Ionic conductivity improvement in primary pores of fuel cell catalyst layers: Electropolymerization of m-aminobenzenesulfonic acid and its effect on the performance

Catalyst layers of direct methanol fuel cells (DMFCs) are modified by in situ electropolymerization of m-aminobenzenesulfonic acid. By using electrochemical impedance spectroscopy and porosimetry, this modification is found to add polymer electrolyte into primary pores (<10 nm), where ionic resistance is high for lack of polymer electrolyte (i.e., Nafion), and the additional electrolyte successfully decreases the ionic resistance by 10-15% compared to the plain carbon surface with a slight ion-conductivity (>40 kΩ cm). In view of methanol oxidation characteristics, this modification decreases the resistance by ca. 25% (from 5.1 Ω cm² to 3.7 Ω cm²) at 0.6 V vs. DHE, resulting in the increase in the cell voltage of DMFC test by ca. 20 mV. The clear relation between the performance and the microstructures is concluded to be helpful to understand the performance of fuel cell electrodes in detail.     

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.     

Enhanced performance of a passive direct methanol fuel cell with decreased Nafion aggregate size within the anode catalytic layer

The decrease in Nafion ionomer size within the anode catalytic layer for a passive direct methanol fuel cell (DMFC) results in a significant enhancement in fuel cell’s performance. Dynamic light scattering measurement demonstrates that the agglomerate size of Nafion ionomer in the solution decreases and the aggregate particle size distribution becomes narrow until a monodispersed Nafion ionomer was obtained with an increase in heat treatment temperature. The improved performance of the passive DMFC with smaller Nafion ionomer agglomerates within the anode catalytic layer can be ascribed to a decrease in charge-transfer resistance of anodic reaction obtained by electrochemical impedance analysis and to an improvement in catalyst utilization verified by cyclic voltammetric measurement. Furthermore, the small congeries formed between catalyst nanoparticles and Nafion ionomers could lead to a decrease in Nafion loading within the catalytic layer. This study confirms that the decrease in Nafion aggregation within the catalytic ink is beneficial to an improvement in both catalyst and Nafion ionomer utilization, thus enhancing fuel cell’s performance.     

Low equivalent weight short-side-chain perfluorosulfonic acid ionomers in fuel cell cathode catalyst layers

The morphology and fuel cell performance of cathode catalyst layers (CCLs) using low equivalent weight (EW) short-side-chain (SSC) perfluorosulfonic acid ionomers have been investigated in this work. The results were compared with those for a baseline CCL containing 30 wt% of the conventional ionomer 1100 EW Nafion^®. The CCLs fabricated with 10-20 wt% of the Aquivion™ ionomer displayed a similar morphology to the Nafion^®-based CCLs. Electrochemical surface areas (ECSA) and double layer capacitances of all the Aquivion™-based samples were similar to those of the baseline. The oxygen reduction reaction (ORR) kinetics in CCLs with 20 wt% and 30 wt% Aquivion™ were lower than the baseline under 100% relative humidity (RH), yet similar to the baseline at 70% RH. In situ electrochemical impedance spectroscopy (EIS) measurements suggested that the lowered ORR kinetics at 100% RH may be attributed to the large mass transport resistance in Aquivion™-based samples at low current densities. Relative to the baseline, CCLs containing 20 wt% Aquivion™ ionomer demonstrated an improvement in fuel cell performance under operating conditions of 95 °C and RH values of 30, 50 and 70%. The greater hydrophilicity of the SSC ionomers is believed to account for the improved fuel cell performance at the relatively higher operating temperature and dry conditions.     

