A study on fabrication of sulfonated poly(ether ether ketone)-based membrane-electrode assemblies for polymer electrolyte membrane fuel cells

The porosity effect of catalyst electrodes in membrane-electrode assemblies (MEAs) using a hydrocarbon-based polymer as electrolyte and ionomer was investigated on physical and electrochemical properties by varying the content of ionomer binder (dry condition) in the catalyst electrodes. The MEAs were compared with the Nafion^®-based MEA using Nafion^® 112 and 5 wt.% ionomer solution (EW = 1100) in terms of porosity values, scanning electron microscopic images, Nyquist plots, dielectric spectra and I–V polarization curves. In this study, sulfonated poly(ether ether ketone) (SPEEK) membranes with 25 ± 5 μm of thickness and 5 wt.% ionomer solutions have been prepared. The prepared membranes were characterized in terms of FT-IR, DSC and proton conductivity. Proton conductivity of the SPEEK membranes was compared with one of the Nafion^® membranes with relative humidity. The porosity of the catalyst electrodes was calculated using the properties of catalyst, ionomer solution and solvent. As a result, the performance of the new type polymer (i.e., SPEEK in this study)-based MEA with the similar membrane conductivity and porosity of the catalyst electrode in the Nafion^® MEA was similar to that of the Nafion^® MEA.     

Crosslinked sulfonated poly(ether ether ketone) proton exchange membranes for direct methanol fuel cell applications

In the present study, a series of the crosslinked sulfonated poly(ether ether ketone) (SPEEK) proton exchange membranes were prepared. The photochemical crosslinking of the SPEEK membranes was carried out by dissolving benzophenone and triethylamine photo-initiator system in the membrane casting solution and then exposing the resulting membranes after solvent evaporation to UV light. The physical and transport properties of crosslinked membranes were investigated. The membrane performance can be controlled by adjusting the photoirradiation time. The experimental results showed that the crosslinked SPEEK membranes with photoirradiation 10 min had the optimum performance for proton exchange membranes (PEMs). Compared with the non-crosslinked SPEEK membranes, the crosslinked SPEEK membranes with photoirradiation 10 min markedly improved thermal stabilities and mechanical properties as well as hydrolytic and oxidative stabilities, greatly reduced water uptake and methanol diffusion coefficients with only slight sacrifice in proton conductivities. Therefore, the crosslinked SPEEK membranes with photoirradiation 10 min were particularly promising as proton exchange membranes for direct methanol fuel cell (DMFC) applications.     

Novel modification method to prepare crosslinked sulfonated poly(ether ether ketone)/silica hybrid membranes for fuel cells

Crosslinked organic-inorganic hybrid membranes are prepared from hydroxyl-functionalized sulfonated poly(ether ether ketone) (SPEEK) and various amounts of silica with the aims to improve dimensional stability and methanol resistance. The partially hydroxyl-functionalized SPEEK is prepared by the reduction of some benzophenone moieties of SPEEK into the corresponding benzhydrol moieties which is then reacted with (3-isocyanatopropyl)triethoxysilane (ICPTES) to get a side chained polymer bearing triethoxysilyl groups. These groups are subsequently co-hydrolyzed with tetraethoxysilane (TEOS) and allow the membrane to form a crosslinked network via a sol-gel process. The obtained hybrid membranes with covalent bonds between organic and inorganic phases exhibit much lower methanol swelling ratio and water uptake. With the increase of silica content, the methanol permeability coefficient of the hybrid membranes decreases at first and then increased. At silica content of about 6 wt.%, the methanol permeability coefficient reaches a minimum of 7.15 × 10⁻⁷ cm² s⁻¹, a 5-fold decrease compared with that of the pristine SPEEK. Despite the fact that the proton conductivity is decreased to some extent as a result of introduction of the silica, the hybrid membranes with silica content of 4-8 wt.% shows higher selectivity than Nafion117.     

The influences of multi-walled carbon nanotube addition to the anode on the performance of direct methanol fuel cells

Different amounts of multi-walled carbon nanotubes (MWCNTs) are added to anode catalyst layer in the membrane electrode assemblies (MEAs) of direct methanol fuel cells (DMFCs). The MEA with 0.5 wt.% carbon nanotubes (CNTs) shows the best performance in DMFC. In the protonic conductivity tests, a 0.5 wt.% amount of MWCNTs results in the highest protonic conductivity. SEM and TEM observations show that a continuous and uniform distribution of Nafion ionomer layer is formed on the MWCNT surface. Therefore, the dispersed MWCNTs in the catalyst layer are considered to be helpful for developing the pathways of protons transport.     

