The design of the cathode catalyst layer (CCL) for the
oxygen reduction
reaction is critical to improving the performance of anion-exchange
membrane-based direct ammonia fuel cells (AEM-DAFCs) due to the impact
of ammonia crossover. Herein, the effects of three factors (cathode
catalyst loading, binder type, and binder content) and their corresponding
three levels on the CCL have been investigated to achieve optimal
cell performance by the orthogonal test for the first time. CCLs are
characterized by scanning electron microscopy, mercury intrusion porosimetry,
and contact angle measurements, which further verify the reliability
of the orthogonal test results. The results show the following order
of influence on the cell performance: binder type > binder content
> cathode catalyst loading. These factors affect the mass transport
and the number of three-phase interfaces in the CCL by changing its
thickness, surface morphology, pore structure, and hydrophobicity,
thus affecting the cell performance. An AEM-DAFC with a champion peak
power density (PPD) of 158.6 mW cm–2 has been achieved
under the optimal combination of cathode catalyst loading (2 mg cm–2), binder type (poly(tetrafluoroethylene) (PTFE)),
and binder content (15 wt %). This work provides an alternative avenue
to improve the performance of AEM-DAFCs using state-of-the-art catalysts
and binders through rapid optimization of the CCL structure in the
future.