l-Ascorbic acid as an alternative fuel for direct oxidation fuel cells

l-Ascorbic acid (AA) was directly supplied to polymer electrolyte fuel cells (PEFCs) as an alternative fuel. Only dehydroascorbic acid (DHAA) was detected as a product released by the electrochemical oxidation of AA via a two-electron transfer process regardless of the anode catalyst used. The ionomer in the anode may inhibit the mass transfer of AA to the reaction sites by electrostatic repulsion. In addition, polymer resins without an ionic group such as poly(vinylidene fluoride) and poly(vinyl butyral) were also useful for reducing the contact resistance between Nafion membrane and carbon black used as an anode, although an ionomer like Nafion is needed for typical PEFCs. A reaction mechanism at the two-phase boundaries between AA and carbon black was proposed for the anode structure of DAAFCs, since lack of the proton conductivity was compensated by AA. There was too little crossover of AA through a Nafion membrane to cause a serious technical problem. The best performance (maximum power density of 16 mW cm⁻²) was attained with a Vulcan XC72 anode that included 5 wt.% Nafion at room temperature, which was about one-third of that for a DMFC with a PtRu anode.     

Application of hyperdispersant to the cathode diffusion layer for direct methanol fuel cell

In this study, Nafion ionomer, as a kind of hyperdispersant, was added to polytetrafluoroethylene (PTFE) water dispersion system to suppress the size of PTFE particles in the ink of microporous layer (MPL). The agglomeration behavior of PTFE in ethanol and MPL were investigated by laser diffraction, dynamic light scattering (DLS) and metallurgical microscopes. The electronic resistance, pore size distribution, gas permeability and surface hydrophobic/hydrophilic properties were also characterized for prepared gas diffusion layers (GDLs). It was shown that PTFE water dispersion system suffered flocculating when dispersed in ethanol and this agglomeration behavior was reduced by employing Nafion ionomer. With the increase in the Nafion ionomer adopted in the MPL, not only the decreased hydrophobic property was shown in the MPL, but the decreased PTFE particle size was also achieved, which results in improved crosslink of carbon and pores themselves as well as the volume loss of pores in micron scale. The increased gas permeability and electronic conductivity of the GDL made the one employing the PTFE dispersion system with 1% Nafion content own its advantages as the cathode diffusion layer for a direct methanol fuel cell (DMFC) under near-ambient conditions.     

Key parameters of active layers affecting proton exchange membrane (PEM) fuel cell performance

The 2ⁿ full factorial design was applied to identify the key parameters of the active layer affecting the performance of a proton exchange membrane (PEM) fuel cell. Three main selected parameters were considered: carbon-type (Vulcan XC 72R and Black Pearls 2000 conducting furnace blacks, Cabot Corporation Boston, MA), Pt loading (0.1 and 0.5 mg/cm²), and Nafion™ sulfonic acid fluoropolymer (Du Pont de Nemours, Wilmington, DE) ionomer content (10% and 60%) for variables A, B, and C, respectively. The results from full factorial analysis indicated that the key factors affecting the exchange current density or activation loss were Pt loading whereas the key factors controlling the resistance due to ohmic loss were Nafion content and carbon type. In addition, there are the interactions between these parameters controlling the thin-film active layer performance, especially the interaction of carbon type and Nafion content. From cyclic voltammograms and cell performance testing, a Nafion content of 30% in a catalyst layer consisting of 0.5 mg/cm² Pt on Vulcan XC 72R is optimal.     

Fuel cell catalyst layers containing short-side-chain perfluorosulfonic acid ionomers

Porous catalyst layers (CLs) containing short-side-chain (SSC) perfluorosulfonic acid (PFSA) ionomers of different ion exchange capacity (IEC: 1.3, 1.4 and 1.5 meq g⁻¹) were deposited onto Nafion 211 to form catalyst-coated membranes. The porosity of SSC-PFSA-based CLs is larger than Nafion-CL analogues. CLs incorporating SSC ionomer extend the current density of fuel cell polarization curves at elevated temperature and lower relative humidity compared to those based on long-side chain PFSA (e.g., Nafion)-based CLs. Fuel cell polarization performance was greatly improved at 110 °C and 30% relative humidity (RH) when SSC PFSI was incorporated into the catalyst layer.     

