Physical degradation of membrane electrode assemblies undergoing freeze/thaw cycling: Micro-structure effects

The objective of this work is to investigate physical damage of polymer electrolyte fuel cell (PEFC) materials subjected to freeze/thaw cycling. Effects of membrane electrode assembly micro-structures (catalyst layer cracking, membrane thickness, and membrane reinforcement) and diffusion media with micro-porous layers were analyzed by comparing scanning electron microscopy images of freeze/thaw cycled samples (−40 °C/70 °C) with those of virgin material and thermal cycled samples without freezing (5 °C/70 °C). Ex situ testing performed in this study has revealed a strong direction for the material choices in the PEFC and confirmed the previous computational model in the literature [S. He, M.M. Mench, J. Electrochem. Soc., 153 (2006) A1724–A1731; S. He, S.H. Kim, M.M. Mench, J. Electrochem. Soc., in press]. Specifically, the membrane electrode assemblies were found to be a source of water that can damage the catalyst layers under freeze/thaw conditions. Damage was found to occur almost exclusively under the channel, and not under the land (the graphite that touches the diffusion media). Conceptually, the best material to mitigate freeze-damage is a crack free virgin catalyst layer on a reinforced membrane that is as thin as possible, protected by a stiff diffusion media.