GDLs. It was believed that adding PTFE to the anode GDL was not helpful for improving the CO₂ gas transport in the anode GDL of the low-temperature DMFC.     

Structure and electrocatalytic performance of carbon-supported platinum nanoparticles

The structure of Pt nanoparticles and the composition of the catalyst-Nafion films strongly determine the performance of proton exchange membrane fuel cells. The effect of Nafion content in the catalyst ink, prepared with a commercially available carbon-supported Pt, in the kinetics of the hydrogen oxidation reaction (HOR), has been studied by the thin layer rotating disk electrode technique. The kinetic parameters have been related to the catalyst nanoparticles structure, characterized by X-ray diffraction and high-resolution transmission electron microscopy. The size-shape analysis is consistent with the presence of 3D cubo-octahedral Pt nanoparticles with average size of 2.5 nm. The electrochemically active surface area, determined by CO stripping, appears to depend on the composition of the deposited Pt/C-Nafion film, with a maximum value of 73 m² g_Pt⁻¹ for 30 wt.% Nafion. The results of CO stripping indicate that the external Pt faces are mainly (1 0 0) and (1 1 1) terraces, thus confirming the cubo-octahedral structure of nanoparticles. Cyclic voltammetry combined with the RDE technique has been applied to study the kinetic parameters of HOR besides the ionomer resistance effect on the anode kinetic current at different ionomer contents. The kinetic parameters show that H₂ oxidation behaves reversibly with an estimated exchange current density of 0.27 mA cm⁻².     

High utilization of Pt nanocatalysts fabricated using a high-pressure sputtering technique

Pt nanocatalysts formed on a gas diffusion layer substrate for use in proton exchange membrane fuel cells were fabricated by using a high-pressure sputtering technique in a gaseous mixture of Ar and He. Rather than the dense film deposited by conventional sputtering techniques, the resulting structure was comprised of a porous Pt nanocatalyst layer with an average particle size of 8.9 nm. The porous Pt nanocatalysts were characterized by scanning electron microscopy, transmission electron microscopy, X-ray diffraction, and X-ray absorption near edge spectroscopy. Compared with the dense Pt catalyst layer, the electrochemical activated surface of the porous Pt nanocatalyst layer, measured using cyclic voltammetry, was enhanced about 250%. Polarization characteristics of the membrane electrode assembly, which utilized the porous Pt nanocatalyst layer in the proton exchange membrane fuel cells, showed that the maximum power density per unit area increased with an increase in the sputtering pressure. The high performance of Pt nanocatalysts fabricated at a sputtering pressure of 200 mTorr (Ar/He = 1) was due to miniaturization of the Pt particles and formation of the porous catalyst layer.     

Nanoimprinted electrodes for micro-fuel cell applications

Nanoimprint lithography (NIL) was used to fabricate electrodes with high specific Pt surface areas for use in micro-fuel cell devices. The Pt catalyst structures were characterized electrochemically using cyclic voltammetry and were found to have electrochemical active surface areas (EAS) ranging from 0.8 to 1.5 m² g⁻¹ Pt. These NIL catalyst structures were tested in fuel cell membrane electrode assemblies (MEA) by directly embossing a Nafion 117 membrane. The features of the mold were successfully transferred to the Nafion and a 7.5 nm thin film of Pt was deposited at a wide angle to form the anode catalyst layer. The resulting MEA yielded a very high Pt utilization of 15,375 mW mg⁻¹ Pt compared to conventionally prepared MEAs (820 mW mg⁻¹ Pt). Embossing pattern transfer was also demonstrated for spin casted Nafion films which could be used for new applications.     