Proton conduction in Nafion composite membranes filled with mesoporous silica

Studies of proton-conductive polymer membranes are vital for the future development of high-performance polymer electrolyte membrane fuel cells (PEM-FC). In particular, a method for inhibiting the volatility of water in the polymer matrix at high temperatures is a crucial issue, directly related to the operation of PEM-FC system. In this study, we focus on polymer composite membranes, which consist of commercial Nafion and mesoporous silica (MPSi) as novel inorganic additives, and investigate an improvement in the total proton conductivities and the good electrochemical stability at high temperatures. MPSi, which can be synthesized with pore sizes from 1 to 10 nm, has a wide range of potential applications because of its extraordinary properties, such as extremely large surface area, flawless surface condition and well-regulated porous structure. We found that the Nafion composites filled with MPSi have approximately 1.5 times higher proton conductivities (more than 0.1 S cm⁻¹ at 80 °C and 95%RH) than pure Nafion and can display good temperature performance relative to pure Nafion and the particle SiO₂ composite. Moreover, the conductivity of Nafion/sulfonated MPSi was the highest (0.094 S cm⁻¹) at 40 °C and 95%RH. These are probably due to the large surface area of MPSi, which can increase the water adsorption in Nafion matrix.     

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.     

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.     

Sulfonated poly(ether ether ketone) as an ionomer for direct methanol fuel cell electrodes

Sulfonated poly(ether ether ketone) has been investigated as an ionomer in the catalyst layer for direct methanol fuel cells (DMFC). The performance in DMFC, electrochemical active area (by cyclic voltammetry), and limiting capacitance (by impedance spectroscopy) have been evaluated as a function of the ion exchange capacity (IEC) and content (wt.%) of the SPEEK ionomer in the catalyst layer. The optimum IEC value and SPEEK ionomer content in the electrodes are found to be, respectively, 1.33 meq. g⁻¹ and 20 wt.%. The membrane-electrode assemblies (MEA) fabricated with SPEEK membrane and SPEEK ionomer in the electrodes are found to exhibit superior performance in DMFC compared to that fabricated with Nafion ionomer due to lower interfacial resistance in the MEA as well as larger electrochemical active area. The MEAs with SPEEK membrane and SPEEK ionomer also exhibit better performance than that with Nafion 115 membrane and Nafion ionomer due to lower methanol crossover and better electrode kinetics.     

Study on the membrane electrode assembly fabrication with carbon supported cobalt triethylenetetramine as cathode catalyst for proton exchange membrane fuel cell

An improved fabrication technique for conventional hot-pressed membrane electrode assemblies (MEAs) with carbon supported cobalt triethylenetetramine (CoTETA/C) as the cathode catalyst is investigated. The V-I results of PEM single cell tests show that addition of glycol to the cathode catalyst ink leads to significantly higher electrochemical performance and power density than the single cell prepared by the traditional method. SEM analysis shows that the MEAs prepared by the conventional hot-pressed method have cracks between the cathode catalyst layer and Nafion membrane, and the contact problem between cathode catalyst layer and Nafion membrane is greatly suppressed by addition of glycol to the cathode catalyst ink. Current density-voltage curve and impedance studies illuminate that the MEAs prepared by adding glycol to the cathode catalyst ink have a higher electrochemical surface area, lower cell ohmic resistance, and lower charge transfer resistance. The effects of CoTETA/C loading, Nafion content, and Pt loading are also studied. By optimizing the preparation parameters of the MEA, the as-fabricated cell with a Pt loading of 0.15 mg cm⁻² delivers a maximum power density of 181.1 mW cm⁻², and a power density of 126.2 mW cm⁻² at a voltage of 0.4 V.     

