Synthesis of transport layers with controlled anisotropy and application thereof to study proton exchange membrane fuel cell performance

We report on a novel method for the synthesis of fibre-based proton exchange membrane (PEM) fuel cell porous transport layers (PTLs) with controllable fibre alignment. We also report the first application of such layers as diagnostics tools to probe the effect of within-plane PTL anisotropy upon PEM fuel cell performance. These structures are realized via adaptation of electrospinning technology. Electrospun layers with progressive anisotropy magnitude are produced and evaluated. This novel approach is distinguished from the state-of-the-art because an equivalent study using commercially available materials is impossible due to lack of structurally similar substrates with different anisotropies. The anisotropy is visualized via scanning electron microscopy, and quantified using electrical resistivity. The capacity is demonstrated to achieve fibre alignment, and the associated impact on transport properties. A framework is presented for assessing the in-situ performance, whereby transport layer orientation versus bipolar plate flow-field geometry is manipulated. While an effect upon the commercial baseline cannot be discerned, electrospun transport layers with greater anisotropy magnitude suggest greater sensitivity to orientation; where greater performance is obtained with fibres cross-aligned to flow-field channels. Our approach of electrospun transport enables deterministic structures by which fuel cell performance can be explained and optimized. [Display omitted] •Novel PEM fuel cell transport layers with controlled anisotropy are presented.•Electrospinning enables transport layers with progressive fibre alignment.•Preferential fibre alignment creates anisotropic transport properties.•Anisotropy is confirmed qualitatively (SEM) and quantitatively (resistivity).•Electrospun layers are applied to probe effect of anisotropy upon cell performance.