Nanostructured membrane electrode assemblies from layer‐by‐layer composite/catalyst containing membranes and their fuel cell performances

In this study, two approaches are compared to develop nanostructured membrane electrode assemblies (MEA) using layer‐by‐layer (lbl) technique. The first is based on the direct deposition of polyallylamine hydrochloride (PAH) and sulfonated polyaniline (sPAni) on Nafion support to prepare lbl composite membrane. In the second approach, sPAni is coated on the support in the presence of platinum (Pt) salt, Nafion solution and Vulcan for obtaining catalyst containing membranes (CCMs). SEM and UV–vis analysis show that the multilayers are deposited on both sides of Nafion successfully. Although H₂/O₂ single cell performances of acid doped lbl composite membrane based MEA are found to be at the range of 126 and 160 mW cm^?2 depending on the number of deposited layers, the cell performance of MEA obtained from catalyst containing lbl self‐assembled thin membrane (PAH/sPAni‐H⁺)_10‐Pt is found to be 360 mW cm^?2 with a Pt utilization of 720 mW mgPt^?1. This performance is 82% higher as compared to original Nafion^®117 based MEA (198 mW cm^?2). From the cell performance evaluations for different structured MEAs, it is mainly found out that the use of lbl CCMs instead of composite membranes and fabrication of thinner electrolytes result in a higher H₂/O₂ cell activity due to significant reduction in ohmic resistivity. Also, it is observed that the use of sPAni slightly improves the cell performance due to an increased probability of the triple phase contact and it can lead to superior physicochemical properties such as conductivity and thermal stability. © 2014 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 40314.     

Benefits of Membrane Electrode Assemblies with Asymmetrical GDL Configurations for PEM Fuel Cells

Membrane electrode assemblies (MEAs), based on commercial catalyst‐coated membranes combined with various gas diffusion layers (GDLs) on anode and cathode, were studied in terms of their specific advantages for different operations regimes of proton exchange membrane fuel cells (PEMFCs.) It is verified that MEAs with optimized gas diffusion layer designs (backing and micro‐porous layers) on anode and cathode are able to provide improved cell performance combined with a largely reduced sensitivity towards changes in the relative humidity as compared to MEAs with symmetrical gas diffusion layer configuration.     

The Influence of Pt Loading,Support and Nafion Content on the Performance of Direct Methanol Fuel Cells: Examined on the Example of the Cathode

Nano‐sized Pt colloids were prepared using the polyol method and supported on Ketjen black EC 600J (KB), Vulcan XC‐72 (VC) and high surface area graphite 300 (HG). The effects of the Nafion ionomer content, and the Pt loading of the cathode catalyst layer as well as the Pt loading on the support on the performance of direct methanol fuel cells (DMFCs), were studied. The membrane electrode assemblies (MEAs) were analysed using current–voltage curves, cyclic voltammetry, electrochemical impedance spectroscopy (EIS) and adsorbed CO stripping voltammetry. Optimum Nafion to carbon (N/C) ratios (N/C being defined as the weight ratio of the Nafion ionomer to the carbon) were determined. The optimum N/C ratios were found to depend on the support as follows, 1.4, 0.7 and 0.5 for Pt/KB, Pt/VC and Pt/HG, respectively and to be independent of the Pt/C loading range of 20–80 wt% tested in this work. The highest DMFC performances, as well as the highest electrochemical active surface areas, and improved gas diffusivities, were achieved using these ratios. For the catalysts prepared in this work, the average Pt crystallite size was found to decrease with increasing surface area of the support for a particular Pt loading. MEAs made using KB as support and the optimal N/C ratio of 1.4 showed the best performances, i.e. higher than the VC and HG supports for any N/C ratio. The highest DMFC performance was observed using 60 wt% Pt on KB cathode electrodes of 1 mg Pt cm^–2 loading and an N/C value of 1.4. For all three supports studied, the 60 wt% Pt on carbon loading resulted in the best DMFC performance. This may be linked to the Pt particle size and catalyst preparation method used in this work. In comparison to literature results, high DMFC performances were achieved using relatively ‘low' Pt and Ru loadings. For example, a maximum power density of >100 mW cm^–2 at 60 °C was observed using a 1 mg Pt cm^–2 cathode loading and a 2 mg PtRu cm^–2 anode loading.     

