Sulfonated poly(ether ether ketone) as an ionomer for direct methanol fuel cell electrodes

Sulfonated poly(ether ether ketone) has been investigated as an ionomer in the catalyst layer for direct methanol fuel cells (DMFC). The performance in DMFC, electrochemical active area (by cyclic voltammetry), and limiting capacitance (by impedance spectroscopy) have been evaluated as a function of the ion exchange capacity (IEC) and content (wt.%) of the SPEEK ionomer in the catalyst layer. The optimum IEC value and SPEEK ionomer content in the electrodes are found to be, respectively, 1.33 meq. g⁻¹ and 20 wt.%. The membrane-electrode assemblies (MEA) fabricated with SPEEK membrane and SPEEK ionomer in the electrodes are found to exhibit superior performance in DMFC compared to that fabricated with Nafion ionomer due to lower interfacial resistance in the MEA as well as larger electrochemical active area. The MEAs with SPEEK membrane and SPEEK ionomer also exhibit better performance than that with Nafion 115 membrane and Nafion ionomer due to lower methanol crossover and better electrode kinetics.     

The effect of Nafion content in a graphitized carbon nanofiber-based anode for the direct methanol fuel cell

The performance and stability of a direct methanol fuel cell (DMFC) with membrane electrode assemblies (MEA) using different Nafion^® contents (30, 50 and 70 wt% or MEA30, MEA50 and MEA70, respectively) and graphitized carbon nanofiber (GNF) supported PtRu catalyst at the anode was investigated by a constant current measurement of 9 days (230 h) in a DMFC and characterization with various techniques before and after this measurement. Of the pristine MEAs, MEA50 reached the highest power and current densities. During the 9-day measurement at a constant current, the performance of MEA30 decreased the most (−124 μV h⁻¹), while the MEA50 was almost stable (−11 μV h⁻¹) and performance of MEA70 improved (+115 μV h⁻¹). After the measurement, the MEA50 remained the best MEA in terms of performance. The optimum anode Nafion content for commercial Vulcan carbon black supported PtRu catalysts is between 20 and 40 wt%, so the GNF-supported catalyst requires more Nafion to reach its peak power. This difference is explained by the tubular geometry of the catalyst support, which requires more Nafion to form a penetrating proton conductive network than the spherical Vulcan. Mass transfer limitations are mitigated by the porous 3D structure of the GNF catalyst layer and possible changes in the compact Nafion filled catalyst layers during constant current production.     

Highly fluorinated comb-shaped copolymer as proton exchange membranes (PEMs): Fuel cell performance

The fuel cell performance (DMFC and H₂/air) of highly fluorinated comb-shaped copolymer is reported. The initial performance of membrane electrode assemblies (MEAs) fabricated from comb-shaped copolymer containing a side-chain weight fraction of 22% are compared with those derived from Nafion and sulfonated polysulfone (BPSH-35) under DMFC conditions. The low water uptake of comb copolymer enabled an increase in proton exchange site concentrations in the hydrated polymer, which is a desirable membrane property for DMFC application. The comb-shaped copolymer architecture induces phase separated morphology between the hydrophobic fluoroaromatic backbone and the polysulfonic acid side chains. The initial performance of the MEAs using BPSH-35 and Comb 22 copolymer were comparable and higher than that of the Nafion MEA at all methanol concentrations. For example, the power density of the MEA using Comb 22 copolymer at 350 mA cm⁻² and 0.5 M methanol was 145 mW cm⁻², whereas the power densities of MEAs using BPSH-35 were 136 mW cm⁻². The power density of the MEA using Comb 22 copolymer at 350 mA cm⁻² and 2.0 M methanol was 144.5 mW cm⁻², whereas the power densities of MEAs using BPSH-35 were 143 mW cm⁻².     

Surface-modified Nafion membrane by oleylamine-stabilized Pd nanoparticles for DMFC applications

The surface of Nafion was modified by applying palladium nanoparticles as methanol barrier materials to decrease methanol crossover and improve the performance of fuel cells. The properties of the Pd-modified membrane, in terms of conductivity, methanol permeability, percentage of liquid uptake as well as the performance of its membrane electrode assembly (MEA) in the direct methanol fuel cell, were analyzed and compared with those using bare Nafion. The modified membrane showed considerable improvement on reducing methanol loss without decreasing proton conductivity. The DMFC performance of modified membrane was superior to that of bare Nafion both at a typical fuel state of 2 M and at high concentration of 5 M, implying that the palladium-modified Nafion can be a good alternative approach for DMFC applications.     

