Dry layer preparation and characterisation of polymer electrolyte fuel cell components

The main problem for future fuel cell commercialisation is the cost of membrane–electrode assemblies (MEAs) satisfying both power density and lifetime requirements. At DLR, low-cost MEA production techniques are being developed. These new MEAs are characterised and investigated with physical and electrochemical methods in order to study the power loss processes, the lifetime, the reaction mechanisms and in support of MEA development. The possibilities for the characterisation methods used will be demonstrated by various examples. At DLR, a new production technique based on the adaptation of a rolling process is developed for fuel cell electrode and MEA preparation. After mixing the dry powder electrode material in a mill, it is blown onto the membrane (or backing) resulting in a uniformly distributed layer. This reactive layer is fixed and thoroughly connected to the membrane by passing them through a calender. In order to produce the second electrode, the same steps are repeated. This procedure is very simple and, as a dry process, avoids the use of any solvents and drying steps. We have achieved a thickness of the reactive layer as low as 5 μm, reducing the amount of catalyst needed and, thus, the costs. Electrochemical investigations have shown a performance comparable to that of commercial electrodes. The degradation of MEA for polymer membrane fuel cell (PEFC) components during the cellʹs lifetime, yields a change in the electrochemical behaviour. The characterisation of PEFC MEA-components after electrochemical operation has given information about the degradation of electrodes and membranes and about the change in the platinum distribution on the anode, whilst on the cathode, the platinum content is unchanged.