Comparative Study of On‐Line Membrane Electrode Assembly Activation Procedures in Proton Exchange Membrane Fuel Cell

The major objectives of this study are to identify the best activation procedure between commonly used procedures that can significantly reduce the conditioning duration and to understand the change in interfacial properties during conditioning. In order to do that, three on‐line activation procedures were employed for activating of identical MEAs in PEMFC and studied by polarization curve and electrochemical impedance spectroscopy (EIS). These methods are constant current (0.25 A cm^–2) for 19 h, constant voltage (0.6 V) for 9 h, and USFCC protocol. The best performance was achieved by USFCC protocol within 15 h, but by constant voltage procedure, 96% of mentioned protocol was obtained during 6 h. So constant voltage activation proceeded remarkably fast, and most of the activation process was achieved in the first few hours. Obtained results from Nyquist plots during/after MEA conditioning indicate mentioned process are irreversible and interfacial structures of MEAs are different even after finishing of MEA break‐in. It could be affected the MEA performance and even its durability. These results are consistence with the obtained performance of activated MEAs either in H₂/air or H₂/O₂ PEMFC. We found the mentioned constant current procedure consume long time without reaching to expectable performance even after 19 h.     

Fabrication and Performance of Different Structural Cathode Catalyst Layers by EHDA Deposition for DMFC

In this work, electrohydrodynamic atomization Layer‐by‐Layer deposition was used to deposit cathode catalyst layers (CLs) at different working distances of 3, 5, and 7 mm. The influence of working distance on the structural characteristics of cathode CLs was analyzed. The cyclic voltammograms of the cathode electrodes with different structures and the performance of the assembled membrane‐electrode assemblies (MEAs) were examined. It was observed that the cathode CLs presented well‐packed and porous features. The dispersity of the deposited catalyst and the thickness of cathode CL increased with higher working distance, which resulted in larger electrochemical active surface area (ESA), higher performance of the assembled MEAs and higher catalyst utilization. The ESA increased by approximately 70% when the cathode CL produced at the working distance of 7 mm compared with that at 3 mm. The peak power density of 56.1 mW cm^–2 and the peak cathode catalyst specific power of 140.3 mW mg^–1 Pt were obtained when the cathode CLs produced at the working distance of 7 mm.     

Durability of ABPBI‐based MEAs for High Temperature PEMFCs at Different Operating Conditions

High temperature PEMFCs based on phosphoric acid‐doped ABPBI membranes have been prepared and characterised. At 160 °C and ambient pressure fuel cell power densities of 300 mW cm^–2 (with hydrogen and air as reactants) and 180 mW cm^–2 (with simulated diesel reformate/air) have been achieved. The durability of these membrane electrode assemblies (MEAs) in the hydrogen/air mode of operation at different working conditions has been measured electrochemically and has been correlated to the cell resistivity, the phosphoric acid loss rate and the catalyst particle size. Under stationary conditions, a voltage loss of only –25 μV h^–1 at a current density of 200 mA cm^–2 has been deduced from a 1,000 h test. Under dynamic load changes or during start–stop cycling the degradation rate was significantly higher. Leaching of phosphoric acid from the cell was found to be very small and is not the main reason for the performance loss. Instead an important increase in the catalyst particle size was observed to occur during two long‐term experiments. At high gas flows of hydrogen and air ABPBI‐based MEAs can be operated at temperatures below 100 °C for several hours without a significant irreversible loss of cell performance and with only very little acid leaching.     

Effect of fabrication methods of bifunctional catalyst layers on unitized regenerative fuel cell performance

In order to understand the origins of performance variations in unitized regenerative fuel cells (URFCs), bifunctional catalyst layers (BCLs) fabricated with two different methods, i.e., ink deposition on membrane or GDL, were designed in this paper. The performances of the two different methods were evaluated, and their reaction dynamics were measured by electrochemical impedance spectra. The different BCLs, caused by the different preparation processes, were found to influence the fuel cell performance. The cell potentials of the URFCs using platinum sprayed onto the gas diffusion layer (GDL) are above 0.100 V higher than those with platinum sprayed onto the membrane at 800 mA cm⁻² in fuel cell (FC) mode. The mass transport resistances of the URFCs at different operation modes were also compared. It was proved that the platinum layer formed by applying platinum onto the GDL could prevent the cell from water flooding in FC mode. However, it was found that the cell performance changed slightly in water electrolysis mode with different BCLs. The electron conduction path was also found to be hindered by an IrO₂ agglomerate, which led to a decrease in cell performance. The highest and lowest round-trip efficiencies of the URFC with different BCLs were 42.1% and 22.3%, respectively, at 800 mA cm⁻².     

