Final Report - MEA and Stack Durability for PEM Fuel Cells

Proton exchange membrane fuel cells are expected to change the landscape of power generation over the next ten years. For this to be realized one of the most significant challenges to be met for stationary systems is lifetime, where 40,000 hours of operation with less than 10% decay is desired. This project conducted fundamental studies on the durability of membrane electrode assemblies (MEAs) and fuel cell stack systems with the expectation that knowledge gained from this project will be applied toward the design and manufacture of MEAs and stack systems to meet DOE’s 2010 stationary fuel cell stack systems targets. The focus of this project was PEM fuel cell durability – understanding the issues that limit MEA and fuel cell system lifetime, developing mitigation strategies to address the lifetime issues and demonstration of the effectiveness of the mitigation strategies by system testing. To that end, several discoveries were made that contributed to the fundamental understanding of MEA degradation mechanisms. (1) The classically held belief that membrane degradation is solely due to end-group “unzipping” is incorrect; there are other functional groups present in the ionomer that are susceptible to chemical attack. (2) The rate of membrane degradation can be greatly slowed or possibly eliminated through the use of additives that scavenge peroxide or peroxyl radicals. (3) Characterization of GDL using dry gases is incorrect due to the fact that fuel cells operate utilizing humidified gases. The proper characterization method involves using wet gas streams and measuring capillary pressure as demonstrated in this project. (4) Not all Platinum on carbon catalysts are created equally – the major factor impacting catalyst durability is the type of carbon used as the support. (5) System operating conditions have a significant impact of lifetime – the lifetime was increased by an order of magnitude by changing the load profile while all other variables remain the same. (6) Through the use of statistical lifetime analysis methods, it is possible to develop new MEAs with predicted durability approaching the DOE 2010 targets. (7) A segmented cell was developed that extend the resolution from ~ 40 to 121 segments for a 50cm2 active area single cell which allowed for more precise investigation of the local phenomena in a operating fuel cell. (8) The single cell concept was extended to a fuel size stack to allow the first of its kind monitoring and mapping of an operational fuel cell stack. An internal check used during this project involved evaluating the manufacturability of any new MEA component. If a more durable MEA component was developed in the lab, but could not be scaled-up to ‘high speed, high volume manufacturing’, then that component was not selected for the final MEA-fuel cell system demonstration. It is the intent of the team to commercialize new products developed under this project, but commercialization can not occur if the manufacture of said new components is difficult or if the price is significantly greater than existing products as to make the new components not cost competitive. Thus, the end result of this project is the creation of MEA and fuel cell system technology that is capable of meeting the DOEs 2010 target of 40,000 hours for stationary fuel cell systems (although this lifetime has not been demonstrated in laboratory or field testing yet) at a cost that is economically viable for the developing fuel cell industry. We have demonstrated over 2,000 hours of run time for the MEA and system developed under this project

Chemical and Morphological Origins of Improved Transport in Perfluoro Ionene Chain Extended Ionomers

The performance of proton-conducting ionomer membranes used in electrochemical applications such as fuel cells is complicated by an intricate interplay between chemistry and morphology that is challenging to characterize and control. Here, we report on a class of perfluoro ionene chain extended (PFICE) ionomers that contain either one (PFICE-2) or two (PFICE-3) bis(sulfonyl)imide groups on the side-chain in addition to a terminal sulfonic acid group. PFICE ionomers are promising materials, exhibiting greater water uptake and conductivity over a range of relative humidity values compared to prototypical perfluorinated sulfonic acid (PFSA) ionomers. Advanced in situ synchrotron characterization combined with simulations reveals insights into the connections between molecular structure and morphology that dictate performance. Energy-tunable X-rays with sensitivity to sulfur can decipher the unique bonding environment of different protogenic groups on the polymer side-chain. Guided by simulations, X-ray absorption spectroscopy can be sensitive to hydration level and configuration that dictates proton dissociation. In situ resonant X-ray scattering reveals that PFICE ionomers have a phase-separated morphology with enhanced short-range order that persists in both dry and hydrated state, allowing for improved transport pathways across hydration levels. Furthermore, side-chain chemistry and length can be used as a molecular design parameter to predict phase-separated domain spacing. The enhanced conductivity of PFICE ionomers is attributed to a unique side-chain chemistry and structure promoting hydrogen bonding configurations that facilitate proton dissociation at low water content in combination with a well-ordered phase-separated morphology that forms transport pathways. Overall, these results provide guidelines to design new ionomers with improved transport properties and demonstrate the value of in situ characterization methods such as resonant X-ray scattering and spectroscopy for unraveling the structural features in chemically-heterogeneous materials used in electrochemical systems

Chemical and Morphological Origins of Improved Ion Conductivity in Perfluoro Ionene Chain Extended Ionomers.

The performance of ion-conducting polymer membranes is complicated by an intricate interplay between chemistry and morphology that is challenging to understand. Here, we report on perfuoro ionene chain extended (PFICE) ionomers that contain either one or two bis(sulfonyl)imide groups on the side-chain in addition to a terminal sulfonic acid group. PFICE ionomers exhibit greater water uptake and conductivity compared to prototypical perfluorinated sulfonic acid ionomers. Advanced in situ synchrotron characterization reveals insights into the connections between molecular structure and morphology that dictate performance. Guided by first-principles calculations, X-ray absorption spectroscopy at the sulfur K-edge can discern distinct protogenic groups and be sensitive to hydration level and configurations that dictate proton dissociation. In situ resonant X-ray scattering at the sulfur K-edge reveals that PFICE ionomers have a phase-separated morphology with enhanced short-range order that persists in both dry and hydrated states. The enhanced conductivity of PFICE ionomers is attributed to a unique multi-acid side-chain chemistry and structure that facilitates proton dissociation at low water content in combination with a well-ordered phase-separated morphology with nanoscale transport pathways. Overall, these results provide insights for the design of new ionomers with tunable phase separation and improved transport properties as well as demonstrating the efficacy of X-rays with elemental sensitivity for unraveling structural features in chemically heterogeneous functional materials for electrochemical energy applications

