Characterization of Proton Exchange Membrane Fuel Cells with Catalyst Layers Obtained by Electrospraying

Abstract

Electrostatic polymer processing ~electro-spraying, electrospinning, and combinations of the two! represents a new and highly versatile approach for the fabrication of polymer-based electrochemical device components. 1,2 Electrospraying and electrospinning can afford particles and fibers with diameters of 100 nm or less, suggesting that nanostructured electrolytes and electrodes may be obtained by judicious choice of materials and electrostatic processing parameters. Moreover, these electrostatic processing approaches may have applicability to a wide variety of polymer-based electrochemical devices, including fuel cells, batteries, capacitors, and electrochromic and electroluminescent displays. We believe that electrostatic processing could be used for the construction of an entire proton-exchange membrane fuel cell ~PEMFC!, including the membrane, electro-catalyst layers, and gas diffusion layers. Particularly appealing is the potential ability to control composition, porosity, and wettability of these fuel cell components. As a first step in the development of this technology, Nafion was electrosprayed from solution to afford thin films and subsequently characterized as having physical properties ~water uptake, dimensional changes, electrical conductivity! similar to those of Nafion 117 films. 1 Following that, electrochemical properties of half-cells with commercial Nafion 117 and catalyst layers obtained by electrostatic processing were characterized. 2 The present research is focused on evaluation of PEM single cells with catalyst layers obtained by the electrospraying technique on commercial Nafion 112 films.