Performance of an integrated composite membrane electrode assembly in DMFC

We report here the performance of a metal-based integrated composite membrane electrode assembly (IC-MEA) in direct methanol fuel cell (DMFC). The IC-MEA integrates the multi-functions of a conventional MEA, gas diffusion layer (GDL) and current collector. It was fabricated by impregnating Nafion electrolyte into a sandwiched structure containing expanding-Polytetrafluoroethylene (e-PTFE) and porous titanium sheets and subsequently coating with catalyst layer and microporous layer (MPL). While operating with air and 2 M methanol under ambient pressure, the IC-MEA in DMFC can yield a maximum power density of 19 mW cm⁻² at 26 °C, higher than a in-house made Nafion 115 MEA under the same working conditions. The IC-MEAs has been successfully applied to planar multi-cell stacks.     

Fabrication and evaluation of membrane electrode assemblies by low-temperature decal methods for direct methanol fuel cells

In this study, a low-temperature decal transfer method is used to fabricate membrane electrode assemblies (MEAs) and the MEAs are tested for application in a direct methanol fuel cell (DMFC). The low-temperature decal transfer uses a carbon-layered decal substrate with a structure of ionomer/catalyst/carbon/substrate to facilitate the transfer of catalyst layers from the decal substrates to the membranes at a temperature as low as 140 °C, and also to prevent the formation of ionomer skin layer that is known to be formed on the surface of the transferred catalyst layer. The DMFC performance of the MEA (with carbon layer) fabricated by the low-temperature decal transfer method is higher than those of MEAs fabricated by the same method without a carbon layer, a conventional high-temperature decal method, and a direct spray-coating method. The improved DMFC performance of the MEA fabricated with carbon layer by the low-temperature decal transfer method can be attributed to the absence of an ionomer skin on the catalyst layer, which can streamline the diffusion of reactants. Furthermore, the intrinsic properties of the MEA fabricated by the low-temperature decal transfer method are elucidated by field-emission scanning electron microscopy (FESEM), electrochemical impedance spectroscopy (EIS), cyclic voltammetry (CV) techniques, and cathode CO₂ analysis.     

Long-term durability test for direct methanol fuel cell made of hydrocarbon membrane

A long-term durability test has been conducted for a direct methanol fuel cell (DMFC) using the commercial hydrocarbon membrane and Nafion ionomer bonded electrodes for 500 h. Membrane electrode assembly (MEA) made by a decal method has experienced a performance degradation about 34% after 500 h operation. Cross-sectional analysis of the MEA shows that the poor interfacial contact between the catalyst layers and membrane in the MEA has further deteriorated after the durability test. Therefore, the internal resistance of a cell measured by electrochemical impedance spectroscopy (EIS) has considerably increased. The delamination at the interfaces is mainly attributed to incompatibility between polymeric materials used in the MEA. Furthermore, X-ray diffraction (XRD) analysis reveals that the catalyst particles have grown; thereby decreasing the electrochemical surface area. Electron probe micro analysis (EPMA) shows a small amount of Ru crossover from anode to cathode; and its effect on the performance degradation has been analyzed.     

Sulfonated poly(arylene ether sulfone) as a methanol-barrier layer in multilayer membranes for direct methanol fuel cells

Novel poly(arylene ether sulfone) copolymers containing different amount of pendant sulfonic acid groups have been synthesized by an aromatic substitution polymerization reaction. The properties of the synthesized sulfonated poly(diphenylsulfone-diphenol) (SDPS-DP) copolymers depend on the sulfonic acid group content in the copolymers. Although all the copolymers show good thermal stability, low liquid uptake, and low methanol crossover, they exhibit lower proton conductivity than Nafion or sulfonated poly(ether ether ketone) (SPEEK). Taking advantage of the low methanol crossover, multilayer membranes consisting of the SDPS-DP copolymer as a methanol-barrier center layer and SPEEK as the proton-conducting outer layers have been fabricated and characterized. The SPEEK/SDPS-DP-60/SPEEK multilayer membranes with an optimized center layer thickness are found to exhibit better performance and higher power density in DMFC than plain SPEEK and Nafion 115 membranes.     

