On the Importance of MPL Structural Characteristics for PEM Fuel Cell Performance

Gas diffusions layers (GDLs) constitute vital subcomponents of proton exchange membrane fuel cells (PEMFCs) since they participate in all relevant transport processes (gases, vapor, liquid water, electricity and heat).Meanwhile, state-of-the-art GDLs are produced on commercial scale using high volume reel-to-reel (R2R) processes. In almost any case, GDLs are designed as dual-layer structures with a macro-porous carbon fiber-based substrate (backing) and a micro-porous layer (MPL) consisting of carbon particulates bonded with polytetrafluoroethylene (PTFE) binder. A body of scientific work has verified that different aspects of the MPL microstructure and the MPL/macroporous substrate interface play a substantial role in the water management of PEMFCs [1-6]. A systematic study was performed based on a singular backing using different MPL types and penetration levels.A simple method to estimate the micro-porous layer penetration in gas diffusion layers based on data obtained from force-deflection behavior of backings and MPL-coated GDLs is proposed. Comparison with SEM and previously published tomographic studies shows that a good estimate for the extent of MPL intrusion into the backing is obtained. MPL loading and penetration is shown to affect different ex-situ GDL properties (in-plane gas permeability, electrical and thermal conductivity) as well as the GDL single cell performance characteristics with respect to humification and high current density operation. Keywords: Gas diffusion layers, Microporous Layer, PEMFC fuel cells Weber, and J. Newman, “Effects of microporous layers in polymer electrolyte fuel cells”, J. Electrochem. Soc. 152, A677-A688 (2005). Lee, R. Yip, P. Antonacci, N. Ge, T. Kotaka, Y. Tabuchi, and A. Bazylak, Synchrotron investigation of microporous layer thickness on liquid water distribution in a PEM fuel cell, J. Electrochem. Soc. 162, F669-F676 (2015). Zhou, S. Shukla, A. Putz, and M. Secanell, “Analysis of the role of the microporous layer in improving polymer electrolyte fuel cell performance”, Electrochim. Acta. 268, 366-382 (2018). Cho, J. Park, H. Oh, K. Min, E. Lee, and J.Y. Jyoung, “Analysis of the transient response and durability characteristics of a proton exchange membrane fuel cell with different micro-porous layer penetration thicknesses”, Appl. Energy 111, 300-309 (2013). T. Gostick, M. A. Ioannidis, M. W. Fowler, and M. D. Pritzker, “On the role of the microporous layer in PEMFC operation.”, Electrochem. Comm. 11, 576-579 (2009). P. Ramasamy, E. C. Kumbur, M. M. Mench, W. Liu, D. Moore, and M. Murthy, “Investigation of macro- and micro-porous layer interaction in polymer electrolyte fuel cells”, Int. J. Hydrogen Energy 33, 3351-3367 (2008).