Effect of Nafion aggregation in the anode catalytic layer on the performance of a direct formic acid fuel cell

The effect of Nafion ionomer aggregation within the anode catalytic layer for a direct formic acid fuel cell (DFAFC) has been investigated. By simple heat treatment, the aggregation states of Nafion ionomers in aqueous solution can be tuned. Nafion agglomerate sizes in the solution decrease and aggregate size distribution becomes narrow with the increase in heat-treatment temperature. At a heat-treatment temperature of ca. 80 °C, nearly monodispersed Nafion ionomers corresponding to an aggregate size of ca. 25 nm in the solution are observed. The use of small Nafion ionomer agglomerates in the Nafion solution for anode catalytic layer significantly improves the performance of the passive DFAFCs. Impedance analysis indicates that the increased performance of the passive DFAFC with the anode using Nafion solution pretreated at elevated temperatures could be attributed to the decrease in charge-transfer resistance of the anode reaction. The decrease in Nafion aggregation within the catalyst ink leads to an increase in Nafion ionomer utilization within the catalyst layer and an improvement in catalyst utilization; thus enabling us to decrease Nafion loading within the anode catalytic layer but with slight improvement in DFAFC's performance.     

Modelling and experimental validation of high performance low platinum multilayer cathode for polymer electrolyte membrane fuel cells (PEMFCs)

The aim of this paper is to demonstrate numerically the feasibility of using a sputtering technique for the design of Polymer Electrolyte Membrane Fuel Cell cathodes having low platinum loading and offering high performance. A two-dimensional steady state model accounting for electrochemical reactions, momentum, saturation, species and charge conservation equations have been developed. It has been applied to three different cathode configurations where the platinum is assumed to be sputtered one, two and three times on the same number of carbon–Nafion layers (CNL). The predicted polarization curves were validated with the experimental data obtained in our laboratory. Our results showed that the best performance is obtained with a three Pt sputtered layer cathode. A parametric study proved the dependence of the PEM fuel cell cathode performance on the CNL porosity, the (Pt/C) agglomerate radius and the thickness of this agglomerate structure.     

Performance of an ultra-low platinum loading membrane electrode assembly prepared by a novel catalyst-sprayed membrane technique

Membrane electrode assemblies (MEAs) with ultra-low platinum loadings are attracting significant attention as one method of reducing the quantity of precious metal in polymer electrolyte membrane fuel cells (PEMFCs) and thereby decreasing their cost, one of the key obstacles to the commercialization of PEMFCs. In the present work, high-performance MEAs with ultra-low platinum loadings are developed using a novel catalyst-sprayed membrane technique. The platinum loadings of the anode and cathode are lowered to 0.04 and 0.12 mg cm⁻², respectively, but still yield a high performance of 0.7 A cm⁻² at 0.7 V. The influence of Nafion content, cell temperature, and back pressures of the reactant gases are investigated. The optimal Nafion content in the catalyst layer is ca. 25 wt.%. This is significantly lower than for low platinum loading MEAs prepared by other methods, indicating ample interfacial contact between the catalyst layer and membrane in our prepared MEAs. Scanning electron microscopy (SEM) and electrochemical impedance spectroscopy (EIS) measurements reveal that our prepared MEA has very thin anode and cathode catalyst layers that come in close contact with the membrane, resulting in a MEA with low resistance and reduced mass transport limitations.     

Novel multilayer Nafion/SPI/Nafion composite membrane for PEMFCs

A novel multilayer membrane for the proton exchange membrane fuel cell (PEMFC) was developed. Nafion was dispersed uniformly onto both sides of the sulfonated polyimide (SPI) membrane. The Nafion/SPI/Nafion composite membrane was prepared by immersing the SPI into the Nafion-containing casting solution. Through immersing both membranes into the Fenton solution at 80 °C for 0.5 h for an accelerated ex situ test, chromatographic analysis of the water evacuated from the cathode and the anode of the cells and a durability test of a single proton exchange membrane fuel cells, it was proved that the stability of the composite membrane has been greatly improved by adding the Nafion layer compared with the SPI membrane. The fuel cell performance with the SPI and Nafion/SPI/Nafion membranes was similar to the performance with the commercial product Nafion^® NRE-212 membrane at 80 °C.     