Water-alcohol dispersible and self-cross-linkable sulfonated poly(ether ether ketone): Application as ionomer for direct methanol fuel cell catalyst layer

A sulfonated poly(ether ether ketone) containing hydroxyl groups (HO-SPEEK) has been synthesized for investigation as the ionomer in cathode of direct methanol fuel cells. Na salt-formed HO-SPEEK shows excellent solubility in some aqueous solutions of monohydric alcohol and can be successfully self-cross-linked in-situ during the hot-pressing process of membrane-electrode assembly (MEA) fabrication. The resulted cross-linked HO-SPEEK displays improved stability and mechanical strength. MEA incorporating the HO-SPEEK as both membrane and ionomer shows excellent peak power density of 29.0 mW cm⁻² at 25 °C with 4 M methanol, which is comparable to the Nafion reference MEA (31.8 mW cm⁻²) and 2.9-fold higher than that of the MEA prepared from catalyst ink that contained dimethyl sulfoxide (10.3 mW cm⁻²). Thanks to the avoidance of high-boiling point solvent, the resulted HO-SPEEK-based cathode is loosened with many large pores for reactant gas and product transportation. These results demonstrate that water-alcohol dispersible and cross-linkable sulfonated hydrocarbons hold technological promise as ionomer for electrode.     

Preparation of nitrated sulfonated poly(ether ether ketone) membranes for reducing methanol permeability in direct methanol fuel cell applications

Sulfonated poly(ether ether ketone)s (SPEEKs) were further substituted on the polymer main chain by nitration. All sulfonation and nitration were achieved with an inexpensive and simple post substitute reaction. The nitrated SPEEKs have a high glass transition temperature and thermal decomposition temperature, and a lower water uptake than SPEEK, which provides sufficient mechanical strength without swelling in the direct methanol fuel cell (DMFC) application. The methanol permeability of nitrated SPEEKS is reduced to 1.76 × 10⁻⁷ cm² s⁻¹ for S53N22 and 1.86 × 10⁻⁷ cm² s⁻¹ for S63N17 with no loss of conductivity in the DMFC application, and a proton conductivity that reached 0.026 S cm⁻¹. The nitrated SPEEK membranes satisfy the requirements of proton-exchange membranes for the DMFC.     

The effect of Nafion content in a graphitized carbon nanofiber-based anode for the direct methanol fuel cell

The performance and stability of a direct methanol fuel cell (DMFC) with membrane electrode assemblies (MEA) using different Nafion^® contents (30, 50 and 70 wt% or MEA30, MEA50 and MEA70, respectively) and graphitized carbon nanofiber (GNF) supported PtRu catalyst at the anode was investigated by a constant current measurement of 9 days (230 h) in a DMFC and characterization with various techniques before and after this measurement. Of the pristine MEAs, MEA50 reached the highest power and current densities. During the 9-day measurement at a constant current, the performance of MEA30 decreased the most (−124 μV h⁻¹), while the MEA50 was almost stable (−11 μV h⁻¹) and performance of MEA70 improved (+115 μV h⁻¹). After the measurement, the MEA50 remained the best MEA in terms of performance. The optimum anode Nafion content for commercial Vulcan carbon black supported PtRu catalysts is between 20 and 40 wt%, so the GNF-supported catalyst requires more Nafion to reach its peak power. This difference is explained by the tubular geometry of the catalyst support, which requires more Nafion to form a penetrating proton conductive network than the spherical Vulcan. Mass transfer limitations are mitigated by the porous 3D structure of the GNF catalyst layer and possible changes in the compact Nafion filled catalyst layers during constant current production.     

Sulfonated poly(ether ether ketone)/poly(ether sulfone) composite membranes as an alternative proton exchange membrane in microbial fuel cells

Custom-made proton exchange membranes (PEM) are synthesized by incorporating sulfonated poly(ether ether ketone) (SPEEK) in poly(ether sulfone) (PES) for electricity generation in microbial fuel cells (MFCs). The composite PES/SPEEK membranes at various composition of SPEEK are prepared by the phase inversion method. The membranes are characterized by measuring roughness, proton conductivity, oxygen diffusion, water crossover and electrochemical impedance. The conductivity of hydrophobic PES membrane increases when a small amount (3–5%) of hydrophilic SPEEK is added. The electrochemical impedance spectra shows that the conductivity and capacitance of PES/SPEEK composite membranes during MFC operation are reduced from 6.15 × 10⁻⁷ to 6.93 × 10⁻⁵ (3197 Ω–162 Ω) and from 3.00 × 10⁻⁷ to 1.56 × 10⁻³ F, respectively when 5% of SPEEK added into PES membrane. The PES/SPEEK 5% membrane has the highest performance compared to other membranes with a maximum power density of 170 mW m⁻² at the maximum current density of 340 mA m⁻². However, the interfacial reaction between the membrane and the cathode with Pt catalyst indicates moderate reaction efficiency compared to other membranes. The COD removal efficiency of MFCs with composite membrane PES/SPEEK 5% is nearly 26-fold and 2-fold higher than that of MFCs with Nafion 112 and Nafion 117 membranes respectively. The results suggest that the PES/SPEEK composite membrane is a promising alternative to the costly perfluorosulfonate membranes presently used as separators in MFC systems.     