A study on the overall efficiency of direct methanol fuel cell by methanol crossover current

This paper was presented to determine the methanol crossover and efficiency of a direct methanol fuel cell (DMFC) under various operating conditions such as cell temperature, methanol concentration, methanol flow rate, cathode flow rate, and cathode backpressure. The methanol crossover measurements were performed by measuring crossover current density at an open circuit using humidified nitrogen instead of air at the cathode and applied voltage with a power supply. The membrane electrode assembly (MEA) with an active area of 5 cm² was composed of a Nafion 117 membrane, a Pt–Ru (4 mg/cm²) anode catalyst, and a Pt (4 mg/cm²) cathode catalyst. It was shown that methanol crossover increased by increasing cell temperature, methanol concentration, methanol flow rate, cathode flow rate and decreasing cathode backpressure. Also, it was revealed that the efficiency of the DMFC was closely related with methanol crossover, and significantly improved as the cell temperature and cathode backpressure increased and methanol concentration decreased.     

Low methanol-permeable polyaniline/Nafion composite membrane for direct methanol fuel cells

Protonated polyaniline (PANI) is directly polymerized on Nafion 117 (N117), forming a composite membrane, to act as a methanol-blocking layer to reduce the methanol crossover in the direct methanol fuel cell (DMFC), which is beneficial for the DMFC operating at high methanol concentration. The PANI layer grown on the N117 with a thickness of 100 nm has an electrical conductivity of 13.2 S cm⁻¹. The methanol permeability of the PANI/N117 membrane is reduced to 59% of that of the N117 alone, suggesting that the PANI/N117 can effectively reduce the methanol crossover in the DMFC. Comparison of membrane-electrode-assemblies (MEA) using the conventional N117 and the newly developed PANI/N117 composite shows that the PANI/N117-based MEA outputs higher power at high methanol concentration, while the output power of the N117-based MEA is reduced at high methanol concentration due to the methanol crossover. The maximum power density of the PANI/N117-based MEA at 60 °C is 70 mW cm⁻² at 6 M methanol solution, which is double the N117-based MEA at the same methanol concentration. The resistance of PANI/N117 composite membrane is reduced at elevated methanol concentration, due to the hydrogen bonding between methanol and PANI pushes the polymer chains apart. It is concluded that the PANI/N117-based MEA performs well at elevated methanol concentration, which is suitable for the long-term operation of the DMFC.     

A facile surface modification of Nafion membrane by the formation of self-polymerized dopamine nano-layer to enhance the methanol barrier property

By immersing Nafion membrane into dopamine aqueous solution under mild conditions, a series of modified Nafion membranes for the application in direct methanol fuel cell (DMFC) were fabricated. High resolution scanning electron microscope and Fourier transform infrared spectra characterization revealed that a dense nano-layer around 50 nm was formed and adhered tightly to Nafion surface. Small-angle X-ray scattering, wide X-ray diffractometer and positron annihilation lifetime spectroscopy analysis implied that the microstructure such as phase-separated structure and ion-cluster channel of Nafion layer was slightly changed after surface modification. The influence of modification conditions including pH value, dopamine concentration and immersing time upon membrane performance was investigated. Due to the effective reduction of methanol dissolution and enhancement of methanol diffusion resistance, the methanol crossover of the modified membranes was dramatically suppressed by about 79% from 3.14 × 10⁻⁶ to about 0.65 × 10⁻⁶ cm² s⁻¹. Meanwhile, the proton conductivity of the modified membranes was slightly decreased to be around 0.06 S cm⁻¹. Consequently, the comprehensive performance of the modified membranes was improved by about five times. These results hinted the application promises of such modified Nafion membranes in DMFC.     

Double microporous layer cathode for membrane electrode assembly of passive direct methanol fuel cells

A novel membrane electrode assembly (MEA) is described that utilizes a double microporous layer (MPL) structure in the cathode of a passive direct methanol fuel cell (DMFC). The double MPL cathode uses Ketjen Black carbon as an inner-MPL and Vulcan XC-72R carbon as an outer-MPL. Experimental results indicate that this double MPL structure at the cathode provides not only a higher oxygen transfer rate, but enables more effective back diffusion of water; thus, leading to an improved power density and stability of the passive DMFC. The maximum power density of an MEA with a double MPL cathode was observed to be ca. 33.0 mW cm⁻², which is found to be a substantial improvement over that for a passive DMFC with a conventional MEA. A. C. impedance analysis suggests that the increased performance of a DMFC with the double MPL cathode might be attributable to a decreased charge transfer resistance for the cathode oxygen reduction reaction.     

