Structures of Membrane Electrode Assembly Catalyst Layers for Proton Exchange Membrane Fuel Cells

In this paper, we modify the conventional 5-layer membrane electrode assembly (MEA, in which a proton exchange membrane (PEM) is located at its center, two Pt-C-40 (Pt on carbon powder support, Pt content 40 wt.%) catalyst layers (CLs) are located on the surfaces of the both sides of the PEM and two gas diffusion layers (GDLs) are attached next on the outer surfaces of two Pt-C-40 layers) and propose 7-layer and 9-layer MEAs by coating thin Pt-black CLs at the interfaces between the Pt-C-40 layer and the GDL and between the PEM and the Pt-C-40 layer and reducing the Pt-C-40 loading. The reduced Pt loading quantity of the Pt-C-40 layer is equal to the increased Pt loading quantity of the Pt-black layer, thus the total amount of Pt loadings in the unmodified conventional MEA and the modified MEAs are at a fixed Pt loading quantity. These modified MEAs may complicate the manufacture process. The main advantage of these 7- and 9-layer MEAs is the thinner CL thickness and thus lower CL proton transport resistance. Because of the thin Pt-black layer thickness in MEA, we avoid agglomeration of the Pt-black particles and maintain high Pt catalytic activity. We show these new CL structure MEAs have better fuel cells performance than the conventional 5-layer MEA.