Effect of loading and distributions of Nafion ionomer in the catalyst layer for PEMFCs

The electrode with various contents of Nafion ionomer for inside and/or on the surface in the catalyst layer, respectively, was designed for proton exchange membrane fuel cell (PEMFC) electrode to investigate the effect of Nafion ionomer distribution in the catalyst layer on cell performance and improve electrode performance. The effect of Nafion ionomer on the electrode of each design was judged by a cyclic voltammetry measurement and the cell performance obtained through a single cell test using H₂/O₂ gases. Electrodes with different ionomer distributions for inside and on the surface in the catalyst layer, respectively, were examined. It is found that the electrode where the Nafion ionomer is impregnated on the surface of catalyst layer shows better cell performance than that where the Nafion ionomer is incorporated in the inside of catalyst layer. The best cell performance among the catalyst layers tested in this study was obtained for the electrode with 0.5 mg cm⁻² of Nafion ionomer inside the catalyst layer and 1.0 mg cm⁻² of Nafion ionomer on the surface of the catalyst layer together.     

Thin film Pt/TiO2 catalysts for the polymer electrolyte fuel cell

Thin film Pt/TiO₂ catalysts are evaluated in a polymer electrolyte electrochemical cell. Individual thin films of Pt and TiO₂, and bilayers of them, were deposited directly on Nafion membranes by thermal evaporation with varying deposition order and thickness (Pt loadings of 3–6 μg cm⁻²). Structural and chemical characterization was performed by transmission electron microscopy (TEM), and X-ray photoelectron spectroscopy (XPS). Oxygen reduction reaction (ORR) polarization plots show that the presence of a thin TiO₂ layer between the platinum and the Nafion increases the performance compared to a Pt film deposited directly on Nafion. Based on the TEM analysis, we attribute this improvement to a better dispersion of Pt on TiO₂ compared to on Nafion and in addition, substantial proton conduction through the thin TiO₂ layer. It is also shown that deposition order and the film thickness affects the performance.     

Characteristics of SOFC single cells with anode active layer via tape casting and co-firing

SOFC (solid oxide fuel cell) single cells with anode active layers of various thicknesses were fabricated successfully via tape casting and co-firing in order to improve their electrochemical performance and long-term stability. The mercury porosimeter and the gas permeability were measured so as to examine the effects of the anode active layer while under a gaseous flow. It was found that the anode active layers affected the microstructural characteristics as a result of the pore distribution and the gas permeation behavior. The anode active layers improved the cell performance by increasing the number of active sites in the anode. The thickness of the anode active layer was optimized at 20 μm in this work through a combination of the power density, the ohmic ASR (area specific resistance), and the cell ASR. SOFCs with the optimized active layer showed good electrochemical performance at 600–700 °C in hydrogen or hydrocarbon fuel (methane) and excellent long-term stability for 500 h.     

A novel proton exchange membrane fuel cell anode for enhancing CO tolerance

A novel proton exchange membrane fuel cell (PEMFC) anode which can facilitate the CO oxidation by air bleeding and reduce the direct combustion of hydrogen with oxygen within the electrode is described. This novel anode consists of placing Pt or Au particles in the diffusion layer which is called Pt- or Au-refined diffusion layer. Thus, the chemical oxidation of CO occurs at Pt or Au particles before it reaches the electrochemical catalyst layer when trace amount of oxygen is injected into the anode. All membrane electrode assemblies (MEAs) composed of Pt- or Au-refined diffusion layer do perform better than the traditionary MEA when 100 ppm CO/H₂ and 2% air are fed and have the performance as excellent as the traditionary MEA with neat hydrogen. Furthermore, CO tolerance of the MEAs composed of Au-refined diffusion layer was also assessed without oxygen injection. When 100 ppm CO/H₂ is fed, MEAs composed of Au-refined diffusion layer have the slightly better performance than traditionary MEA do because Au particles in the diffusion layer have activity in the water gas shift (WGS) reaction at low temperature.     

