Performance and Durability of Membrane Electrode Assemblies Based on Radiation‐Grafted FEP‐g‐Polystyrene Membranes

Membrane electrode assemblies (MEAs) based on radiation‐grafted proton exchange membranes developed at PSI have shown encouraging performance in the past in hydrogen and methanol fuelled polymer electrolyte fuel cells. In this study, the effect of the pre‐treatment of crosslinked radiation‐grafted FEP membranes prior to lamination with the electrodes on the performance of the MEAs was investigated. Two approaches were assessed separately and in combination: (1) the impregnation of the radiation‐grafted membranes with solubilised Nafion®, and (2) the use of a swollen vs. dry membrane. It is found that the combination of coating the membrane with Nafion® ionomer and hot‐pressing the MEA with the membrane in the wet state produce the best single cell performance. In the second part of the study, the durability of an MEA, based on a radiation‐grafted FEP membrane, was investigated. The performance was stable for 4,000 h at a cell temperature of 80 °C. Then, a notable degradation of the membrane, as well as the electrode material, started to occur as a consequence of either controlled or uncontrolled start‐stop cycles of the cell. It is assumed that particular conditions, to which the cell is subjected during such an event, strongly accelerate materials degradation, which leads to the premature failure of the MEA.     

Performance Study of Direct Borohydride Fuel Cells Employing Polyvinyl Alcohol Hydrogel Membrane and Nickel‐Based Anode

A direct borohydride fuel cell (DBFC) employing a polyvinyl alcohol (PVA) hydrogel membrane and a nickel‐based composite anode is reported. Carbon‐supported platinum and sputtered gold have been employed as cathode catalysts. Oxygen, air and acidified hydrogen peroxide have been used as oxidants in the DBFC. Performance of the PVA hydrogel membrane‐based DBFC was tested at different temperatures and compared with similar DBFCs employing Nafion® membrane electrolytes under identical conditions. The borohydride–oxygen fuel cell employing PVA hydrogel membrane yielded a maximum peak power density of 242 mW cm^–2 at 60 °C. The peak power densities of the PVA hydrogel membrane‐based DBFCs were comparable or a little higher than those using Nafion® 212 membranes at 60 °C. The fuel efficiency of borohydride–oxygen fuel cell based on PVA hydrogel membrane and Ni‐based composite anode was found to be between 32 and 41%. The cell was operated for more than 100 h and its performance stability was recorded.     

Durability enhancement of Nafion® fuel cell membranes via in situ sol‐gel‐derived titanium dioxide reinforcement

To improve durability of Nafion® membranes, samples were modified via an in situ sol‐gel polymerization of titanium isopropoxide to generate titania quasi‐networks in the polar domains. The incorporated titania reduced water uptake but equivalent weight was essentially unchanged. Fuel cell performance of the modified membrane was inferior to that of the unfilled membrane although these were considered as model studies with focus on mechanical durability. Mechanical analysis of contractile stress buildup during drying from a swollen state in samples clamped at constant length demonstrated considerable reinforcement of Nafion® by the titania structures. Tensile studies showed that at 80°C and 100% relative humidity the dimensional change of the composite membrane is one half and the initial modulus is three times higher than that of the unmodified membrane. During an open circuit voltage decay test the voltage decay rate for the modified membrane is 3.5 times lower than that of control Nafion®. Fluoride emission for the composite is at least an order of magnitude lower than that of the control Nafion® membrane indicating reduced chemical degradation. These model studies indicate that this in situ inorganic modification offers a way to enhance fuel cell membrane durability by reducing both physical and chemical degradation. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Temperature Effects on the Molecular Dynamics of Modified Nafion® Membranes Incorporating Ionic Liquids' Cations: A 1H NMRD Study