High performance of low electrocatalysts loading on CNT directly grown on carbon cloth for DMFC

This study demonstrated the feasibility of a high-performance membrane-electrode-assembly (MEA), with low electrocatalyst loading on carbon nanotubes (CNTs) grown directly on carbon cloth as an anode. The direct growth of CNTs was synthesized by microwave plasma-enhanced chemical vapor deposition using CH₄/H₂/N₂ as precursors. The cyclic voltammetry and electrochemical impedance measurements with 1 mM Fe(CN)₆^3−/4− redox reaction reveal a fast electron transport and a low resistance of charge transfer on the direct growth of CNT. The electrocatalysts, platinum and ruthenium, were coated on CNTs by sputtering to form Pt-Ru/CNTs-CC with carbon cloth for CC. Pt-Ru electrocatalysts are uniformly dispersed on the CNT, as indicated by high-resolution scanning electron microscopy (HRSEM) and transmission electron microscopy (TEM), because the nitrogen doped in the CNT acts as active sites for capturing electrocatalysts. The MEA, the sandwiched structure which comprises 0.4 mg cm⁻² Pt-Ru/CNTs-CC as the anode, 3.0 mg cm⁻² Pt black as the cathode and Nafion 117 membrane at the center, performs very well in a direct methanol fuel cell (DMFC) test. The micro-structural MEA analysis shows that the thin electrocatalyst layer is uniform, with good interfacial continuity between membrane and the gas diffusion layer.     

Design of a MEA with multi-layer electrodes for high concentration methanol DMFCs

According to the conventional MEA test, methanol and water crossover are the main factors to determine performance of a passive DMFC. Thus, to ensure the high cell performance of a passive DMFC using high concentration methanol of 50–95 vol%, the MEA in this study introduces the barrier layer to limit the crossover of high concentration methanol, a hydrophobic layer to reduce water crossover, and a hydrophilic layer to enhance the water recovery from the cathode to the anode. The functional layers of the MEA have the effect of improving the performance of the passive DMFC by decreasing the methanol and water crossover. In spite of the operation with 95 vol% methanol, the MEA with multi-layer electrodes for high concentration methanol DMFCs shows a maximum power density of 35.1 mW cm⁻² and maintains a high power density of 30 mW cm⁻² (0.405 V) under constant current operation.     

Influence of annealing of membrane electrode assembly (MEA) on performance of direct methanol fuel cell (DMFC)

The influence of annealing of membrane electrode assembly (MEA) of a direct methanol fuel cell (DMFC) on the cell performance was investigated. The annealing was conducted at various temperatures of 110, 130, 150 and 200 °C. Annealing at 130 °C could produce highest proton conductivity of the recast Nafion binder and electrochemical active surface area of the electrode, leading to the highest cell performance.     

The influences of multi-walled carbon nanotube addition to the anode on the performance of direct methanol fuel cells

Different amounts of multi-walled carbon nanotubes (MWCNTs) are added to anode catalyst layer in the membrane electrode assemblies (MEAs) of direct methanol fuel cells (DMFCs). The MEA with 0.5 wt.% carbon nanotubes (CNTs) shows the best performance in DMFC. In the protonic conductivity tests, a 0.5 wt.% amount of MWCNTs results in the highest protonic conductivity. SEM and TEM observations show that a continuous and uniform distribution of Nafion ionomer layer is formed on the MWCNT surface. Therefore, the dispersed MWCNTs in the catalyst layer are considered to be helpful for developing the pathways of protons transport.     

Characterization of direct methanol fuel cell (DMFC) applications with H2SO4 modified chitosan membrane

Chitosan (Chs) flakes were prepared from chitin materials that were extracted from the exoskeleton of Cape rock lobsters in South Africa. The Chs flakes were prepared into membranes and the Chs membranes were modified by cross-linking with H₂SO₄. The cross-linked Chs membranes were characterized for the application in direct methanol fuel cells. The Chs membrane characteristics such as water uptake, thermal stability, proton resistance and methanol permeability were compared to that of high performance conventional Nafion 117 membranes. Under the temperature range studied 20-60 °C, the membrane water uptake for Chs was found to be higher than that of Nafion. Thermal analysis revealed that Chs membranes could withstand temperature as high as 230 °C whereas Nafion 117 membranes were stable to 320 °C under nitrogen. Nafion 117 membranes were found to exhibit high proton resistance of 284 s cm⁻¹ than Chs membranes of 204 s cm⁻¹. The proton fluxes across the membranes were 2.73 mol cm⁻² s⁻¹ for Chs- and 1.12 mol cm⁻² s⁻¹ Nafion membranes. Methanol (MeOH) permeability through Chs membrane was less, 1.4 × 10⁻⁶ cm² s⁻¹ for Chs membranes and 3.9 × 10⁻⁶ cm² s⁻¹ for Nafion 117 membranes at 20 °C. Chs and Nafion membranes were fabricated into membrane electrode assemblies (MAE) and their performances measure in a free-breathing commercial single cell DMFC. The Nafion membranes showed a better performance as the power density determined for Nafion membranes of 0.0075 W cm⁻² was 2.7 times higher than in the case of Chs MEA.     

