The Impact of Catalyst Layer Fabrication Procedure on Layer Morphology, Transport Properties and Performance in Low-Temperature PEM Fuel Cell
Authors: Prokop Martin , Hala Miroslav , Vesely Martin , Capek Pavel , Zubkova Tatiana , Heinrich Kathleen , Willert Andreas , Zichner Ralf , Bouzek Karel 
Published: August 2024

Hydrogen mobility represents a progressive, low carbon imprint option for the replacement of internal combustion engines. A core of this technology is low-temperature fuel cell with proton-exchange membrane (LTPEMFC), using hydrogen and atmospheric oxygen as fuel and oxidant, respectively. The membrane-electrode assembly (MEA) which makes up a cell consists of polymer electrolyte membrane, cathodic and anodic catalyst layers and carbon-based porous gas-diffusion layers. LTPEMFC require Pt catalyst on both the anode and the cathode in non-negligible total amount, increasing investing costs for stack unit. In order to maximise fuel cell performance, the formation of three-phase boundary has to be achieved during deposition of catalyst layers, interconnecting Pt nanoparticles on carbon support and ionomer with membrane in complex, porous structure. The quality of catalyst layer determines to high degree final MEA performance.

Catalyst layers can be deposited either on gas-diffusion layers or onto the membrane, with latter being considered a more advantageous and feasible approach. Deposition itself can be realised by various methods, including airbrush spraying, decal printing, doctor blade deposition from paste and, most often used nowadays, ultrasonically-assisted spray coating. Each of these methods brings its own advantages and disadvantages, though the common problem of these methods is low suitability for serial production. On the other hand, the quality of so-prepared catalyst layers is sufficient. Methods for large-capacity coating of catalyst layers, especially roll-to-roll technology have exactly opposite pros and cons, high output but unsatisfactory layer quality. An interesting alternative to state-of-the-art catalyst layer fabrication procedures is inkjet printing.

Inkjet printing is a well-established technology, though the application in LTPEMFC field brings various issues, mainly connected to quality of layers and prevention of nozzle-clogging during the deposition. Solving of these issues, however, will result in technology suitable for catalyst layer printing, combining high production throughput, very good reproducibility, minimal losses of the ink, suitability to additive manufacturing and possibility of printing specific geometries with gradient layer thickness. Accordingly, the goal of this study is the comparison of catalyst layers, deposited onto the membrane by ultrasonically-assisted spray coating and inkjet printing, in terms of morphology, electric conductivity, permeability and performance in LTPEMFC, using commercially-available materials for layer fabrication.

Catalyst layers of the same composition and Pt loading were deposited by either ultrasonically-assisted spray coating or inkjet printing onto FTO conductive glass for the determination of electric conductivity, onto gas-diffusion layer for permeability determination in Loschmidt cell and FIB-SEM morphology studies and onto the membrane for the fabrication of MEA and evaluation of its performance in LTPEMFC. Characterisation of layers deposited on materials above underlined feasibility of inkjet printing for catalyst layer fabrication. In comparison with sprayed layers, layers prepared by inkjet printing tend to be thinner, more homogenous and compact. This results in superior electric conductivity but lower permeability at the same time. Single cell tests proved that performance of inkjet-printed layers is at least on par with sprayed ones, surpassing them with optimised ink composition and Pt loading. Overall, inkjet printing technology is a highly attractive technology for industrial catalyst layer production with great possibilities for contributing to decrease LTPEMFC unit’s investment costs.

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 958174. This project is co-financed from the state budget by the Technology agency of the Czech Republic under the M-ERA.Net Programme, project No. TH80020006. This work was supported by the project "The Energy Conversion and Storage", funded as project No. CZ.02.01.01/00/22_008/0004617 by Programme Johannes Amos Commenius, call Excellent Research. This project is co-financed with tax funds on the basis of the budget passed by the Saxon state parliament.