Current Status on the Manufacturing of Nanomaterials for Proton Exchange Membrane Energy Systems by Vapor-Based Processes

Abstract

Development of novel technologies for catalyst synthesis and membrane electrode assembly (MEA) fabrication is of primary importance for further improvement of the performance and economics of proton exchange membrane fuel cells (PEMFCs) and proton exchange membrane water electrolyzers (PEMWEs). While the traditional manufacturing methods are time-consuming, energy intensive, and require many processing steps, newer vapor-based methods provide many benefits including the development of improved catalysts and catalyst supports, deposition of uniform thin films, reduction of catalyst loading, and minimizing the number of manufacturing steps. Recent publications in the field identified spray pyrolysis, reactive spray deposition technology, chemical vapor deposition, and atomic layer deposition as advanced vapor-based catalyst synthesis and deposition methods used for fabrication of MEAs for PEMFCs and PEMWEs. The MEAs fabricated via vapor-based processes have shown significant performance improvements in comparison to the state-of-the-art MEAs, which are attributed to better catalyst distribution, improved catalyst supports, and controlled, uniform catalyst layer microstructures. This review provides an overview of the vapor-based synthesis and deposition methods currently being used for the development of PEM-based devices. The advantages and disadvantages of these methods are critically compared and discussed while the outlook for future development is provided.

Review on Electric Resistance in Proton Exchange Membrane Fuel Cells: Advances and Outlook

“…161 However, CL composites containing pyrrolic N and pyridinic N may offer superior electron and proton transfer capabilities compared to those containing graphitic N. 162 Shahgaldi et al 163 provided a comprehensive review on deposition methods for carbon-supported CLs, aiming for reduced electric resistance and enhanced stability and performance. Ouimet et al 164 observed that carbon nanotubes supporting Pt, synthesized via the chemical vapor deposition (CVD) method, exhibited relatively higher electrical conductivity compared to conventional carbon black and other synthesis methods.…”

“…Similarly, TiN coatings via heat treatment also demonstrated enhanced electronic conductivity. 183 Ouimet et al 164 discussed the coating of carbon cloth used in GDL with carbon nanotubes via the CVD method. This coating was found to be effective not only in enhancing the contact conductivity between the GDL and CL, but also in improving the conductivity between the GDL and BPP.…”

Virtual Special Issue of Recent Advances in Gas-Phase Synthesis of Functional Materials for Energy

“…Meierhofer and Fritsching contribute a comprehensive overview on the spray-flame synthesis of metal oxide nanoparticles, with the focus on history, processes of flame aerosol-based manufacturing, particle growth modeling, and various diagnostic techniques. Ouimet et al review vapor-based synthesis and deposition for proton exchange membrane (PEM)-based devices. The review of Rahinov et al provides comprehensive insight in the mechanism of combustion synthesis of iron oxide nanoparticles based on combined laser spectroscopy, mass spectrometry, and detailed simulation.…”

Supported Ir-Based Oxygen Evolution Catalysts for Polymer Electrolyte Membrane Water Electrolysis: A Minireview

“…Low durability, to a significant extent, arises from the dissolution of Ir , with oxidation states of 3+ and 6+ . Moreover, the Ir-based catalyst for OER is characterized by mixed Ir oxidation states, depending on the preparation approach applied. , For instance, commercially available quasi-amorphous IrO x and crystalline IrO 2 are often used as the baselines . The trade-off between OER catalyst activity and stability has been established for Ir oxides.…”