In a PEM fuel cell, catalyst ink formulation and mixing processes are closely related to catalyst layer coating quality and the subsequent fuel cell performance and durability. Catalyst inks based on non-aqueous solvents such as glycerol and ethylene glycol (EG) have shown significant durability advantages over 1-propanol/water-based inks when using decal coating.1,2 Complex solvent-catalyst-ionomer interactions were used to direct the ink properties for coating requirements and optimize them for maximum fuel cell performance, matching the performance of 1-propanol/water-based CLs, while retaining improved durability. Ink rheology and catalyst particle size were used to monitor ink properties, which were later correlated to electrode morphology and structure. These methods were also used to monitor the ink quality and consistency from batch to batch, and from small lab scale to subsequent scale-up. The transition from coating EG-based catalyst ink on decals to coating on gas diffusion layers (GDLs), followed by a roll-to-roll (R2R) fabrication process are crucial for scale up and commercialization. However, coating EG-based catalyst inks on hydrophobic GDLs presented an initial challenge due to EG’s high boiling point and viscosity. Air plasma treatment was successfully used to allow coating of EG-based ink on hydrophobic GDLs. To establish the correlation between ink properties and MEA performance, gas diffusion electrodes made of 1-propanol/water and EG-based inks were tested for fuel cell performance and durability and compared to previously obtained results with decals. The performance and durability of EG-GDEs was better than that of the 1-propanol/water GDEs. The EG-GDE fabrication process was transferred from Giner to NREL for small scale ‘in-operando’ R2R trials. Multiple drying temperatures were evaluated, and the optimal drying temperature was identified. Finally, the electrode performance and durability of R2R fabricated GDEs was tested, and correlated to catalyst microstructures.This work provides a comprehensive understanding of interactions between Pt, carbon, ionomer, GDL and their impact on electrode structure, fuel cell performance and durability, as well as considerations for scale up to a R2R fabrication process. The attained information will be used to improve fuel cell electrode design, fabrication and scale-up. Acknowledgement: The project is financially supported by the Department of Energy’s Fuel Cell Technology Office under the Grant DE-SC0012049. References K-S. Lee, T. Rockward, A. Labouriau, N. Mack, Y. S. Kim, C. Johnston, 2009, Impact of Solvent on Ionomer Structure and Fuel Cell Durability. ECS Transactions. 25. 10.1149/1.3210717.C. Lei, F. Yang, N. Macauley, M. Spinetta, G. Purdy, J. Jankovic, D. Cullen, K. More, H. Xu, JES, 2021 168 044517.
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