The production of components in polymer electrolyte membrane fuel cells is a widely researched topic and still has a lot of potential for optimization. Especially the reduction of used materials like ionomer and platinum in fuel cell electrodes and the improvement of their performance are highly desired. In this study we discuss the potential of structured cathode catalyst layers by introducing a through plane ionomer gradient. For this purpose different catalyst layers with a platinum loading of 0.25 mg/cm2 have been produced by screen printing, followed by extensive In-Situ characterization in a fuel cell test bench. The results show that combining high amounts of ionomer at the membrane/electrode interface, and decreasing amounts towards the gas diffusion layer enable a good protonic connection of the catalyst layer to the membrane while improving the performance in the high current area due to lower diffusion resistance. This trend was also supported by limiting current measurements, showing increasing diffusion resistances with higher ionomer contents at the gas diffusion layer interface.

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Afin de pouvoir utiliser les piles à combustible du type PEMFC dans une application automobile, leur coût doit être diminué et leur durée de vie doit être augmentée. De nombreux résultats montrent que la gestion de l'eau dans les piles PEMFC est essentielle sur ces aspects et qu’une meilleure maitrise contribuera a développer des piles plus performantes. La couche active cathodique (CCL, Cathode Catalyst Layer) est le lieu de production de l'eau ce qui en rend l'optimisation importante pour assurer une bonne gestion de l'eau. Dans ce travail, la méthode réseau de pores a été adaptée pour modéliser le transport diphasique dans la structure poreuse de la CCL. Dans l'état de l'art actuel, le modèle développé est le seul permettant d’analyser l'effet des proprietes locales de la CCL (structure, mouillabilite…) sur les mecanismes de transport diphasique. Cet outil de compréhension constitue également une base pour proposer des améliorations de la CCL afin d'améliorer les performances des piles. Les algorithmes d'invasion développés ont été analysés d'une façon détaillée. Le transport fluidique (gaz et liquide) est couplé avec le transport des charges (électrons et protons) par un modèle de réaction électrochimique. Les mécanismes de capillarité, de diffusion gazeuse et d’evaporation sont integres au modele afin d'avoir une représentation la plus complète possible du fonctionnement de la CCL. La description de la structure poreuse par un réseau de pore régulier, l'algorithme d'invasion de l'eau liquide et le modèle de la diffusion des gaz ont été validés par des comparaisons avec des résultats expérimentaux de la littérature ou spécifiques de ce travail. Le modèle est ensuite exploité pour analyser l'effet des paramètres de la CCL tels que la mouillabilité et la taille des pores sur les performances de la couche active. Les résultats permettent d’analyser de premieres idees de modifications de la CCL pour ameliorer la gestion de l’eau et les performances des PEMFC. / In order to use PEM fuel cells in an automotive application, their cost must be reduced and their lifetime must be increased. Many results show that water management is a critical issue in PEMFC optimization. The water is produced in the cathode active layer (CCL) which makes the optimization of this component very important to ensure a better water management in the PEMFC. In this work, the pore network method has been adapted to model the two-phase transport in the porous structure of the CCL. Considering the state of the art, this is the only model developed to analyze the effect of local properties of the CCL (structure, wetting ...) on the two-phase transport mechanisms. This model is proposed as a scientific tool to help understanding the fundamentals behind the transport phenomena inside the CCL and also to help in the conception of the future CCL. The liquid invasion algorithms developed in this work were analyzed in details. The fluids transport (gas and liquid) is coupled with the charges transport (electrons and protons) using an electrochemical reaction model. The capillary driven liquid transport, the gas phase diffusion and the evaporation process are all integrated into the model in order to have the most possible complete description of the CCL. The description of the porous structure by a regular network, the liquid invasion algorithm and the gas diffusion model all have been validated by comparisons with experimental results from literature or specific work . The model is then exploited to analyze the effect of parameters such as the CCL wettability and pore size distribution on the performance. The results allow analysis of initial ideas that can help in the conception of the CCL in order to improve the water management and the performances of the PEMFC.

