Exploring the process design and parameters for a fuel cell membrane electrode assembly by decal transfer

Abstract

Proton exchange membrane fuel cells (PEM FCs) are a promising key component in a renewable energy infrastructure. At their heart is the membrane electrode assembly (MEA), where both the hydrogen oxidation and oxygen reduction reactions occur. Decal transfer is an effective method for fabricating MEAs, as it is highly scalable and noted for its low interfacial resistance. In this thesis, the main processing parameters for the decal transfer – temperature, pressure and transfer time – are varied to explore the parameter space available for MEA production. Based on these results, in-situ performance tests using polarization curves and high frequency resistance (HFR) measurements are performed in a 2k experiment matrix to study the effects of these parameters on the MEA performance. Further experiments are conducted for different proton exchange membranes and for in-house produced cathodes to understand the effects of these materials on the performance and processing parameter space. Further studies are performed to explore the glass transition temperatures of the membranes, to understand the real temperature profiles of the MEA during the transfer, and to explore the morphological changes undergone by the electrode during transfer. The results of this thesis most notably illustrate the sets of parameters that can result in a good transfer, demonstrate the effects of these parameters on the transfer quality and MEA performance.