Effect of organic solvents on catalyst structure of PEM fuel cell electrode fabricated via electrospray deposition

Proton exchange membrane fuel cells (PEMFCs) are some of the most efficient electrochemical energy sources for transportation applications because of their clean, green, and high efficiency characteristics. The optimization of catalyst layer morphology is considered a feasible approach to achieve high performance of PEMFC membrane electrode assembly (MEA). In this work, we studied the effect of the solvent on the catalyst layer of PEMFC MEAs fabricated using the electrostatic spray deposition method. The catalyst ink comprised of Pt/C, a Nafion ionomer, and a solvent. Two types of solvent were used: isopropyl alcohol (IPA) and dimethylformamide (DMF). Compared with the catalyst layer prepared using IPA-based ink, the catalyst layer prepared with DMF-based ink had a dense structure because the DMF dispersed the Pt/C-Nafion agglomerates smaller and more homogeneously. The size distribution of the agglomerates in catalyst ink was confirmed through Dynamic Light Scattering (DLS) and the microstructure of the catalyst layer was compared using field emission scanning electron microscopy (FE-SEM). In addition, the electrochemical investigation was performed to evaluate the solvent effect on the fuel cell performance. The catalyst layer prepared with DMF-based ink significantly enhanced the cell performance (1.2 A cm-2 at 0.5 V) compared with that fabricated using IPA-based ink (0.5 A cm-2 at 0.5 V) due to the better dispersion and uniform agglomeration on the catalyst layer.