Sublayers for Pt catalyst electrodeposition electrodes in PEMFC

The effect of sublayers on the deposited platinum (Pt) catalyst layer fabricated by electrodeposition, and on the resulting fuel cell performance, was investigated. The substrate was prepared by applying a hydrophobic sublayer, composed of polytetrafluoroethylene (PTFE) and carbon black, and a hydrophilic sublayer, composed of Nafion and glycerol, onto an uncatalyzed gas diffusion layer prior to the electrodeposition of the Pt catalyst. The hydrophilic sublayer was found to play a substantial role in the Pt electrodeposition, since the structure of the resultant Pt catalyst significantly depended on the presence of the hydrophilic sublayer, the total loading amount and the Nafion to glycerol weight ratio, which in turn affected the fuel cell performance. The hydrophobic sublayer, which did not directly contact with the plating solution, did not show as marked an effect on the Pt deposit structure compared to that of the hydrophilic sublayer, except at high PTFE to carbon black weight ratios (≥70:30). However, the suitable PTFE to carbon black weight ratio in the hydrophobic sublayer was still important for the water management, mass transport of reactant gases and ohmic resistance of the membrane electrode assembly (MEA) during fuel cell operation. In this study, a total hydrophilic loading of 0.8 mg cm⁻² with a Nafion to glycerol weight ratio of 50:50, and a PTFE to carbon black weight ratio in the hydrophobic sublayer of 30:70 was found to yield the best Pt catalyst layer for PEMFC.     

High performance direct ethanol fuel cell with double-layered anode catalyst layer

Double-layered anode catalyst layers with two reverse configurations, which consist of 45 wt.% Pt₃Sn/C and PtRu black catalyst layers, were fabricated to improve the performance of a direct ethanol fuel cell (DEFC). The in-house 45 wt.% Pt₃Sn/C catalyst was characterized by XRD and TEM. The cross-sectional double-layered anode catalyst layer was observed by SEM. In DEFC performance test and anode linear sweep voltammetry measurement, the anode with double-layered catalyst layer exhibited better catalytic activity for ethanol electro-oxidation than those with single-layered 45 wt.% Pt₃Sn/C and PtRu black catalyst layers. In terms of anode product distribution, the DEFC with double-layered anode catalyst layer showed a higher yield of acetic acid than that with single-layered PtRu black catalyst layer and a higher yield of CO₂ than that with single-layered 45 wt.% Pt₃Sn/C catalyst layer, respectively. These results suggest that the double-layered anode catalyst layer possessed the advantages of both Pt₃Sn/C and PtRu black catalysts for ethanol electro-oxidation, and thus showed a higher ethanol electro-oxidation efficiency and DEFC performance in the practical polarization potential region.     

Optimization of ionomer-free ultra-low loading Pt catalyst for anode/cathode of PEMFC via magnetron sputtering

In this study, thin-film Pt catalysts with ultra-low metal loadings (ranging from 1 to 200 μg cm⁻²) were prepared by magnetron sputtering onto various carbon-based substrates. Performance of these catalysts acting as anode, cathode, or both electrodes in a proton exchange membrane fuel cell (PEMFC) was investigated in H₂/O₂ and H₂/air mode. As base substrates we used standard microporous layers comprising carbon nanoparticles with polytetrafluoroethylene (PTFE) or fluorinated ethylene propylene (FEP) supported on a gas diffusion layer. Some substrates were further modified by magnetron sputtering of carbon in N₂ atmosphere (leading to CN_x) followed by simultaneous plasma etching and cerium oxide deposition. The CN_x structure exhibits higher resistance to electrochemical etching as compared to pure carbon as was determined by mass spectrometry analysis of PEMFC exhaust at different cell potentials for both sides of PEMFC. The role of platinum content and membrane thickness was investigated with the above four different combinations of ionomer-free carbon-based substrates. The results were compared with a series of benchmark electrodes made from commercially available state-of-the-art Pt/C catalysts. It was demonstrated that the platinum utilization in PEMFC with magnetron sputtered thin-film Pt electrodes can be up to 2 orders of magnitude higher than with the standard Pt/C catalysts while keeping the similar power efficiency and long-term stability.     