Sulfonated polyimide/PTFE reinforced membrane for PEMFCs

A sulfonated polyimide (SPI)/PTFE reinforced membrane was synthesized by impregnating PTFE (porous polytetrafluoroethylene) membrane with a SPI/DMSO solution. The resulting composite membrane was mechanically durable and quite thin relative to traditional perfluorosulfonated ionomer membranes (PFSI). We expect the PTFE to restrict the swelling and dimensional change of the SPI when it is immersed into water. And the reinforcement with PTFE can increase the hydrolysis stability of the SPI due to the low swelling and low dimensional change. From ex-situ testing and a short term fuel cell “life” test, we conclude that the PTFE reinforced sulfonated polyimide had a higher hydrolytic stability than pure sulfonated polyimide. The thin SPI/PTFE membrane showed comparable fuel cell performance with the commercial NRE-212 membrane with H₂/O₂ at 80 °C under fully humidified conditions. The chemically modified membrane with Nafion layer showed good stability in a 120 h fuel cell test.     

Impact of ionomer resistance in nanofiber-nanoparticle electrodes for ultra-low platinum fuel cells

Previously, nanofiber-nanoparticle electrodes produced via a simultaneous electrospinning and electrospraying (E/E) process (E/E electrodes) resulted in polymer electrolyte membrane fuel cells with high power densities at ultra-low platinum (Pt) loadings (<0.1 mg_Pt cm⁻²). In this study, E/E electrodes were fabricated at various Nafion contents to investigate the impact of ionomer content on catalyst layer transport resistances and fuel cell power density at ultra-low Pt loadings. Regardless of the Nafion content in the electrospray, the Nafion nanofiber diameters and catalyst aggregate particle sizes are constant in the E/E electrodes evidenced by electron microscopy. Therefore, this study allows for the exclusive investigation of the effect of transport resistances on fuel cell performances at different ionomer contents at a constant catalyst layer morphology, which differs from conventional electrodes. At higher magnifications, changes are evident in the micrographs around the catalyst aggregate particles, where an increase in ionomer thin film thickness is observed with increasing ionomer content. The maximum fuel cell performance and a minimum in catalyst layer resistance for E/E electrodes is observed at a total Nafion content of 62 wt%, which differs from conventional electrodes (ca. 30 wt%).     

Preparation and performance of nano silica/Nafion composite membrane for proton exchange membrane fuel cells

Composite membranes made from Nafion ionomer with nano phosphonic acid-functionalised silica and colloidal silica were prepared and evaluated for proton exchange membrane fuel cells (PEMFCs) operating at elevated temperature and low relative humidity (RH). The phosphonic acid-functionalised silica additive obtained from a sol–gel process was well incorporated into Nafion membrane. The particle size determined using transmission electron microscope (TEM) had a narrow distribution with an average value of approximately 11 nm and a standard deviation of ±4 nm. The phosphonic acid-functionalised silica additive enhanced proton conductivity and water retention by introducing both acidic groups and porous silica. The proton conductivity of the composite membrane with the acid-functionalised silica was 0.026 S cm⁻¹, 24% higher than that of the unmodified Nafion membrane at 85 °C and 50% RH. Compared with the Nafion membrane, the phosphonic acid-functionalised silica (10% loading level) composite membrane exhibited 60 mV higher fuel cell performance at 1 A cm⁻², 95 °C and 35% RH, and 80 mV higher at 0.8 A cm⁻², 120 °C and 35% RH. The fuel cell performance of composite membrane made with 6% colloidal silica without acidic group was also higher than unmodified Nafion membrane, however, its performance was lower than the acid-functionalised silica additive composite membrane.     

