High Durability of Pemion® Proton Exchange Membranes in Cross-Pressure Accelerated Mechanical Stress Tests

Polymer electrolyte membrane fuel cells (PEMFC) are the dominant technology for hydrogen-powered fuel cell electric vehicles in clean transportation systems. To be suitable for commercialization and applicability in real-world use-cases, light and heavy-duty fuel cell vehicles require lifetimes of over 8,000 and 30,000 hours, respectively [1]. Hence, enhancing the durability of all fuel cell components, particularly the proton exchange membrane (PEM), is of great importance. Recently, fuel cell membranes based on hydrocarbon (HC) chemistries have become increasingly common in the literature [2]. Materials with polyaromatic backbones, tunable electrochemical properties, and low reactant permeability are increasingly seen as potential alternatives to incumbent perfluorosulfonic acid (PFSA) materials [2]. Additionally, as restrictions on the use of fluorinated materials in various industries continue to grow, the importance of HC chemistries will as well. Sulfo-phenylated polyphenylenes (sPPPs) are a particular class of HC materials that show promise [3]. However, the phase separation between hydrophilic and hydrophobic domains within sPPPs may not be as discrete as in PFSAs [3], requiring higher ion exchange capacity (IEC) values than PFSAs to achieve similar protonic conductivity. High IEC typically results in greater material hydrophilicity, which can render membranes dimensionally unstable in a fuel cell [4]. State-of-the-art commercial PEMs are now manufactured as thin films (≤ 18 µm), offering small ohmic loss and therefore high fuel cell performance. To improve dimensional stability and eliminate the risks of electrical shorting, PEMs are commonly mechanically reinforced using a porous, inert, and non-ionic substrate, such as expanded polytetrafluoroethylene (ePTFE). In a work by Miyake et al. [5], sulfonated polyphenylene-based ionomer membranes with flexible polyethylene mechanical reinforcement were prepared and the results indicated promising mechanical properties and improved longevity in RH cycling tests. However, there is still a lack of data about the fatigue durability of HC membranes in the literature, and evaluating and comparing the mechanical durability of numerous PEMs with a mechanical reinforcement layer in a traditional wet-dry cycling accelerated stress test would be a time-consuming and thus costly process [6]. In our previous work, [7] we combined constant pressure differential across an ePTFE-reinforced perfluorosulfonic acid (PFSA