Pore‐forming technology and performance of MEA for direct methanol fuel cells

BACKGROUND: The commercialization of DMFCs is seriously restricted by its relatively low power density. Lots of work has been concentrated on catalysts with high activity, the optimization of flow path design, development of new kinds of proton exchange membrane and modification of Nafion membrane. Meanwhile, very few reports have involved the structure optimization of the membrane electrode assembly (MEA). To improve the performance of direct methanol fuel cells (DMFCs), the catalyst layer (CL) structures of anode and cathode were optimized by utilizing ammonium carbonate as pore forming agent. RESULTS: The polarization curves showed that in catalyst slurry the optimal content of ammonium carbonate was 50 wt%, and the DMFC performance was enhanced from 75.65 mW cm^?2 to 167.42 mW cm^?2 at 55 °C and 0.2 MPa O₂. Electrochemical impedance spectroscopy and electrochemical active surface area (EASA) testing revealed that the improved performance of optimized MEAs could be mainly attributed to the increasing EASA and the enhanced mass transfer rate of CLs. But poor methanol crossover limited the performance enhancement of MEAs with porous anodes. CONCLUSION: With regard to improving cell performance, this pore‐forming technology is better applied to the cathode catalyst layer to improve its structure rather than the anode catalyst layer. © 2012 Society of Chemical Industry     

The Effect of Methanol Crossover on the Cathode Overpotential of DMFCs

The effects of methanol crossover on cathode overpotential of direct methanol fuel cells (DMFCs) were investigated by focusing on a mixed potential effect and surface poisoning of the catalyst. Experiments using different membranes and catalyst loadings were performed and compared with a semi‐quantitative model to discuss the main cause of the cathode overpotential. When the measured methanol crossover increased, cathode overpotential increased at particular threshold values, which were 150 mA cm^–2 at 0.3 mg cm^–2 of cathode platinum (Pt) loading and above 200 mA cm^–2 at 1.1 mg cm^–2. The modelling results also supported this tendency, and showed that Pt surface was poisoned to a great extent above the threshold methanol crossover where the cathode overpotential increased sharply, while the cathode overpotential remained low and was explained solely by the mixed potential below the threshold value. The threshold methanol crossover can be regarded as the acceptable value, below which the cathode overpotential from methanol crossover remains low, and was related with the Pt loading in the cathode. The reduction of methanol crossover through membranes below the acceptable values will contribute greatly to a decrease in the cathode overpotential and to the reduction of catalyst loadings.     

Gas Diffusion Layers for Proton Exchange Membrane Fuel Cells Using In situ Modified Carbon Papers with Multi‐walled Carbon Nanotubes Nanoforest

Gas diffusion layers (GDLs) in the proton exchange membrane fuel cells (PEMFCs) enable the distribution of reactant gases to the reaction zone in the catalyst layers by controlling the water in the pore channels apart from providing electrical and mechanical support to the membrane electrode assembly (MEA). In the present work, we report the in situ growth of carbon nanotubes nanoforest (CNN) directly onto macro‐porous carbon paper substrates. The surface property as analysed by a Goniometer showed that the CNN/carbon paper surface is highly hydrophobic. CNN/carbon paper was employed as a GDL in an MEA using Nafion‐212 membrane as an electrolyte and evaluated in single cell PEMFCs. While the GDLs prepared by wire‐rod coating process have major performance losses at lower humidities, the in situ CNN/carbon paper, developed in this work, shows very stable performance at all humidity conditions demonstrating a significant improvement for fuel cell performance. The CNN/carbon‐based MEAs showed very stable performance with power density values of ∼1,100 and 550 mW cm^–2, respectively, both using O₂ and air as oxidants at ambient pressure.     

Fuel cell performance of polymer electrolyte membrane based on hexafluorinated sulfonated poly(ether sulfone)

The potential-current fuel cell characteristics of membrane electrode assemblies (MEAs) using hexafluorinated sulfonated poly(ether sulfone) copolymer are compared to those of Nafion^® based MEAs in the case of proton exchange membrane fuel cell (PEMFC) and direct methanol fuel cell (DMFC). The hexafluorinated copolymer with 60 mol% of monosulfonated comonomer based acid form membrane is chosen for this study due to its high proton conductivity, high thermal stability, low methanol permeability, and its insolubility in boiling water. The catalyst powder is directly coated on the membrane and the catalyst coated membrane is used to fabricate MEAs for both fuel cells. A current density of 530 mA cm^?2 at 0.6 V is obtained at 70 °C with H₂/air as the fuel and oxidant. The peak power density of 110 mW cm^?2 is obtained at 80 °C under specific DMFC operating conditions. Other electrochemical characteristics such as electrochemical impedance spectroscopy, cyclic voltammetry, and linear sweep voltammetry are also studied.     

