(Invited) Model-Predictive Design of Low Pt Loaded PEMFC Catalyst Layers

Abstract

Proton exchange membrane fuel cells (PEMFCs) are a promising means to decarbonize the global vehicle fleet, but commercialization is limited by costly Pt catalysts, among other challenges. PEMFC designs with low Pt loading typically suffer anomalous performance losses. Previous studies have agreed that poor device performance is linked to complex physiochemical processes in the cathode catalyst layer (CL) [1]. More specifically, poor performance with low Pt-loading is attributed to sluggish proton and/or oxygen transport through the nano-thin Nafion ionomer in the CL. Previous studies have also identified that the properties of the Nafion thin films in the CL vary from those previously measured for thicker membranes. However, research has not yet definitively connected CL polymer properties with PEMFC limitations in low Pt-loaded cells, nor found a means to address the limitations for low cost, higher-performance PEMFCs.In this presentation, we will describe efforts to quantify structure-property relationships for thin-film Nafion and incorporate these relationships into PEMFC numerical simulations to identify advantageous PEMFC catalyst layer designs. We model nm-scale transport in thin-film Nafion to develop structure-property relationships for thin-film Nafion, based on in situ neutron reflectometry [2], and conductivity measurements [3] on thin film Nafion. These result in a model that calculates the conductivity as a function of temperature, local water uptake, film thickness, and underlying substrate (Pt or carbon). Incorporating these structure-property models into a continuum-scale PEMFC cathode half-cell model to locally resolve proton conductivity and O2 diffusion improves model fits to PEMFC data with varying Pt loading [4]. The fits provide new insights into the coupling between kinetic, mass transport, and Ohmic losses in low-Pt-loaded PEMFC cathodes and show that Ohmic losses in thin film Nafion play a key limiting role in low-Pt loaded cells. We conclude with a parametric study of PEMFC CL design parameters with low Pt loading. Incorporating multi-scale modelling of Nafion transport processes enhances the predictive model capabilities and unlocks new insights into CL design. We will present a detailed analysis of how best to manage coupled limiting phenomena in PEM fuel cells, and identify functionally graded catalyst layer designs that could significantly improve PEMFC power density with low Pt loading [4]. Weber, A. and Kusoglu, A. Mater. Chem. A. 2014. DOI: 10.1039/c4ta02952fDeCaluwe, S.C. et al. Nano Energy 2018. DOI: 10.1016/j.nanoen.2018.01.008Paul, D.K. et al. Electrochem. Soc. 2014. DOI: 10.1149/2.0571414jesRandall, C.R. and DeCaluwe, S.C., Electrochem. Soc. 2022. DOI: 10.1149/1945-7111/ac8cb4