Ionomer content in the catalyst layer of polymer electrolyte membrane fuel cell (PEMFC): Effects on diffusion and performance

The percolating paths of the carbons and electrolytes in a cathode catalyst layer (CCL) could be successfully visualized in three-dimensions in order to investigate both the electronic and ionic connectivity by modeling a three-dimensional (3-D), meso-scale CCL of a polymer electrolyte membrane fuel cell (PEMFC). The effective Knudsen diffusion coefficients could also be obtained by computing pore tortuosity values. Electrochemical simulation studies were carried out by feeding air at 70 °C. Low platinum (Pt) loading (0.1 mg cm⁻²) catalysts with ionomer contents ranging from 14 to 50% were studied. The performance of a PEMFC electrode was affected by the ionomer content which is optimal at about 33%. In this case, both electronic and ionic connectivity produced the broadest active surface area of the Pt catalyst. The polarization drop tendency was in good agreement with the experiment, and this percolation study could successfully explain the existence of an optimum amount of ionomer.     

In and ex situ characterization of an anion-exchange membrane for alkaline direct methanol fuel cell (ADMFC)

Anion exchange membrane fumasep^® FAA-2 was characterized with ex and in situ methods in order to estimate the membranes’ suitability as an electrolyte for an alkaline direct methanol fuel cell (ADMFC). The interactions of this membrane with water, hydroxyl ions and methanol were studied with both calorimetry and NMR and compared with the widely used proton exchange membrane Nafion^® 115. The results indicate that FAA-2 has a tighter structure and more homogeneous distribution of ionic groups in contrast to the clustered structure of Nafion, moreover, the diffusion of OH⁻ ions through this membrane is clearly slower compared to water molecules. The permeability of methanol through the FAA-2 membrane was found to be an order of magnitude lower than for Nafion. Fuel cell experiments in 1 mol dm⁻³ methanol with FAA-2 resulted in OCV of 0.58 V and maximum power density of 0.32 mW cm⁻². However, even higher current densities were obtained with highly concentrated fuels. This implies that less water is needed for fuel dilution, thereby decreasing the mass of the fuel cell system. In addition, electrochemical impedance spectroscopy for the ADMFC was used to determine ohmic resistance of the cell facilitating the further membrane development.     

Platinum-plated nanoporous gold: An efficient,low Pt loading electrocatalyst for PEM fuel cells

Platinum-plated nanoporous gold leaf (Pt-NPGL) is made by coating a conformal, atomically thin skin of platinum over the high surface area pores of a thin membrane of nanoporous gold. Because Pt loading in Pt-NPGL can be controlled down to 0.01 mg cm⁻² using only simple benchtop chemistry, the material holds promise as a low Pt loading, carbon-free electrocatalyst. Here, we report successful use of Pt-NPGL as a catalyst in proton exchange membrane (PEM) fuel cells. Stable and high performance Pt-NPGL/Nafion membrane electrode assemblies (MEAs) were made using a stamping technique. The performance of Pt-NPGL MEAs is comparable to conventional carbon-supported nanoparticles-based MEAs with much higher loading, generating an output power density of up to 4.5 kW g⁻¹ Pt in our non-optimized test configuration. Correlations between the performance of Pt-NPGL MEAs, the electrochemically accessible surface area, and material microstructure are discussed. Our success in using Pt-NPGL as a fuel cell catalyst suggests that creating precious metals skins over nanoporous metal supports is a viable strategy for designing new catalysts for PEM fuel cells. This promising approach allows tailoring catalytic activity by engineering precious metal/substrate interactions, employs materials with dual functionality acting both as current collector and catalyst, and may avoid the sintering problems plaguing conventional nanoparticle-based catalysts.     

Development of high-performance planar borohydride fuel cell modules for portable applications

Direct borohydride fuel cell (DBFC) as a liquid type fuel cell is promising for portable applications. In this study, we report our recent progress in the micro-fuel cell development. A power density of 80 mW cm⁻² was achieved in passive mode at ambient conditions when using the anode containing nickel, carbon-supported Pd catalyst and Nafion ionomer. Current efficiency was also found to be greatly increased due to the use of Nafion rather than polytetrafluoroethylene (PTFE). Based on improvements on single cell performance, planar multi-cell power modules were assembled to study the feasibility of making high-performance and practical DBFC power units. A power of 2.5 W was achieved in a fully passive eight-cell module after significantly simplifying cell structure.