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.     

DMFC electrode preparation,performance and proton conductivity measurements

A method that involves stenciling electrodes using dry powders for fuel cells is described and compared to anodes and cathodes prepared by the traditional spraying method using catalyst inks. Methods to determine the proton conductivity of the DMFC anode layer are also discussed. The stenciling method allows for the preparation of highly reproducible membrane electrode assemblies (MEAs) utilizing little waste material. MEAs can be prepared in a controlled manner using the stenciling technique. The resulting morphology of the as-prepared electrodes is observed to be dependent on the preparation method, while the thickness of the once hot-pressed catalyst layers appears to be independent of the preparation method. Stenciled anodes of the same catalyst loading were found to show a lower proton resistance (R_p) than sprayed anodes. However, the lower R_p value was not sufficient to result in a measurable increase in the performance of a direct methanol fuel cell (DMFC); as in fact, the average steady-state DMFC performance was found to be the same using sprayed or stenciled electrodes. The DMFC performance was found to be strongly dependent on the Nafion content and large increases in the Nafion content were needed to increase the DMFC performance measurably. Even though thick electrodes were prepared in this work, the R_p values of the stenciled anodes were found to be comparable to results reported in the literature for much thinner electrodes made using high metal catalyst loadings on carbon. This observation is most probably due to the higher Nafion content used in this work.     

Sulfonated poly(ether sulfone)‐based catalyst binder for a proton‐exchange membrane fuel cell

Sulfonated poly(ether sulfone) copolymer (PES 60) and its partially fluorinated analogue (F‐PES 60) were synthesized via the nucleophilic aromatic polycondensation of commercially available monomers to make a polymer electrolyte membrane and a binding material in the electrodes of a membrane–electrode assembly (MEA). PES 60 and F‐PES 60 showed proton conductivities of 0.091 and 0.094 S/cm, respectively, in water at room temperature. The copolymer was dissolved in the mixture of alcohol and water to get a 1 wt % binder solution. A catalyst slurry was prepared with the copolymer solution and sprayed on the copolymer (PES 60 or F‐PES 60) membrane to obtain a MEA. Both PES 60 and F‐PES 60 based MEAs were fabricated with different amounts of their binder in the electrodes to examine the effect of the copolymer binder in the catalyst layer on the fuel cell performance. The MEA with 2 wt % copolymer binder in the electrodes showed the best fuel cell performance. © 2009 Wiley Periodicals, Inc. J Appl Polym Sci, 2009     

Characterization of Membrane Electrode Assemblies for High‐Temperature PEM Fuel Cells

This paper will present the characterization of two types of membrane‐electrode‐assemblies (MEAs) for high‐temperature polymer electrolyte membrane fuel cells (HT‐PEMFC) working under reformate stream. The important aspects to be considered in the characterization of these MEAs are: (i) presence of contaminants, and (ii) composition of the anode. Start/stop cycling test were performed for two different Dapozol® MEAs using different GDL materials, using first hydrogen and then synthetic reformate as a fuel gas, both with a dew point of 80 °C. With these results the influence of contaminants present in the reformate was compared for the two types of MEAs, showing the superior performance of the Dapozol® 101 MEA under these conditions. The possibility to further enhance the MEAs' resilience against the operation of reformates by changing the anode catalyst composition was evaluated in a half MEA configuration, considering that the impact of the H₂S present in the fuel presents a major issue. For this reason the hydrogen oxidation reaction (HOR) was evaluated for two types of Pt‐based electrocatalysts in an anodic half MEA configuration using different hydrogen‐rich fuel mixtures. These results provide valuable information for the optimization of the MEA and the anode catalyst for HT‐PEMFC.     

