Numerical evaluation of a dual-function microporous layer under subzero and normal operating temperatures for use in automotive fuel cells

In a previous study, we proposed a dual-function microporous layer (MPL) to improve the cold-start capability of polymer electrolyte fuel cells (PEFCs). The conceptual MPL design is to use an ionomer-based binder with low Pt loading, thereby allowing the MPL to provide additional volume for ice storage during cold-start PEFC operations. Although the benefit of using a dual-function MPL was numerically elucidated in our previous study, the question regarding the use of this new MPL under normal PEFC operation remains to be addressed. In this paper, we extend our discussion to the effects of a dual-function MPL under subzero to normal operating temperatures. The three-dimensional (3D) cold-start PEFC model developed in our previous study is modified for transient PEFC simulations to consider a wide range of operating temperatures from −20 °C to 80 °C. Simulation results show a negligible performance drop at the normal PEFC temperature of 80 °C, because of the presence of the dual-function MPL in a PEFC membrane electrode assembly. In addition, water back flow from the cathode to anode is reduced on using the dual-function MPL, owing to the additional water uptake driven by its ionomer content. This study clearly demonstrates that this dual-function MPL technology may be applied to automotive PEFC stack development without sacrificing fabrication cost and cell performance during normal PEFC operations. •MPL with ionomer binder and Pt loading can extend cold start operation time.•MPL with ionomer binder takes more time to reach the steady-state.•Use of dual-function MPLs does not cause significant cell performance drop.•Dual-function MPL can be applied to automotive PEFC stack development.