Chemical modification of Nafion membrane with 3,4-ethylenedioxythiophene for direct methanol fuel cell application

Nafion 117 membranes were modified by in situ chemical polymerization of 3,4-ethylenedioxythiophene using H₂O₂ as oxidant for direct methanol fuel cell application. Methanol permeability and proton conductivity of the poly(3,4-ethylenedioxythiophene)-modified Nafion membranes as a function of temperature were investigated. An Arrhenius-type dependency of methanol permeability and proton conductivity on temperature exists for all the modified membranes. Compared with Nafion 117 membrane at 60 °C, the methanol permeability of these modified membranes is reduced from 30% to 72%, while the proton conductivity is decreased from 4% to 58%, respectively. Because of low methanol permeability and adequate proton conductivity, the DMFC performances of these modified membranes were better than that of Nafion 117 membrane. A maximum power density of 48.4 mW cm⁻² was obtained for the modified membrane, while under same condition Nafion 117 membrane got 37 mW cm⁻².     

Factors affecting methanol transport in a passive DMFC employing a porous carbon plate

The effect of the pore structure and thickness of the porous carbon plate, PCP, as well as the gas barrier thickness on the methanol transport and the performance of a passive DMFC under the different cell voltages of 0.1, 0.2 and 0.3 V using different methanol concentrations was investigated. As a result of the mass transfer restrictions by employing the PCP, high methanol concentrations over 20 M could be efficiently used to produce the relatively high power density of 30 mW cm⁻² for more than 10 h. The DMFC was operated under limiting current conditions in all the PCPs at 0.1 and 0.2 V to more than 20 M. The main factors for controlling the methanol transport were the barrier of the gas layer with CO₂, which was formed between the anode surface and the PCP and the properties of the PCP. At the low current densities of less than 60 mA cm⁻², when no CO₂ bubbles are emitted, both the pore structure and thickness of the PCP did not affect the methanol transport and the current voltage relationship. At the higher current densities, CO₂ bubbles were evolved through the PCP and different resistances to the methanol transport were observed depending on the PCP pore structure and thickness. The CO₂ gas layer between the MEA and the PCP caused a major resistivity for the methanol transport, and its resistivity increased with its thickness increasing. By using the PCP at 0.1 V, the energy density of the passive DMFC was significantly increased, e.g., more than seven times.     

Nafion/polyaniline/silica composite membranes for direct methanol fuel cell application

This work investigates the characterization and performance of polyaniline and silica modified Nafion membranes. The aniline monomers are synthesized in situ to form a polyaniline film, whilst silica is embedded into the Nafion matrix by the polycondensation of tetraethylorthosilicate. The physicochemical properties are studied by means of X-ray diffraction and Fourier transform infrared techniques and show that the polyaniline layer is formed on the Nafion surface and improves the structural properties of Nafion in methanol solution. Nafion loses its crystallinity once exposed to water and ethanol, whilst the polyaniline modification allows crystallinity to be maintained under similar conditions. By contrast, the proton conductivities of polyaniline modified membranes are 3–5-fold lower than that of Nafion. On a positive note, methanol crossover is reduced by over two orders of magnitude, as verified by crossover limiting current analysis. The polyaniline modification allows the membrane to become less hydrophilic, which explains the lower proton conductivity. No major advantages are observed by embedding silica into the Nafion matrix. The performance of a membrane electrode assembly (MEA) using commercial catalysts and polyaniline modified membranes in a cell gives a peak power of 8 mW cm⁻² at 20 °C with 2 M methanol and air feeding. This performance correlates to half that of MEAs using Nafion, though the membrane modification leads to a robust material that may allow operation at high methanol concentration.     