Sulfonated poly(ether ether ketone) membranes with sulfonated graphene oxide fillers for direct methanol fuel cells

Sulfonated organosilane functionalized graphene oxides (SSi-GO) synthesized through the grafting of graphene oxide (GO) with 3-mercaptopropyl trimethoxysilane and subsequent oxidation have been used as a filler in sulfonated poly(ether ether ketone) (SPEEK) membranes. The incorporation of SSi-GOs greatly increases the ion-exchange capacity (IEC), water uptake, and proton conductivity of the membrane. With well-controlled contents of SSi-GOs, the composite membranes exhibit higher proton conductivity and lower methanol permeability than Nafion^® 112 and Nafion^® 115, making them particularly attractive as proton exchange membranes (PEMs) for direct methanol fuel cells (DMFC). The composite membrane with optimal SSi-GOs content exhibit over 38 and 17% higher power densities, respectively, than Nafion^® 112 and Nafion^® 115 membranes in DMFCs, offering the possibilities to reduce the DMFC membrane cost significantly while keeping high-performance.     

Sulfonated polyether ether ketone and hydrated tin oxide proton conducting composites for direct methanol fuel cell applications

Composite membranes based on sulfonated polyether ether ketone (SPEEK) and hydrated tin oxide (SnO₂·nH₂O) were prepared and characterized. The formation of the composite substantially modified the properties of SPEEK in terms of durability and electrochemical performance. The structural and electrochemical performance of the samples were investigated using scanning electron microscopy (SEM), X-ray diffraction (XRD) analysis, electrochemical impedance spectroscopy (EIS), water and methanol uptake (WU, MU), and direct methanol fuel cell (DMFC) tests. The polymer electrolyte membrane doped with 50 wt% SnO₂·n(H₂O) possess good proton transport characteristics, reduced methanol uptake and improved stability with respect to a reference unfilled membrane and it is then suitable for application as electrolyte in DMFCs.     

Sulfonated poly(ether ether ketone)/polybenzimidazole oligomer/epoxy resin composite membranes in situ polymerization for direct methanol fuel cell usages

A diamine-terminated polybenzimidazole oligomer (o-PBI) has been synthesized for introducing the benzimidazole groups (BI) into sulfonated poly(ether ether ketone) (SPEEK) membranes. SPEEK/o-PBI/4,4′-diglycidyl(3,3′,5,5′-tetramethylbiphenyl) epoxy resin (TMBP) composite membranes in situ polymerization has been prepared for the purpose of improving the performance of SPEEK with high ion-exchange capacities (IEC) for the usage in the direct methanol fuel cells (DMFCs). The composite membranes with three-dimensional network structure are obtained through a cross-linking reaction between PBI oligomer and TMBP and the acid-base interaction between sulfonic acid groups and benzimidazole groups. Resulting membranes show a significantly increasing of all of the properties, such as high proton conductivity (0.14 S cm⁻¹ at 80 °C), low methanol permeability (2.38 × 10⁻⁸ cm² s⁻¹), low water uptake (25.66% at 80 °C) and swelling ratio (4.11% at 80 °C), strong thermal and oxidative stability, and mechanical properties. Higher selectivity has been found for the composite membranes in comparison with SPEEK. Therefore, the SPEEK/o-PBI/TMBP composite membranes show a good potential in DMFCs usages.     

Sulfonated titania submicrospheres-doped sulfonated poly(ether ether ketone) hybrid membranes with enhanced proton conductivity and reduced methanol permeability