Nafion® is the polymer electrolyte membrane most used in fuel cells (PEMFC), however Nafion® presents some limitations due to the water loss with increasing temperature. In this work is presented the study of the molecular dynamics in modified Nafion®/ionic liquids (IL) cations membranes with increasing temperature, by proton NMR relaxometry (¹H NMRD). Three Nafion® membranes modified with Phenyltrimethylammonium (TMPA⁺), 1‐n‐butyl‐3‐methylimidazolium (BMIM⁺) and n‐dodecyltrimethylammonium (DTA⁺) IL cations were considered. This study allowed the evaluation of the effect of the IL cations incorporation in Nafion® membranes and to assess the degree of confinement of the IL cations in the membranes matrix in relation with the water content. Thermogravimetry analysis was also performed to study the water loss with increasing temperature of the Nafion®/IL cations membranes. It was possible to establish a correlation between the water content and the IL cations self‐diffusion coefficients. The sequential order of the hydration level obtained for the studied systems was Nafion®/DTA⁺>Nafion®/BMIM⁺ ≳ Nafion®/H⁺>Nafion®/TMPA⁺, while the water loss follows the sequence Nafion®/H⁺>Nafion®/BMIM⁺∼Nafion®/DTA⁺>Nafion®/TMPA⁺. The Nafion®/BMIM⁺ presented the largest temperature variation of both the self‐diffusion coefficient and the hydration conditions. In terms of PEMFCs efficiency, the Nafion®/DTA⁺ modified membrane seems to offer the largest and stable hydration conditions with temperature.     

A Sulfophenylated Polysulfone as the DMFC Electrolyte Membrane – an Evaluation of Methanol Permeability and Cell Performance

A sulfophenylated polysulfone (PSU‐sph), carrying 0.8 sulfonic acid units per repeating unit of the polymer, is evaluated as a membrane electrolyte for DMFC applications. The liquid uptake, methanol transport characteristics, electrolyte conductivity, and fuel cell performance are investigated. The methanol transport and DMFC performance results are compared to those of Nafion® 117. The PSU‐sph membrane investigated shows superior qualities with regard to methanol crossover, with a methanol permeability of approximately 25% compared to that of Nafion®. The conductivity was measured to be 15% compared to that of Nafion®. However, this could not fully account for the internal resistance of the cell, implying that the contact resistance between the electrodes and electrolyte is higher when PSU‐sph is used, probably because the electrodes are developed for use with Nafion® membranes. The stability of the PSU‐sph membrane seems promising, with very low degradation observed over a period of 72 hours. It was concluded that although the mass transport properties of the PSU‐sph membrane sample investigated were superior, it could not match the performance of Nafion® 117 in a DMFC application. However, a higher degree of sulfonation may have a significant positive effect on cell performance. The results also showed that a fully intergrated MEA is needed to fully assess new menbrane materials.     

A Porous Silicon‐Based Ionomer‐Free Membrane Electrode Assembly for Miniature Fuel Cells

Previous work showed the pertinence of using grafted porous silicon as the proton exchange membrane for miniature fuel cells. One of the limitations was the membrane‐electrodes assembly, which required an ionomer, in the current study a 5% Nafion®‐117 solution, to ensure a proton‐conducting link between the commercial carbon cloth electrodes and the membrane. Here, new developments for this fuel cell, with a totally Nafion®‐free process, are reported. The Pt catalyst is sputtered and electrodeposited onto the surface of the proton conducting porous silicon membrane. The initial performance of this fuel cell is shown and demonstrates the validity of the technique.     

In situ grown titania composition for optimal performance and durability of Nafion® fuel cell membranes

Nafion® membranes were modified via in situ, catalyzed sol–gel reactions of titanium isopropoxide to form titania particles in the polar acid domains. FTIR spectroscopy showed successful intraparticle chemical bond formation with incomplete condensation of TiOH groups. Although such modification can lower membrane fuel cell performance, this study was aimed at reducing membrane degradation without significantly altering performance in the sense of material optimization. These incorporated particles did not change membrane equivalent weight and the water uptake was similar to that of the unmodified Nafion® membrane. Membrane dimensional stability, mechanical properties, and ability to withstand contractile stresses associated with humidity change at 80°C and 100% RH were improved. An open circuit voltage (OCV) accelerated degradation test showed the titania modification held voltage better than the unmodified membrane. Performance deterioration of Nafion® after the OCV test was much higher than that of the modified membrane and the fluoride emission of the latter was lower. The degraded Nafion® membrane failed when subjected to creep, whereas the modified membrane remained intact with significantly low deformation. This inorganic modification offers a simple way to enhance membrane durability by reducing both physical and chemical degradation. © 2011 Wiley Periodicals, Inc. J Appl Polym Sci, 2011     

