Manufacturing and structural control of slurry-cast catalyst layers for AEMFC

Fabrication of the catalyst layer (CL) in a cost-effective and scalable manner is a critical step toward commer-cialization of anion exchange membrane fuel cells (AEMFCs). Herein, we present a CL manufactured by slurry-casting that is compatible with the roll-to-roll process. Careful control of the rheological properties of the catalyst slurry enables casting onto a gas diffusion layer. The slurry cast CL features uniform thickness and well-developed mesoporous structure. By adjusting the solid content and ionomer-to-carbon ratio of the slurry, the pore structure and ionomer connectivity in the CL are controlled and the power performance is enhanced. This work suggests a practical strategy for mass production of the CL and extends the understanding of the struc-ture-property relationship for slurry-cast CLs.

Automated summary

In this study, a catalyst layer (CL) compatible with the roll-to-roll process was fabricated through slurry-casting method. The rheological properties of the catalyst slurry were carefully controlled to enable casting onto a gas diffusion layer with uniform thickness and well-developed mesoporous structure. By adjusting the slurry's solid content and ionomer-to-carbon ratio, the pore structure and ionomer connectivity in the CL were controlled, leading to enhanced power performance. This work suggests a practical strategy for mass production of the CL and extends the understanding of the structure-property relationship for slurry-cast CLs.