Sulfonated titania submicrospheres (TiO₂-SO₃H) prepared through a facile chelation method are incorporated into sulfonated poly(ether ether ketone) (SPEEK) to fabricate organic-inorganic hybrid membranes with enhanced proton conductivity and reduced methanol permeability for potential use in direct methanol fuel cells (DMFCs). The pristine titania submicrospheres (TiO₂) with a uniform particle size are synthesized through a modified sol-gel method and sulfonated using 4,5-dihydroxy-1,3-benzenedisulfonic acid disodium salt as the sulfonation reagent. The sulfonation process is confirmed by Fourier transform infrared spectroscopy (FTIR) and X-ray photoelectron spectra (XPS). The hybrid membranes are systematically characterized in terms of thermal property, mechanical property, ionic exchange capacity (IEC), swelling behavior, and microstructural features. The methanol barrier property and the proton conductivity of the SPEEK/TiO₂-SO₃H hybrid membranes are evaluated. The presence of the fillers reduces methanol crossover through the membrane. Compared with the unsulfonated TiO₂-doped membranes, the TiO₂-SO₃H-doped ones exhibit higher proton conductivity due to the additional sulfonic acid groups on the surface of TiO₂. The hybrid membrane doped with 15 wt.% TiO₂-SO₃H submicrospheres exhibits an acceptable proton conductivity of 0.053 S cm⁻¹ and a reduced methanol permeability of 4.19 × 10⁻⁷ cm² s⁻¹.     

Surface-modified Nafion membrane by oleylamine-stabilized Pd nanoparticles for DMFC applications

The surface of Nafion was modified by applying palladium nanoparticles as methanol barrier materials to decrease methanol crossover and improve the performance of fuel cells. The properties of the Pd-modified membrane, in terms of conductivity, methanol permeability, percentage of liquid uptake as well as the performance of its membrane electrode assembly (MEA) in the direct methanol fuel cell, were analyzed and compared with those using bare Nafion. The modified membrane showed considerable improvement on reducing methanol loss without decreasing proton conductivity. The DMFC performance of modified membrane was superior to that of bare Nafion both at a typical fuel state of 2 M and at high concentration of 5 M, implying that the palladium-modified Nafion can be a good alternative approach for DMFC applications.     

Influence of annealing of membrane electrode assembly (MEA) on performance of direct methanol fuel cell (DMFC)

The influence of annealing of membrane electrode assembly (MEA) of a direct methanol fuel cell (DMFC) on the cell performance was investigated. The annealing was conducted at various temperatures of 110, 130, 150 and 200 °C. Annealing at 130 °C could produce highest proton conductivity of the recast Nafion binder and electrochemical active surface area of the electrode, leading to the highest cell performance.     

Optimization of Nafion content in Nafion–polyaniline nano-composite modified cathodes for PEMFC application

In this research several Nafion–Polyaniline nano-composite modified cathodes have been fabricated and evaluated in oxygen reduction reaction (ORR) in order to use in proton exchange membrane fuel cell (PEMFC). Modified cathodes made by the wide range of Nafion content (from 0 to 1.6 mg cm⁻²) and investigated in the acidic solution by different electrochemical techniques at 25 °C. The results indicate the activity of the modified electrodes is increased by employing of Nafion–Polyaniline nano-composite in the reaction layer, but there is an optimum value for Nafion content in the catalyst layer. The modified electrode impregnated by 0.4 mg cm⁻² of Nafion shows the highest activity. Analysis of the surface morphology of the Nafion–polyaniline modified electrodes by scanning electron microscopy and electrochemical data reveal that the existence of polyaniline (PANI) nanofibers in the catalyst layer before adding Nafion solution, improves the homogeneity distribution of the ionomer in catalyst layer, change the morphology of electrode and increase the performance of gas diffusion electrodes (GDEs) in oxygen reduction reaction.     

Cross-linked membranes based on sulfonated poly (ether ether ketone) (SPEEK)/Nafion for direct methanol fuel cells (DMFCs)

A series of cross-linked membranes based on SPEEK/Nafion have been prepared to improve methanol resistance and dimension stability of SPEEK membrane for the usage in the direct methanol fuel cells (DMFCs). Sulfonated diamine monomer is synthesized and used as cross-linker to improve the dispersion of Nafion in the composite membranes and decrease the negative effect of cross-linking on proton conductivity of membranes. FT-IR analysis shows that the cross-linking reaction is performed successfully. The effects of different contents of Nafion on the properties of cross-linked membranes are investigated in detail. All the cross-linked membranes show lower methanol permeability and better dimensional stability compared with the pristine SPEEK membrane. SPEEK-N30 with the 30 wt % Nafion shows a methanol permeability of 0.73 × 10⁻⁶ cm² s⁻¹ and a water uptake of 24.4% at 25 °C, which are lower than those of the pristine membrane. Meanwhile, the proton conductivity of SPEEK-N30 still remains at 0.041 S cm⁻¹ at 25 °C, which is comparable to that of the pristine SPEEK membrane. All the results indicate that these cross-linked membranes based on SPEEK/Nafion show good prospect for the use as proton exchange membranes.