The Ionic Conductivity of a Nafion® 1100 Series of Proton‐exchange Membranes Re‐cast from Butan‐1‐ol and Propan‐2‐ol

The ionic conductivity of Nafion® 1100 extruded membranes re‐cast from solutions of butan‐1‐ol and propan‐2‐ol is measured in 0.5 mol dm^–3 H₂SO₄ at 295 K, using an immersed, four‐electrode d.c. technique. The general trend is an increasing conductivity for the thicker membranes. Materials which were solution‐cast from butan‐1‐ol yielded the highest conductivity while a series of membranes with lower conductivities (similar to those of an extruded Nafion® 1100 series of membranes) was found using propan‐2‐ol. The conductivity results indicate that membranes manufactured by extrusion and casting from various solvents might have different structures. Differences in the water content and conductivity of the membranes are considered to arise from the impact of processing conditions on the surface and bulk structure of the membranes.     

Stereoselective Behavior of Nafion® Membranes towards (+)‐α‐Pinene and (−)‐α‐Pinene

α‐Pinene enantiomers were sorbed in Nafion® membranes. The membranes included a commercial extruded Nafion® 115 membrane as well as membranes prepared by casting a Nafion® solution, evaporating the solvent, and a thermal treatment at different temperatures. The microstructure of membranes was studied by small‐angle and wide‐angle X‐ray scattering, and magic‐angle spinning nuclear magnetic resonance spectroscopy. The change of membrane weight during the sorption process was determined with a sorption microbalance. Noticeable differences concerning the sorption behavior of the various membranes could be stated. The sorption of (+)‐α‐pinene and (?)‐α‐pinene in an extruded Nafion® membrane turned out to be rather low.     

Proton Conducting Sulphonated Fluorinated Poly(Styrene) Crosslinked Electrolyte Membranes

Potential membranes for polymer electrolyte membrane fuel cell based on crosslinked sulphonated fluorinated polystyrenes (PS) were synthesised in two steps. First, azide‐telechelic polystyrene was obtained by iodine transfer polymerisation of styrene in the presence of 1,6‐diiodoperfluorohexane followed by azido chain‐end functionalisation. Then azide‐telechelic polystyrene was efficiently crosslinked with 1,10‐diazido‐1H,1H,2H,2H,9H,9H,10H,10H‐perfluorodecane under UV irradiation. After 45 min only, almost completion of azide crosslinking could be achieved, resulting in crosslinked membranes with insoluble fractions higher than 95%. The sulphonation of the crosslinked membranes afforded ionic exchange capacities (IECs) ranging from 2.2 to 3.2 meq g^–1. The hydration number was shown to be very high (from 30 to 75), depending on both the content of perfluorodecane and of sulphonic acid groups. The morphology of the membranes, assessed by small‐angle X‐ray scattering, was found to be a lamellar‐type structure with two types of ionic domains. For the membrane that exhibited an IEC value of 2.2 meq·g^–1, proton conductivity was in the same range as that of Nafion® (120–135 mS·cm^–1), whereas the membrane IEC value of 3.2 meq·g^–1 showed a proton conductivity higher than that of Nafion® in liquid water from 25 to 80 °C, though a high water uptake.     

