Continuous Graded Catalyst Layers for PEM Fuel Cells with Improved Humidity Range Tolerance

Grading electrodes is a promising approach to reduce ohmic and mass transport-related voltage losses in proton exchange membrane fuel cells. In graded electrodes, the ionomer and/or catalyst are spatially non-uniformly distributed to optimize performance over a wide operating range. In this study, through-plane ionomer gradients were fabricated with a simple wet-layer deposition technique that can readily be adapted in a roll-to-roll process. The presence of ionomer gradients was verified using scanning transmission electron microscopy and the profiles were found to be continuous despite using only two coating steps. Single cell tests revealed that the gradients outperform conventional electrodes and maintain the optimal performance for different relative humidities. These improvements were traced back to enhanced mass transport and protonic conduction properties identified by detailed electrochemical analysis. This manufacturing approach for electrodes offers an accessible toolbox to produce versatile and specialized multi-layered catalyst layers for different applications.