Electrospun fabrication and experimental characterization of highly porous microporous layers for PEM fuel cells

To meet the demands for high power density, enhancing the water discharge capacity of proton exchange membrane fuel cells (PEMFCs) is imperative. The microporous layer (MPL), placed between a catalyst layer and gas diffusion layer, plays a crucial role in water management for PEMFCs. In this study, we fabricated electrospun MPLs of different pore sizes and characterized their morphology and pore structures. The mercury intrusion test showed that the mean pore sizes of electrospun MPLs are about 1.2–2.3 μm, much larger than commercial MPL's (about 70 nm). The electrospun MPLs were assembled in single PEMFCs to test their performance and Electrochemical Impedance Spectroscopy (EIS). The results demonstrate that the electrospun MPLs with a pore size exceeding 1.9 μm significantly enhance water discharge and oxygen transport at the cathode relative humidity (RH) of 50 % and 100 %. Moreover, the EIS testing and fitting outcomes indicate that when the PEMFC performance is dominated by mass transport under high current density and 100 % cathode RH, the electrospun MPLs with a pore size exceeding 1.9 μm exhibit a better water discharge capacity and lower mass transport resistance.