Relationship Between Methanol Permeability and Structure of Different Radiation‐Grafted Membranes

Styrene grafted and sulfonated poly(vinylidene fluoride) and poly(vinylidene fluoride‐co‐hexafluoropropylene) films are candidates as electrolytes in direct methanol fuel cells. Their behaviour in water, 1 and 3 mol dm^–3 aqueous methanol, and pure methanol were studied. According to SAXS results, water and methanol‐water solutions have similar effects on the membranes, i.e., the lamellar period increases and the ionic domains enlarge. Furthermore, differences in the ionic domain structures in pure methanol and water were observed. These structural changes together with dissimilar liquid uptakes in water and in methanol are reflected as changes in the conductivities. An increase in the SAXS intensity and changes in the Bragg distance of the ionic peak were observed in methanol compared to aqueous solutions. This may be related to the hydrophobicity of the CH₃ group on methanol. Dissimilarities in methanol permeability through the radiation‐grafted membrane can be related to structural differences in membranes observed with SAXS. Permeabilities were observed to be lower for the radiation‐grafted membranes compared to Nafion® 115, which compensates for the higher area resistance of the experimental membranes and thus improves their performance in a fuel cell.     

Grafting of 4‐Hydroxybenzenesulfonic Acid onto Commercially Available Poly(VDF‐co‐HFP) Copolymers for the Preparation of Membranes

The grafting of a phenate bearing sulfonate group in solution onto commercially available poly(VDF‐co‐HFP) copolymers, where VDF and HFP stand for vinylidene fluoride and hexafluoropropene, respectively, is presented. This reaction leads to novel fluoropolymers, bearing aryl sulfonic acid side functions, which are fuel cell membrane precursors. A mechanism similar to the grafting of bisphenol onto VDF‐containing copolymers is discussed. First, the sulfonate phenate is modified to give the didecyldimethylammonium bromide sulfonate phenate salt, in order to promote the substitution onto a fluorine atom in VDF unit adjacent to one HFP unit onto a fluorine atom in the copolymer. The substitution of this salt onto the fluorinated copolymer yields low molar percentages of grafted phenate, ranging from 1.8 to 5.1 mol‐%, whereas it reaches values up to 13 mol‐% grafting when the NH₂‐CH₂‐CH₂‐S‐CH₂‐CH₂‐C₆H₄‐SO₃Na amine is used as the grafting agent. NMR characterization is used to monitor the grafting process. The electrochemical properties of the resulting phenate grafted‐poly(VDF‐co‐HFP) copolymer are studied. The theoretical ion exchange capacities are half that of Nafion®. The proton conductivities are also lower than that of Nafion®, although one conductivity measurement reached a value of 5.1 mS cm^–1, showing a non‐negligible conductivity. The water uptake is lower than these noted for a sulfonated amine‐grafted copolymer, and is of the same order as that for Nafion®. Finally, it is shown that these novel materials start to decompose above 200 °C, showing a similar thermostability as that of an amino‐containing aryl sulfonate‐grafted poly(VDF‐co‐HFP) copolymer.     

Fuel Cell Membranes Based on Grafted and Post‐Sulfonated Glycidyl Methacrylate (GMA)

Glycidyl methacrylate (GMA) was pre‐irradiation grafted into ETFE base film of 25 μm thickness up to graft levels of 300%. The grafted films were sulfonated using a mixture of sulfite and bisulfite. FTIR and SEM–EDX analysis of the synthesized films and membranes was performed to confirm the grafting and the sulfonation. A pronounced front mechanism for grafting of GMA into ETFE was found. Regarding ex situ fuel cell relevant properties, conductivities of up to 0.25 S cm^–1 were attained. For the first time, fuel cell testing of this type of membrane is reported. These grafted membranes performed comparable to a commercial benchmark membrane (Nafion® 212) and better than a styrene‐based grafted membrane with similar conductivity. Post‐test FTIR analysis showed that a fraction of the grafted chains was lost during the test under constant current conditions, yet the membrane still exhibited superior durability compared to a styrene‐based grafted membrane. Hydrolysis of the methacrylate groups was shown not to be the principle cause of the loss of sulfonic acid groups.     