<p dir="ltr">Catalyzing a green hydrogen economy can accelerate progress towards achieving the goal of a sustainable energy map with net-zero carbon emissions by rapid strides. An environmentally benign electrochemical energy conversion system is the Polymer Electrolyte Fuel Cell (PEFC) which uses hydrogen as a fuel to produce electricity and is notably used in a variety of markets such as industries, commercial setups, and across the transportation sector, and is gaining prominence for use in heavy-duty vehicles such as buses and trucks. Despite its potential, the commercialization of PEFCs needs to address several challenges which are manifested in the form of mass transport limitations and deleterious mechanisms at the interfacial scale under severe operating conditions. Achieving a robust electrochemical performance in this context is predicated on desired interactions at the triple-phase boundary of the electrochemical engine of the PEFC – the porous cathode catalyst layer (CCL) where the principal oxygen reduction reaction (ORR) takes place. The liquid water produced as a byproduct of the ORR helps minimize membrane dehydration; however, excess water renders the reaction sites inactive causing reactant starvation. In addition, the oxidation of the carbonaceous support in the electrode and loss of valuable electrochemically active surface area (ECSA) pose major barriers that need to be overcome to ameliorate the life expectancy of the PEFC.</p><p dir="ltr">In this thesis, the multimodal physicochemical interactions occurring inside the catalyst layer are investigated through a synergistic blend of visualization and computational techniques. The spatiotemporal dynamics of capillary force-driven liquid transport that ensues concentration polarization thereby affecting the desired response will be probed in detail. The drop in efficacy of the ORR due to competing catalyst aging mechanisms and the impact of degradation stressors on chemical potential-induced instability will be examined. The reaction-transport-mechanics interplay in core-shell nanoparticles, a robust class of electrocatalysts that promises better mass activity compared to the single metal counterparts is further highlighted. Finally, the influence of electrode microstructural attributes on the electrochemical performance of the reverse mode of fuel cell operation, i.e., Proton Exchange Membrane Water Electrolyzers (PEMWEs) is investigated through a mesoscale lens.</p>

Diese Dissertation befasst sich mit der industrienahen Herstellung von Katalysatorschichten für Polymer-Elektrolyt-Membran-Brennstoffzellen mit Hilfe des Tiefdrucks als Fertigungsverfahren. Um die Anforderungen an die Katalysatorschicht hinsichtlich der Schichtdicke zu erreichen, wird ein Linienraster für den Tiefdruck entwickelt. Das patentierte und verifizierte Designkonzept des Linienrasters ermöglicht es, trotz Tinten mit geringem Feststoffgehalt hohe Trockenschichtdicken zu erzeugen. Aufgrund des verwendeten Tiefdruckrasters sind Optimierungsschritte an der Fertigungsanlage notwendig, um eine hohe Schichtqualität zu erreichen. Schließlich werden kontinuierlich und industrienah Katalysatorschichten gefertigt, die als Membran-Elektroden-Einheit in einer Polymer-Elektrolyt-Membran-Brennstoffzelle erfolgreich eingesetzt werden. / This work presents an industrial close manufacturing process of active electrodes for Polymer Electrolyte Fuel Cells utilizing an adapted gravure printing process. To meet the requirements of the electrodes regarding the layer thickness (weight) and quality a novel line screen with maximized dipping volume for gravure printing was developed and investigated. A design rule for this kind of screens was realized and verified by a successful manufacturing of electrodes with different dried layer thicknesses. Due to the rough structure and the high dipping volumes of these line screens an adaption and optimization of the machinery and the whole process was necessary to achieve high quality electrodes. Finally, it is shown that it is possible to manufacture continuiously in an industrial close roll-to-roll process platinum loaded electrodes, working successful as cathode in a Membran-Electrode-Assembly.

