Homogeneity analysis of square meter-sized electrodes for PEM electrolysis and PEM fuel cells

Electrodes for polymer electrolyte membrane electrolyzers and fuel cells are manufactured by coating a catalyst dispersion, consisting of precious metal, ionomer and solvents, onto a substrate that is subsequently dried. One target of current research is to produce square meter-sized electrodes, but so far the homogeneity that can be achieved in this scaling is unclear. To quantify the achievable homogeneity of an electrode, manufactured by means of slot die coating in a roll-to-roll pilot plant, this study focuses first on the selection of an appropriate substrate by investigating thickness, basis weight and surface free energy distribution at the square meter scale. Afterward, a dispersion is coated on the selected substrate, dried and investigated with respect to thickness and basis weight distribution. Among the investigated substrates, Kapton has the smallest scatter in terms of thickness and basis weight. The subsequent coating results in a precious metal loading of 1.10 mg cmwith a scattering of 5.5% that can be further reduced to 4.5% when edge effects can be prevented. These results are now available for further research in which it is necessary to investigate whether or not these fluctuations affect the achievable electrochemical efficiencies of electrodes.