Methanol permeability and performance of Nafion-zirconium phosphate composite membranes in active and passive direct methanol fuel cells

Methanol crossover through polymer electrolyte membranes represents one of the major problems to be solved in order to improve direct methanol fuel cell (DMFC) performance. With this aim, Nafion/zirconium phosphate (ZrP) composite membranes, with ZrP loading in the range 1-6 wt%, were prepared by casting from mixtures of gels of exfoliated ZrP and Nafion 1100 dispersions in dimethylformamide. These membranes were characterised by methanol permeability, swelling and proton conductivity measurements, as well as by tests in active and passive DMFCs in the temperature range 30-80 °C. Increase in filler loading results in a decrease in both methanol permeability and proton conductivity. As a consequence of the reduced conductivity the power density of active DMFCs decreases with increasing ZrP loading (from 46 to 32 mW cm⁻² at 80 °C). However, due to the lower methanol permeability, the room temperature Faraday efficiency of passive DMFCs, with 20 mA cm⁻² discharge current, nearly doubles when Nafion 1100 is replaced by the composite membrane containing 4 wt% ZrP.     

Enhancement of water retention in the membrane electrode assembly for direct methanol fuel cells operating with neat methanol

It is desirable to operate a direct methanol fuel cell (DMFC) with neat methanol to maximize the specific energy of the DMFC system, and hence increasing its runtime. A way to achieve the neat-methanol operation is to passively transport the water produced at the cathode through the membrane to the anode to facilitate the methanol oxidation reaction (MOR). To achieve a performance of the MOR similar to that under the conventional diluted methanol operation, both the water transport rate and the local water concentration in the anode catalyst layer (CL) are required to be sufficiently high. In this work, a thin layer consisting of nanosized SiO₂ particles and Nafion ionomer (referred to as a water retention layer hereafter) is coated onto each side of the membrane. Taking advantage of the hygroscopic nature of SiO₂, the cathode water retention layer can help maintain the water produced from the cathode at a higher concentration level to enhance the water transport to the anode, while the anode retention layer can retain the water that is transported from the cathode. As a result, a higher water transport rate and a higher water concentration at the anode CL can be achieved. The formed membrane electrode assembly (MEA) with the added water retention layers is tested in a passive DMFC and the results show that this MEA design yields a much higher power density than the MEA without water retention layers does.     

The influence of anode gas diffusion layer on the performance of low-temperature DMFC

The influence of the anode gas diffusion layers (GDLs) on the performances of low-temperature DMFCs, and the properties of mass transport and CO₂ removal on these anode GDLs were investigated. The membrane electrode assembly (MEA) based on the hydrophilic anode GDL, which consisted of the untreated carbon paper and hydrophilic anode micro-porous layer (comprised carbon black and 10 wt.% Nafion), showed the highest power density of 13.4 mW cm⁻² at 30 °C and ambient pressure. The performances of the MEAs tended to decline with the increase of the PTFE content in the anode GDLs due to the difficulty of methanol transport. The contact angle measurements revealed that the wettabilities of the anode GDLs decreased as the increase of PTFE content. The wettabilities of the GDLs were improved by addition of hydrophilic Nafion ionomer to the GDLs. From the visualizations of CO₂ gas bubbles dynamics on the anodes using a transparent cell, it was observed that uniform CO₂ gas bubbles with smaller size formed on hydrophilic anode GDLs. And bubbles with larger size were not uniform over the hydrophobic anode GDLs. It was believed that adding PTFE to the anode GDL was not helpful for improving the CO₂ gas transport in the anode GDL of the low-temperature DMFC.     

Development and performance analysis of a metallic micro-direct methanol fuel cell for high-performance applications

As a promising candidate for conventional micro-power sources, the micro-direct methanol fuel cell (μDMFC) is currently attracting increased attention due to its various advantages and prospective suitability for portable applications. This paper reports the design, fabrication and analysis of a high-performance μDMFC with two metal current collectors. Employing micro-stamping technology, the current collectors are fabricated on 300-μm-thick stainless steel plates. The flow fields for both cathode and anode are uniform in shape and size. Two sheets of stainless steel mesh are added between the membrane electrode assembly (MEA) and current collectors in order to improve cell performance. To avoid electrochemical corrosion, titanium nitride (TiN) layers with thickness of 500 nm are deposited onto the surface of current collectors and stainless steel mesh. The performance of this metallic μDMFC is thoroughly studied by both simulation and experimental methods. The results show that all the parameters investigated, including current collector material, stainless steel mesh, anode feeding mode, methanol concentration, anode flow rate, and operating temperature have significant effects on cell performance. Moreover, the results show that under optimal operating conditions, the metallic μDMFC exhibits promising performance, yielding a maximum power density of 65.66 mW cm⁻² at 40 °C and 115.0 mW cm⁻² at 80 °C.