Carbon nanotube/polyaniline composite as anode material for microbial fuel cells

A carbon nanotube (CNT)/polyaniline (PANI) composite is evaluated as an anode material for high-power microbial fuel cells (MFCs). Fourier transform infrared spectroscopy (FTIR) and scanning electron microscopy (SEM) are employed to characterize the chemical composition and morphology of plain PANI and the CNT/PANI composite. The electrocatalytic behaviour of the composite anode is investigated by means of electrochemical impedance spectroscopy (EIS) and discharge experiments. The current generation profile and constant current discharge curves of anodes made from plain PANI, 1 wt.% and 20 wt.% CNT in CNT–PANI composites reveal that the performance of the composite anodes is superior. The 20 wt.% CNT composite anode has the highest electrochemical activity and its maximum power density is 42 mW m⁻² with Escherichia coli as the microbial catalyst. In comparison with the reported performance of different anodes used in E. coli-based MFCs, the CNT/PANI composite anode is excellent and is promising for MFC applications.     

Impact of ultra-low Pt loadings on the performance of anode/cathode in a proton-exchange membrane fuel cell

This study focuses on the elaboration of PEMFC electrodes containing ultra-low platinum (Pt) loadings by direct liquid injection metal organic chemical vapor deposition (DLI-MOCVD). DLI-MOCVD offers a large number of advantages for the elaboration of model PEMFC electrodes. First, by using different metal precursors or elaboration temperature, the size of the Pt nanoparticles and thus the intrinsic catalytic activity can easily be tailored in the nanometer range. In this work, Pt nanoparticles (1-5 nm) with remarkable low degree of agglomeration and uniform distribution were deposited onto the microporous side of a commercial gas-diffusion layer (GDL). Second, reduction of the Pt loading is made possible by varying the Pt deposition time and its influence of the cell performance can be extracted without variation of the thickness of the catalytic layer (in previous studies, a decrease of the catalyst utilization was observed when increasing the Pt loading, i.e. the thickness of the catalytic layer (CL)). The electrocatalytic activity of home-made Pt nanoparticles elaborated by DLI-MOCVD was measured in liquid electrolyte or in complete fuel cell operating on H₂/O₂ or H₂/air and compared vs. that of a commercially available electrode containing 500 μg_Pt cm⁻² (Pt_Ref500). At the cathode, the performance of the electrodes containing 104-226 μg of Pt per cm² of electrode compares favorably with that of the Pt_Ref500 in H₂/O₂ conditions. In H₂/air conditions, additional mass-transport losses are detected in the low-current density region but the high effectiveness of our electrodes improves the performance in the high-current density region. At the anode, the Pt loading can be reduced to 35 μg_Pt cm⁻² without any voltage loss in agreement with previous observations.     

High performance of low electrocatalysts loading on CNT directly grown on carbon cloth for DMFC

This study demonstrated the feasibility of a high-performance membrane-electrode-assembly (MEA), with low electrocatalyst loading on carbon nanotubes (CNTs) grown directly on carbon cloth as an anode. The direct growth of CNTs was synthesized by microwave plasma-enhanced chemical vapor deposition using CH₄/H₂/N₂ as precursors. The cyclic voltammetry and electrochemical impedance measurements with 1 mM Fe(CN)₆^3−/4− redox reaction reveal a fast electron transport and a low resistance of charge transfer on the direct growth of CNT. The electrocatalysts, platinum and ruthenium, were coated on CNTs by sputtering to form Pt-Ru/CNTs-CC with carbon cloth for CC. Pt-Ru electrocatalysts are uniformly dispersed on the CNT, as indicated by high-resolution scanning electron microscopy (HRSEM) and transmission electron microscopy (TEM), because the nitrogen doped in the CNT acts as active sites for capturing electrocatalysts. The MEA, the sandwiched structure which comprises 0.4 mg cm⁻² Pt-Ru/CNTs-CC as the anode, 3.0 mg cm⁻² Pt black as the cathode and Nafion 117 membrane at the center, performs very well in a direct methanol fuel cell (DMFC) test. The micro-structural MEA analysis shows that the thin electrocatalyst layer is uniform, with good interfacial continuity between membrane and the gas diffusion layer.