SAXS Analysis of Catalyst Degradation in High Temperature PEM Fuel Cells Subjected to Accelerated Ageing Tests

The loss in performance during fuel cell operation is one of the critical factors that hamper fuel cells commercialization. This paper presents a research activity related to high temperature polymer electrode membrane fuel cell (HT‐PEMFC) degradation. The aim of the study is to investigate catalyst degradation of membrane electrode assemblies (MEAs) subjected to load cycles. Two HT‐PEM MEAs have been subjected to accelerated ageing tests based on load cycling. The cycles profile has been chosen in order to enhance catalyst degradation. Both the tests show a fuel cell performance loss lower than 30 mV after 100,000 cycles at 600 mA cm⁻². In order to analyze the catalyst evolution, synchrotron small angle X‐ray scattering (SAXS) has been employed. The catalyst degradation of the two conditioned samples has been compared with the data obtained from a new MEA that has been used as reference sample. The SAXS results showed a mean size increase of the platinum nanoparticles up to the 100%.     

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.     

Catalytic para‐xylene maximization: III. Hydroisomerization of meta‐xylene on H‐ZSM‐5 catalysts containing different platinum contents

Hydroisomerization of meta‐xylene was carried out using catalysts containing 0.15–0.60 wt% Pt on H‐ZSM‐5 zeolite, in a pulsed microreactor system connected to a gas chromatograph at a flow of hydrogen of 20 cm³ min⁻¹ and temperatures of 275–500 °C. Increasing temperature, increased isomerization with low rates. Increasing Pt content of the catalyst, decreased hydrodealkylation considerably via masking strong acid sites as revealed by temperature programmed desorption of ammonia measurements. Formation of trimethylbenzenes was inhibited by Pt incorporation in the H‐ZSM‐5 zeolite. The activation energies obtained for meta‐xylene hydroisomerization were relatively low (24.4–61.6 kJ mol⁻¹) on all catalysts under study. Para‐xylene yields in the xylenes mixture of product relative to the corresponding thermodynamic equilibrium values amount to about 0.8–0.9 at temperatures of 400–500 °C but were lower at lower temperatures. © 1999 Society of Chemical Industry     

Layer‐by‐layer assembled hydrogel nanocomposite film with a high loading capacity

The layer‐by‐layer assembly technique is a method that widely used in the preparation of nanostructured multilayer ultrathin films. We fabricated a hydrogel nanocomposite film by alternating the deposition of a core–shell poly[(dimethylimino)(2‐hydroxy‐1,3‐propanedily) chloride] (PDMIHPC)–laponite solution and poly(acrylic acid). The growth of the deposition procedure was proven by ultraviolet–visible spectroscopy and spectroscopic ellipsometry. The surface morphology of the films was observed by scanning electron microscopy. The films could reversibly load and release methylene blue (MB) dye, which was used as an indicator. It took about 4.5 h to reach loading equilibrium at pH 9.0. The loading capacity of the film for MB was as large as 4.48 μg/cm² per bilayer because of the introduction of the core–shell PDMIHPC–laponite as a film component. Nearly 90% of MB was released at pH 3.0 or in a 300 mM NaCl solution within 2.5 h. The loading and release processes were greatly influenced by the ionic strength and pH value of the MB solution. The hydrogel nanocomposite film showed good pH‐triggered loading‐release reversibility and suggested potential applications in controlled drug‐delivery systems and smart materials. © 2013 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2014 , 131, 39352.     

High Temperature Operation of a Solid Polymer Electrolyte Fuel Cell Stack Based on a New Ionomer Membrane

Polymer electrolyte fuel cell stacks assembled with Johnson Matthey Fuel Cells and SolviCore MEAs based on the Aquivion™ E79‐03S short‐side chain (SSC), chemically stabilised perfluorosulphonic acid membrane developed by Solvay Solexis were investigated at CNR‐ITAE in the EU Sixth Framework ‘Autobrane' project. Electrochemical experiments in fuel cell short stacks were performed under practical automotive operating conditions at pressures of 1–1.5 bar abs. over a wide temperature range, up to 130 °C, with varying levels of humidity (down to 18% R. H.). The stacks using large area (360 cm²) MEAs showed elevated performance in the temperature range from ambient to 100 °C (cell power density in the range of 600–700 mWcm^–2) with a moderate decrease above 100 °C. The performances and electrical efficiencies achieved at 110 °C (cell power density of about 400 mWcm^–2 at an average cell voltage of about 0.5–0.6 V) are promising for automotive applications. Duty‐cycle and steady‐state galvanostatic experiments showed excellent stack stability for operation at high temperature. A performance comparison of Aquivion^TM and Nafion^TM‐based MEAs under practical operating conditions showed a significantly better capability for the Solvay Solexis membrane to sustain high temperature operation.