Coordinated Multi‐Component Gradient Engineering of Catalyst Layers for Advanced Polymer Electrolyte Fuel Cells
Advanced Functional Materials, vol. 36
Abstract
Abstract Membrane electrode assemblies (MEAs) are critical to emerging energy technologies such as polymer electrolyte fuel cells (PEFCs), but their performance is often limited by challenges in reactant transport, ionic conduction and water management within the catalyst layer (CL). Conventional CL architectures, whether uniform or layered, struggle to manage these competing transport phenomena effectively, leading to mass transport losses, poor proton conduction and structural inconsistencies. To address these limitations, this study presents a continuous linear gradient CL design that breaks from traditional approaches. By employing a precision‐controlled dual‐nozzle spray coating technique, a smooth gradient in Pt/C ratio, ionomer content and ionomer type is fabricated across the CL thickness. Uniquely, this method relies exclusively on commercially available materials, strategically positioned where they are most effective. The resulting architecture aligns with natural electrochemical gradients in the CL, facilitating improved reactant accessibility, proton transport and water handling. This structure not only enhances performance under realistic operating conditions but also improves long‐term durability. Furthermore, by selectively placing materials only where needed, it has the potential to reduce overall material usage and cost. This gradient approach offers a scalable and practical path toward next‐generation, high‐efficiency PEFCs.
Authors 15
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Shangwei Zhou corresponding
Affiliation as printed
Advanced Propulsion Lab Department of Chemical Engineering University College London London WC1E 6BT UK
Electrochemical Innovation Lab Department of Chemical Engineering University College London London WC1E 7JE UK
Electrochemical Innovation Lab, Department of Chemical Engineering, University College London, London, WC1E 7JE UK
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Affiliation as printed
Advanced Propulsion Lab Department of Chemical Engineering University College London London WC1E 6BT UK
Electrochemical Innovation Lab Department of Chemical Engineering University College London London WC1E 7JE UK
Electrochemical Innovation Lab, Department of Chemical Engineering, University College London, London, WC1E 7JE UK
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Affiliation as printed
Advanced Propulsion Lab Department of Chemical Engineering University College London London WC1E 6BT UK
Electrochemical Innovation Lab Department of Chemical Engineering University College London London WC1E 7JE UK
Electrochemical Innovation Lab, Department of Chemical Engineering, University College London, London, WC1E 7JE UK
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Horiba (United Kingdom) · University College London
Affiliation as printed
Electrochemical Innovation Lab Department of Chemical Engineering University College London London WC1E 7JE UK
HORIBA UK Kyoto Close, Moulton Park Northampton NN3 6FL UK
Electrochemical Innovation Lab, Department of Chemical Engineering, University College London, London, WC1E 7JE UK
HORIBA UK, Kyoto Close, Moulton Park, Northampton, NN3 6FL UK
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University of Oxford · The Faraday Institution
Affiliation as printed
Department of Engineering Science University of Oxford Parks Road Oxford OX1 3PJ UK
Oxford Martin School University of Oxford Oxford OX1 3BD UK
The Faraday Institution, Quad One Harwell Science and Innovation Campus Didcot OX11 ORA UK
The ZERO Institute University of Oxford Oxford OX2 0ES UK
The Faraday Institution, Quad One, Harwell Science and Innovation Campus, Didcot, OX11 ORA UK
The ZERO Institute, University of Oxford, Oxford, OX2 0ES UK
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University of Oxford · The Faraday Institution
Affiliation as printed
Department of Materials University of Oxford Oxford United Kingdom
The Faraday Institution, Quad One Harwell Science and Innovation Campus Didcot OX11 ORA UK
Department of Materials, University of Oxford, Oxford, United Kingdom
The Faraday Institution, Quad One, Harwell Science and Innovation Campus, Didcot, OX11 ORA UK
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Affiliation as printed
Electrochemical Innovation Lab Department of Chemical Engineering University College London London WC1E 7JE UK
Materials and Catalysis Laboratory Department of Chemical Engineering University College London London WC1E7JE UK
Electrochemical Innovation Lab, Department of Chemical Engineering, University College London, London, WC1E 7JE UK
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Affiliation as printed
Electrochemical Innovation Lab Department of Chemical Engineering University College London London WC1E 7JE UK
Electrochemical Innovation Lab, Department of Chemical Engineering, University College London, London, WC1E 7JE UK
-
Affiliation as printed
Electrochemical Innovation Lab Department of Chemical Engineering University College London London WC1E 7JE UK
Electrochemical Innovation Lab, Department of Chemical Engineering, University College London, London, WC1E 7JE UK
-
Affiliation as printed
Materials and Catalysis Laboratory Department of Chemical Engineering University College London London WC1E7JE UK
Materials and Catalysis Laboratory, Department of Chemical Engineering, University College London, London, WC1E7JE UK
-
Affiliation as printed
Advanced Propulsion Lab Department of Chemical Engineering University College London London WC1E 6BT UK
Electrochemical Innovation Lab Department of Chemical Engineering University College London London WC1E 7JE UK
Advanced Propulsion Lab, Department of Chemical Engineering, University College London, London, WC1E 6BT UK
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University of Oxford · The Faraday Institution
Affiliation as printed
Department of Materials University of Oxford Oxford United Kingdom
The Faraday Institution, Quad One Harwell Science and Innovation Campus Didcot OX11 ORA UK
Department of Materials, University of Oxford, Oxford, United Kingdom
The Faraday Institution, Quad One, Harwell Science and Innovation Campus, Didcot, OX11 ORA UK
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University of Oxford · The Faraday Institution
Affiliation as printed
Department of Engineering Science University of Oxford Parks Road Oxford OX1 3PJ UK
Oxford Martin School University of Oxford Oxford OX1 3BD UK
The Faraday Institution, Quad One Harwell Science and Innovation Campus Didcot OX11 ORA UK
The ZERO Institute University of Oxford Oxford OX2 0ES UK
The Faraday Institution, Quad One, Harwell Science and Innovation Campus, Didcot, OX11 ORA UK
The ZERO Institute, University of Oxford, Oxford, OX2 0ES UK
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The Faraday Institution · University College London
Affiliation as printed
Advanced Propulsion Lab Department of Chemical Engineering University College London London WC1E 6BT UK
Electrochemical Innovation Lab Department of Chemical Engineering University College London London WC1E 7JE UK
The Faraday Institution, Quad One Harwell Science and Innovation Campus Didcot OX11 ORA UK
Advanced Propulsion Lab, Department of Chemical Engineering, University College London, London, WC1E 6BT UK
The Faraday Institution, Quad One, Harwell Science and Innovation Campus, Didcot, OX11 ORA UK
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Thomas Samuel Miller corresponding
The Faraday Institution · University College London
Affiliation as printed
Advanced Propulsion Lab Department of Chemical Engineering University College London London WC1E 6BT UK
Electrochemical Innovation Lab Department of Chemical Engineering University College London London WC1E 7JE UK
The Faraday Institution, Quad One Harwell Science and Innovation Campus Didcot OX11 ORA UK
Electrochemical Innovation Lab, Department of Chemical Engineering, University College London, London, WC1E 7JE UK
The Faraday Institution, Quad One, Harwell Science and Innovation Campus, Didcot, OX11 ORA UK
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