Effect of Coupled Microstructural Characteristics of Catalyst Layer on High Temperature: Proton Exchange Membrane Fuel Cell Performance

The widespread adoption of High Temperature-Proton Exchange Membrane Fuel Cells (HT-PEMFC) in commercial applications is limited by their performance and durability compared to conventional energy sources. A key factor affecting these cells is the sluggish oxygen reduction reaction (ORR) at the cathode catalyst layer (CL). Optimizing the structural parameters of the cathode CL can enhance cell performance and longevity. Current research on these parameters is mostly descriptive, lacking numerical evidence to quantify their impact. This study develops a three-dimensional, non-isothermal HT-PEMFC numerical model to investigate the sensitivities of coupled structural parameters of the cathode CL, including Pt loading, CL thickness, and Pt particle diameter, at three levels. The orthogonal/Taguchi approach quantitatively assesses the impact of these parameters. The study reveals that Pt loading significantly affects cell voltage and cathode overpotential, while Pt diameter influences the homogeneity of overpotential distribution. The dominant impact of a single parameter decreases at higher current densities, necessitating careful analysis of trade-offs between different structural characteristics to maximize performance. These findings offer valuable insights for future experimental studies to enhance cell performance through adjustments to cathode catalyst characteristics.