One-step deposition of catalyst layers for high temperature proton exchange membrane fuel cells (PEMFC)

Catalyst-coated membranes (CCMs) for use in high temperature proton exchange membrane fuel cells (PEMFC) were successfully fabricated by a one-step jet-flame direct deposition process using reactive spray deposition technology (RSDT). The as-deposited catalyst layer (CL) was characterized using scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray diffraction (XRD), thermal gravimetric analysis (TGA) and electrochemical measurements. Pt nanoparticles averaging 2.6 nm in diameter formed a good dispersion with a Pt content of 47.5 wt% on the carbon. The Pt/C catalyst had a specific activity and a mass activity of 277 μA/cm_Pt ² and 0.155 A/mg_Pt, respectively. Polybenzimidazole (PBI) was employed as the membrane, and the membrane electrode assemblies (MEAs) were tested in temperatures ranging from 140°C to 160°C. Power densities of 375 mW/cm² in oxygen and 135 mW/cm² in air were achieved with a total Pt loading of 0.8 mg/cm².