Catalyst layers protonic conductivity

The anode and cathode CLs are the key components in PEM fuel cells because both the ORR and the HOR take place within them to yield fuel cell performance. They are thin layers (-10-100 (im, usually <50 (im), mainly composed of catalyst powders, proton conductive ionomer (normally Nafion ionomer), and polytetrafluoroethylene (PTFE). 

A considerable decrease in platinum consumption without performance loss was attained when a certain amount (30 to 40% by mass) of the proton-conducting polymer was introduced into the catalytically active layer of the electrode. To this end a mixture of platinized carbon black and a solution of (low-equivalent-weight ionomeric ) Nafion is homogenized by ultrasonic treatment, applied to the diffusion layer, and freed of its solvent by exposure to a temperature of about 100°C. The part of the catalyst s surface area that is in contact with the electrolyte (which in the case of solid electrolytes is always quite small) increases considerably, due to the ionomer present in the active layer. 

The main components of a PEM fuel cell are the flow channels, gas diffusion layers, catalyst layers, and the electrolyte membrane. The respective electrodes are attached on opposing sides of the electrolyte membrane. Both electrodes are covered with diffusion layers, and the flow channels/current collectors. The flow channels collect current from the electrodes while providing the fuel or oxidant with access to the electrodes. The gas diffusion layer allows gases to diffuse to the electro-catalysts and provides electrical contact throughout the catalyst layers. Within the anode catalyst layer, the fuel (typically H2) is oxidized to produce electrons and protons. The electrons travel through an external circuit to produce electricity, while the protons pass through the proton conducting electrolyte membrane. Within the cathode catalyst layer, the electrons and protons recombine with the oxidant (usually 02) to produce water. 

The function of the electrolyte membrane is to facilitate transport of protons from anode to cathode and to serve as an effective barrier to reactant crossover. The electrodes host the electrochemical reactions within the catalyst layer and provide electronic conductivity, and pathways for reactant supply to the catalyst and removal of products from the catalyst [96], The GDL is a carbon paper of 0.2 0.5 mm thickness that provides rigidity and support to the membrane electrode assembly (MEA). It incorporates hydrophobic material that facilitates the product water drainage and prevents... 

Figure 2.1 shows a schematic structure of the fuel cell membrane electrode assembly (MEA), including both anode and cathode sides. Each side includes a catalyst layer and a gas diffusion layer. Between the two sides is a proton exchange membrane (PEM) conducting protons from the anode to the cathode. 

To overcome these disadvantages, a thin-film CL technique was invented, which remains the most commonly used method in PEM fuel cells. Thin-film catalyst layers were initially used in the early 1990s by Los Alamos National Laboratory [6], Ballard, and Johnson-Matthey [7,8]. A thin-film catalyst layer is prepared from catalyst ink, consisting of uniformly distributed ionomer and catalyst. In these thin-film catalyst layers, the binding material is not PTFE but rather hydrophilic Nafion ionomer, which also provides proton conductive paths for the electrochemical reactions. It has been found that the presence of hydrophobic PTFE in thin catalyst layers was not beneficial to fuel cell performance [9]. 

Typically, Nation ionomer is the predominant additive in the catalyst layer. However, other types of CLs with various hygroscopic or proton conductor additives have also been developed for fuel cells operafed xmder low relative humidity (RH) and/or at elevated temperatures. Many studies have reported the use of hygroscopic y-Al203 [52] and silica [53,54] in the CE to improve the water retention capacity and make such CEs viable for operation af lower relative humidity and/or elevated temperature. Alternatively, proton conducting materials such as ZrP [55] or heteropoly acid HEA [56] have also been added... 

The fabrication of catalyst layers for PEM fuel cells involves maintaining a delicate balance between gas and water transport, and electron and proton conduction. The process of CL fabrication should be guided by both fuel cell performance and cost reduction. 

An effective catalyst layer must serve multiple functions simultaneously electron and proton conduction, oxygen or hydrogen supply, and water management. The composition and structure of a CL can affecf all fhese functions... 

The catalyst layer is composed of multiple components, primarily Nafion ion-omer and carbon-supported catalyst particles. The composition governs the macro- and mesostructures of the CL, which in turn have a significant influence on the effective properties of the CL and consequently the overall fuel cell performance. There is a trade-off between ionomer and catalyst loadings for optimum performance. For example, increased Nafion ionomer confenf can improve proton conduction, but the porous channels for reactanf gas fransfer and water removal are reduced. On the other hand, increased Pt loading can enhance the electrochemical reaction rate, and also increase the catalyst layer thickness. 

