This
Spotlight article presents the state-of-the-art of electrospray
deposition technique applied to the fabrication of proton exchange
membrane fuel cell (PEMFC) components, mainly focusing on catalyst
layers in gas diffusion electrodes. The atomization of a suspension
of particles over a substrate under the influence of a strong electric
field results in the growth of a film with macroporous morphology
and many interesting properties. This so-called electrospray deposition
has reported many noteworthy beneficial effects for the fabrication
of the catalyst layers of gas diffusion electrodes of PEMFCs. The
electrosprayed catalyst layers prepared from suspensions of catalyst
particles and ionomers present a dendritic macroporous morphology
with superhydrophobic character that improves the water management
inside the cell and increases the performance by ∼20% with
respect to standard electrodes prepared by airbrushing. Other interesting
effects observed with electrosprayed catalyst layers are increased
catalyst utilization and water absorption capabilities of the ionomer,
improved performance under nonhumidified conditions, and a reduction
in catalyst degradation. In addition, the electrospray deposition
decreases platinum losses during fabrication thanks to the attractive
electrostatic forces between the ion mist and the substrate compared
with regular ink-based spray methods.