Characterisation of Novel and High Performing Double-Sided Microporous-Layers-Coated Gas Diffusion Layers for Polymer Electrolyte Membrane Fuel Cells

Fernando Ruscillo (), Kun Zhang, Mohammed S. Ismail, Kevin J. Hughes, Derek B. Ingham, Lin Ma and Mohamed Pourkashanian
Additional contact information
Fernando Ruscillo: Energy Institute, The University of Sheffield, Sheffield S3 7RD, UK
Kun Zhang: Centre for Fuel Cell and Hydrogen Research, The University of Birmingham, Birmingham B15 2TT, UK
Mohammed S. Ismail: School of Engineering, University of Hull, Hull HU6 7RX, UK
Kevin J. Hughes: Energy Institute, The University of Sheffield, Sheffield S3 7RD, UK
Derek B. Ingham: Energy Institute, The University of Sheffield, Sheffield S3 7RD, UK
Lin Ma: Energy Institute, The University of Sheffield, Sheffield S3 7RD, UK
Mohamed Pourkashanian: Energy Institute, The University of Sheffield, Sheffield S3 7RD, UK

Energies, 2023, vol. 16, issue 22, 1-18

Abstract: This study aims to experimentally evaluate the impact of a double-sided microporous layer coating on gas diffusion layers in terms of their key properties and fuel cell performance, in comparison to conventional single-sided coated gas diffusion layers (GDLs). Vulcan black and Ketjenblack were used as the carbon black materials. This was to investigate the sensitivity of the results with respect to the type of carbon black used. The results showed that the in-plane electrical conductivity is almost insensitive to microporous layer (MPL) loading and carbon black type. Furthermore, the electrical conductivity of all the MPL-coated GDLs are slightly lower than that of the uncoated GDL. The Ketjenblack black MPL samples were found to demonstrate higher gas permeability than the Vulcan black samples. The addition of the MPL resulted in a favourable shift in pore size distribution, with prominent micropores observed in both single- and double-sided MPL-coated GDLs. Contact angle measurements indicated a slight increase in the hydrophobicity with the addition of a microporous layer, but without significant differences between carbon black types or loading levels. Cross-sectional SEM images showed that there was a higher level of MPL penetration into the carbon substrate for the GDLs coated with Vulcan black as compared to a Ketjenblack coating. In situ fuel cell testing demonstrated the superior performance of the double-sided Vulcan black MPL-coated GDL under high humidity conditions, while the single-sided Vulcan black MPL-coated GDL exhibited better performance at low humidity conditions. All the above findings have been thoroughly discussed and justified.

Keywords: polymer electrolyte fuel cells; gas diffusion layers; microporous layers; carbon black; double-sided MPL coating; MPL loading; fuel cell performance; electrical conductivity; pore size distribution (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2023
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