Sulfonated poly(arylene ether sulfone) membranes based on biphenol for direct methanol fuel cells

A series of sulfonated poly(arylene ether sulfone) (PAES) were synthesized through direct aromatic nucleophilic substitution polycondensation of 3,3′-disulfonate-4,4′-dichlorodiphenylsulfone (SDCDPS), 4,4-dichlorodiphenylsulfone (DCDPS) and 4,4-biphenol (BP). With increasing sulfonate groups in the polymer, water uptake, ion exchange capacity (IEC) and proton conductivities increased, resulting from enhanced membrane hydrophilicity. The membranes exhibited higher thermal stability up to 300 °C, verified by thermogravimetric analysis (TGA). A maximum proton conductivity of 0.11 S/cm at 50 mol% of sulfonation degree was measured at 30 °C, which is slightly higher than Nafion®117 membrane (0.0908 S/cm). However, the methanol permeability of the PAES membrane was much lower than that of Nafion®117 membrane. As a result, a single cell performance test demonstrated that PAES-BP with 50 mol% sulfonation degree exhibited higher power density than Nafion®117.     

Sorption and transport properties of the semi‐interpenetrating network based on crosslinked poly(vinyl alcohol) and poly(styrene sulfonic acid‐co‐maleic anhydride) as proton‐conducting membranes

This study investigates the sorption and transport properties of hydrocarbon membranes based on poly(vinyl alcohol) network and poly(styrene sulfonic acid‐co‐maleic acid) (PSSA‐MA). The water and methanol self‐diffusion coefficients through an 80 wt % PSSA‐MA interpenetrating SIPN‐80 membrane measured 3.75 × 10^?6 and 5.47 × 10^?7 cm²/s, respectively. These results are lower than the corresponding values of Nafion® 115 (8.89 × 10^?6 cm²/s for water and 8.63 × 10^?6 cm²/s for methanol). The methanol permeability of SIPN‐80 membrane is 4.1 × 10^?7 cm²/s, or about one‐fourth that of Nafion® 115. The difference in self‐diffusion behaviors of Nafion® 115 and SIPN‐80 membranes is well correlated with their sorption characteristics. The solvent uptake of Nafion® 115 increased as the methanol concentration increased up to a methanol mole fraction of 0.63, and then decreased. However, the solvent uptake of the SIPN‐80 membranes decreased sluggishly as the methanol concentration increased. The λ values of water and methanol (i.e., λ and λ) in Nafion® 115 are quite close, indicating no sorption preference between water and methanol. In contrast, the λ value is only one‐third λ for a SIPN‐80 membrane. Accordingly, the SIPN membranes are regarded as candidates for direct methanol fuel cell applications. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Sulfonated poly(ether sulfone)/silica composite membranes for direct methanol fuel cells

A series of sulfonated poly(ether sulfone) (SPES)/silica composite membranes were prepared by sol–gel method using tetraethylorthosilicate (TEOS) hydrolysis. Physico–chemical properties of the composite membranes were characterized by thermogravimetric analysis (TGA), X‐ray diffraction (XRD), scanning electron microscope–energy dispersive X‐ray (SEM–EDX), and water uptake. Compared to a pure SPES membrane, SiO₂ doping in the membranes led to a higher thermal stability and water uptake. SEM–EDX indicated that SiO₂ particles were uniformly embedded throughout the SPES matrix. Proper silica loadings (below 5 wt %) in the composite membranes helped to inhibit methanol permeation. The permeability coefficient of the composite membrane with 5 wt % SiO₂ was 1.06 × 10^?7 cm²/s, which was lower than that of the SPES and just one tenth of that of Nafion® 112. Although proton conductivity of the composite membranes decreased with increasing silica content, the selectivity (the ratio of proton conductivity and methanol permeability) of the composite membrane with 5 wt % silica loading was higher than that of the SPES and Nafion® 112 membrane. This excellent selectivity of SPES/SiO₂ composite membranes could indicate a potential feasibility as a promising electrolyte for direct methanol fuel cell. © 2010 Wiley Periodicals, Inc. J Appl Polym Sci, 2010     

Synthesis of Low Methanol Permeation Polymer Electrolyte Membrane from Polystyrene-Butadiene Rubber