Hydrogen production via the electrolysis of water has gained a lot of attention in the last couple of years. Research related to electrolysers is mostly aimed towards decreasing the noble–metal catalyst content. In this study the presently used catalyst application techniques were reviewed and critically examined to find commercially applicable and effective methods. Selected methods were then practically applied to determine their feasibility and to gain “know–how” related to the practical application of these techniques. The selected techniques were the hand paint, inkjet print, screen print and spray paint techniques. Meaningful comparisons were made between the methods in terms of parameters such as practicality, waste of catalyst and microstructure. The results point out that the hand paint and spray paint methods are feasible methods although there are improvements to be made. The hand paint method was improved by applying a carbon micro porous layer to the gas diffusion layer before the painting is carried out. The addition of the carbon layer reduced the soaking of the catalyst–containing ink through the gas diffusion layer. A method not initially investigated was identified an evaluated and showed promising results in lowering the mass of catalyst applied. This method comprised of sputtering a layer of catalyst material onto a prepared gas diffusion layer. It also came to light from the results that electrodes, and therefore membrane electrode assemblies, can be produced at a much lower cost than the commercial available membrane electrode assemblies. / Thesis (M.Ing. (Mechanical Engineering))--North-West University, Potchefstroom Campus, 2012.

Hydrogen production via the electrolysis of water has gained a lot of attention in the last couple of years. Research related to electrolysers is mostly aimed towards decreasing the noble–metal catalyst content. In this study the presently used catalyst application techniques were reviewed and critically examined to find commercially applicable and effective methods. Selected methods were then practically applied to determine their feasibility and to gain “know–how” related to the practical application of these techniques. The selected techniques were the hand paint, inkjet print, screen print and spray paint techniques. Meaningful comparisons were made between the methods in terms of parameters such as practicality, waste of catalyst and microstructure. The results point out that the hand paint and spray paint methods are feasible methods although there are improvements to be made. The hand paint method was improved by applying a carbon micro porous layer to the gas diffusion layer before the painting is carried out. The addition of the carbon layer reduced the soaking of the catalyst–containing ink through the gas diffusion layer. A method not initially investigated was identified an evaluated and showed promising results in lowering the mass of catalyst applied. This method comprised of sputtering a layer of catalyst material onto a prepared gas diffusion layer. It also came to light from the results that electrodes, and therefore membrane electrode assemblies, can be produced at a much lower cost than the commercial available membrane electrode assemblies. / Thesis (M.Ing. (Mechanical Engineering))--North-West University, Potchefstroom Campus, 2012.

Diese Dissertation befasst sich mit der industrienahen Herstellung von Katalysatorschichten für Polymer-Elektrolyt-Membran-Brennstoffzellen mit Hilfe des Tiefdrucks als Fertigungsverfahren. Um die Anforderungen an die Katalysatorschicht hinsichtlich der Schichtdicke zu erreichen, wird ein Linienraster für den Tiefdruck entwickelt. Das patentierte und verifizierte Designkonzept des Linienrasters ermöglicht es, trotz Tinten mit geringem Feststoffgehalt hohe Trockenschichtdicken zu erzeugen. Aufgrund des verwendeten Tiefdruckrasters sind Optimierungsschritte an der Fertigungsanlage notwendig, um eine hohe Schichtqualität zu erreichen. Schließlich werden kontinuierlich und industrienah Katalysatorschichten gefertigt, die als Membran-Elektroden-Einheit in einer Polymer-Elektrolyt-Membran-Brennstoffzelle erfolgreich eingesetzt werden. / This work presents an industrial close manufacturing process of active electrodes for Polymer Electrolyte Fuel Cells utilizing an adapted gravure printing process. To meet the requirements of the electrodes regarding the layer thickness (weight) and quality a novel line screen with maximized dipping volume for gravure printing was developed and investigated. A design rule for this kind of screens was realized and verified by a successful manufacturing of electrodes with different dried layer thicknesses. Due to the rough structure and the high dipping volumes of these line screens an adaption and optimization of the machinery and the whole process was necessary to achieve high quality electrodes. Finally, it is shown that it is possible to manufacture continuiously in an industrial close roll-to-roll process platinum loaded electrodes, working successful as cathode in a Membran-Electrode-Assembly.