The microstructure of a catalyst layer is mainly determined by its composition and the fabrication method. Many attempts have been made to optimize pore size, pore distribution, and pore structure for better mass transport. Liu and Wang [141] found that a CL structure with a higher porosity near the GDL was beneficial for O2 transport and water removal. A CL with a stepwise porosity distribution, a higher porosity near the GDL, and a lower porosity near the membrane could perform better than one with a uniform porosity distribution. This pore structure led to better O2 distribution in the GL and extended the reaction zone toward the GDL side. The position of macropores also played an important role in proton conduction and oxygen transport within the CL, due to favorable proton and oxygen concentration conduction profiles. 

Due to their high electrical and thermal conductivity, materials made out of metal have been considered for fuel cells, especially for components such as current collectors, flow field bipolar plates, and diffusion layers. Only a very small amount of work has been presented on the use of metal materials as diffusion layers in PEM and DLFCs because most of the research has been focused on using metal plates as bipolar plates [24] and current collectors. The diffusion layers have to be thin and porous and have high thermal and electrical conductivity. They also have to be strong enough to be able to support the catalyst layers and the membrane. In addition, the fibers of these metal materials cannot puncture the thin proton electrolyte membrane. Thus, any possible metal materials to be considered for use as DLs must have an advantage over other conventional materials. 

The catalyst layer usually consists of carbon-supported catalyst or carbon black mixed with PIPE and/or proton-conducting ionomer (e.g.. Nation iono-mer). Because the sizes of the pores in a t) ical DL are in the range of 1-100 pm and the average pore size of the CL is just a few hundred nanometers, the risk of having low electrical contact between both layers is high [129]. Thus, the MPL is also used to block the catalyst particles and does not let them clog the pores within the diffusion layer [57,90,132,133]. 

Concentrating on the operation of the so-called membrane electrode assembly (MEA), E includes irreversible voltage losses due to proton conduction in the PEM and voltage losses due to transport and activation of electrocatalytic processes involved in the oxygen reduction reaction (ORR) in the cathode catalyst layer (CCL) ... 

This chapter gives an overview of the state of affairs in physical theory and molecular modeling of materials for PEECs. The scope encompasses systems suitable for operation at T < 100°C that contain aqueous-based, proton-conducting polymer membranes and catalyst layers based on nanoparticles of Pt. 

Microstructures of CLs vary depending on applicable solvenf, particle sizes of primary carbon powders, ionomer cluster size, temperafure, wetting properties of carbon materials, and composition of the CL ink. These factors determine the complex interactions between Pt/carbon particles, ionomer molecules, and solvent molecules, which control the catalyst layer formation process. The choice of a dispersion medium determines whefher fhe ionomer is to be found in solubilized, colloidal, or precipitated forms. This influences fhe microsfrucfure and fhe pore size disfribution of the CL. i It is vital to understand the conditions under which the ionomer is able to penetrate into primary pores inside agglomerates. Another challenge is to characterize the structure of the ionomer phase in the secondary void spaces between agglomerates and obtain the effective proton conductivity of the layer. 

The last part of the polarization curve is dominated by mass-transfer limitations (i.e., concentration overpotential). These limitations arise from conditions wherein the necessary reactants (products) cannot reach (leave) the electrocatalytic site. Thus, for fuel cells, these limitations arise either from diffusive resistances that do not allow hydrogen and oxygen to reach the sites or from conductive resistances that do not allow protons or electrons to reach or leave the sites. For general models, a limiting current density can be used to describe the mass-transport limitations. For this review, the limiting current density is defined as the current density at which a reactant concentration becomes zero at the diffusion medium/catalyst layer interface. 

Figure 13. Plot of cathode potential as a function of current density for a macrohomogeneous embedded model where the proton conductivity is assumed to be uniform (0.044 S/m), curve a, or varies with water production (changing humidity) across the catalyst layer, curve b. (Reproduced with permission from ref 98. Copyright 2002 The Electrochemical Society, Inc.)...

The important processes occurring in a catalyst layer include interfacial ORR at the electrochemically active sites, proton transport in the electrolyte phase, electron conduction in the electronic phase (i.e., Pt/C), and oxygen diffusion through the gas phase, liquid water, and electrolyte phase. 

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