In order to find a low cost polymer electrolyte membrane with low methanol cross-over, the development of novel polymer electrolytes have been actively carried out in recent time as alternatives to Nafion®, which is the state-of-the art membrane. The problems associated with these alternative membranes are higher permeability to the fuel, lower proton attraction and thermal stability. This work therefore was focused on synthesizing low methanol permeable membrane with good proton conductvity and thermal stability from locally available polymer (Polystyrene-butadiene rubber). Results obtained revealed that the synthesized membrane exhibited methanol permeation in the ranges of 2.13 × 10^?7 to 7.58 × 10^?7 mol/cm²s which was lower than that of Nafion® (3.15 × 10^?6 cm²/s). The proton conductivity of the synthesized membrane is in the order of 10^?2 S/cm. The results also show that water and solvent uptake of the synthesized membrane are moderate as compared to that of Nafion®. These results are influenced by the degree of sulphonation and membrane thickness ranging from 0.112 mm?0.420 mm.     

The Use of Fluorocarbon Surfactants to Improve the Manufacture of PEM Fuel Cell Electrodes

Fluorocarbon surfactants are used to improve surface wetting during the screen printing of carbon black inks onto PEM fuel cell electrodes. The fluorosurfactants were tested in inks that comprised a Nafion® ionomer solution with platinum‐loaded carbon black. Four commercially available fluorosurfactants (Zonyl FSO, Zonyl 1033D, Forafac 1098 and Novec FC 4430) were screened and assessed for electrochemical activity (via cyclic voltammetry), leaching and the ability to form ink layers. Good wetting characteristics were observed and the inks showed a similar specific electrochemical active area (200–430 cm² mg^–1 Pt) to a standard reference ink (370 cm² mg^–1 Pt), indicating that the surfactants did not adversely adsorb on the platinum catalyst surface or block the adsorption/desorption of hydrogen. Additionally, the fluorosurfactants in the cured inks were shown to be electrochemically inactive in the potential region relevant to fuel cell operation.     

Lifetime Prediction Approach Applied to the Aquivion™ Short Side Chain Perfluorosulfonic Acid Ionomer Membrane for Intermediate Temperature Proton Exchange Membrane Fuel Cell Application

Degradation and durability studies of the short side chain perfluorosulfonic acid ionomer membrane, Aquivion™, of Solvay Specialty Polymers, are described in a fuel cell operation beyond 100 °C. Specific electrochemical accelerated stress tests under a dynamic electric load cycling profile were developed to submit the membrane to hydration–dehydration cycles, while the effect of operation temperature was also investigated to reproduce typical power demands and/or thermal gradient periods likely to be encountered during seasonal variation of a micro‐combined heat and power system. Aquivion™ is a high performance membrane which is shown in this study to sustain operation until 110 °C, higher than was possible with Nafion® under similar conditions. Post‐test observations studies by electron microscopy and ex situ tensile measurements bring to light modifications of membrane thickness and mechanical properties that rationalize an upper operating temperature of 120 °C. Membrane thermal annealing is shown to increase lifetime with the ageing procedures used. A predictive lifetime model is proposed by correlating the estimated lifetime values and the experimental data via a lifetime coefficient.     

Influence of Radiation‐Induced Grafting Process on Mechanical Properties of ETFE‐Based Membranes for Fuel Cells

The mechanical stability is, in addition to thermal and chemical stability, a primary requirement of polymer electrolyte membranes in fuel cells. In this study, the impact of grafting parameters and preparation steps on stress–strain properties of ETFE‐based proton conducting membranes, prepared by radiation‐induced grafting and subsequent sulphonation, was studied. No significant change in the mechanical properties of the ETFE base film was observed below an irradiation dose of 50 kGy. It was shown that the elongation at break decreases with increasing both the crosslinker concentration and graft level (GL). However, the tensile strength was positively affected by the crosslinker concentration. Yield strength and modulus of elasticity are almost unaffected by the introduction of crosslinker. Interestingly, yield strength and modulus of elasticity increase gradually with GL without noticeable change of the inherent crystallinity of grafted films. The most brittle membranes are obtained via the combination of high GL and crosslinker concentration. The optimised ETFE‐based membrane (GL of ∼25%, 5% DVB v/v), shows mechanical properties superior to those of Nafion® 112 membrane. The obtained results were correlated qualitatively to the other ex situ properties, including crystallinity, thermal properties and water uptake of the grafted membranes.