Construction of catalyst layer network structure for proton exchange membrane fuel cell derived from polymeric dispersion.

A rational design of the structure of catalyst layer (CL) is required for proton exchange membrane fuel cells to attain outstanding performance and excellent stability. It is crucial to have a profound comprehension of the correlations existing between the properties (catalyst ink), network structures of CL and proton exchange membrane fuel cells' performance for the rational design of the structure of CL. This study deeply investigates the effects of a series of alcohol solvents on the properties and network structure of CL. The results demonstrate that the CL aggregates in higher ε solution show smaller particle sizes, and the sulfonic acid groups (∼SOH) tend to extend more outward due to the strong dissociation. A more continuous and homogeneous ionomer distribution around Pt/C aggregates is observed in the CL, which improves the electrochemically active surface area (ECSA) and performance of the electrode. But, the electrode has a poor performance at high current density regions due to the mass transfer resistance. Based on this, a two-step solvent control strategy is proposed to maintain uniform ionomer and aggerates distribution and optimize the mass transfer for CL. The performance of the cell improves from 0.555 V to 0.615 V at 2000 mA·cm.