Novel Approaches to Immobilized Heteropoly Acid Systems for High Temperature, Low Relative Humidity Polymer-Type Membranes - Final Report

Original research was carried out at the CSM and the 3M Company from March 2007 through September 2011. The research was aimed at developing new to the world proton electrolyte materials for use in hydrogen fuel cells, in particular with high proton conductivity under hot and dry conditions (>100mS/cm at 120°C and 50%RH). Broadly stated, the research at 3M and between 3M and CSM that led to new materials took place in two phases: In the first phase, hydrocarbon membranes that could be formed by photopolymerization of monomer mixtures were developed for the purpose of determining the technical feasibility of achieving the program's Go/No-Go decision conductivity target of >100mS/cm at 120°C and 50%RH. In the second phase, attempts were made to extend the achieved conductivity level to fluorinated material systems with the expectation that durability and stability would be improved (over the hydrocarbon material). Highlights included: Multiple lots of an HPA-immobilized photocurable terpolymer derived from di-vinyl-silicotungstic acid (85%), n-butyl acrylate, and hexanediol diacrylate were prepared at 3M and characterized at 3M to exhibit an initial conductivity of 107mS/cm at 120°C and 47%RH (PolyPOM85v) using a Bekktech LLC sample fixture and TestEquity oven. Later independent testing by Bekktech LLC, using a different preheating protocol, on the same material, yielded a conductivity value of approximately 20mS/cm at 120°C and 50%RH. The difference in measured values is likely to have been the result of an instability of properties for the material or a difference in the measurement method. A dispersed catalyst fuel cell was fabricated and tested using a 150¼m thick HPA-based photocurable membrane (above, PolyPOM75v), exhibiting a current density of greater than 300mA/cm2 at 0.5V (H2/Air 800/1800sccm 70°C/75%RH ambient outlet pressure). Multiple lots of a co-polymer based on poly-trifluorovinylether (TFVE) derived HPA were synthesized and fabricated into films, Generation II films. These materials showed proton conductivities as high as 1 S/cm under high RH conditions. However, the materials suffered from compromised properties due to impure monomers and low molecular weights. Multiple lots of an HPA-immobilized fluoropolymer derived from preformed PVDF-HFP (Generation III films) were synthesized and formed into membranes at 3M and characterized at 3M to exhibit conductivity reaching approximately 75mS/cm at 120°C/40%RH using a Bekktech sample fixture and TestEquity oven (optimized membrane, at close of program). Initial fuel cell fabrication and testing for this new class of membrane yielded negative results (no measureable proton conductivity); however, the specific early membrane that was used for the two 5cm2 MEAs was later determined to have <1 mS/cm at 80°C/80%RH using the Bekktech fixture, vs. ca. 200 mS/cm at 80°C/80%RH for samples of the later-optimized type described above. Future work in this area (beyond the presently reported contract) should include additional attempts to fabricate and test fuel cells based on the later-optimized Generation II and III polymer. A manufacturing study was performed which predicted no difficulties in any future scale up of the materials

Novel Approaches to Immobilized Heteropoly Acid Systems for High Temperature, Low Relative Humidity Polymer-Type Membranes - Final Report

Original research was carried out at the CSM and the 3M Company from March 2007 through September 2011. The research was aimed at developing new to the world proton electrolyte materials for use in hydrogen fuel cells, in particular with high proton conductivity under hot and dry conditions (>100mS/cm at 120°C and 50%RH). Broadly stated, the research at 3M and between 3M and CSM that led to new materials took place in two phases: In the first phase, hydrocarbon membranes that could be formed by photopolymerization of monomer mixtures were developed for the purpose of determining the technical feasibility of achieving the program's Go/No-Go decision conductivity target of >100mS/cm at 120°C and 50%RH. In the second phase, attempts were made to extend the achieved conductivity level to fluorinated material systems with the expectation that durability and stability would be improved (over the hydrocarbon material). Highlights included: Multiple lots of an HPA-immobilized photocurable terpolymer derived from di-vinyl-silicotungstic acid (85%), n-butyl acrylate, and hexanediol diacrylate were prepared at 3M and characterized at 3M to exhibit an initial conductivity of 107mS/cm at 120°C and 47%RH (PolyPOM85v) using a Bekktech LLC sample fixture and TestEquity oven. Later independent testing by Bekktech LLC, using a different preheating protocol, on the same material, yielded a conductivity value of approximately 20mS/cm at 120°C and 50%RH. The difference in measured values is likely to have been the result of an instability of properties for the material or a difference in the measurement method. A dispersed catalyst fuel cell was fabricated and tested using a 150¼m thick HPA-based photocurable membrane (above, PolyPOM75v), exhibiting a current density of greater than 300mA/cm2 at 0.5V (H2/Air 800/1800sccm 70°C/75%RH ambient outlet pressure). Multiple lots of a co-polymer based on poly-trifluorovinylether (TFVE) derived HPA were synthesized and fabricated into films, Generation II films. These materials showed proton conductivities as high as 1 S/cm under high RH conditions. However, the materials suffered from compromised properties due to impure monomers and low molecular weights. Multiple lots of an HPA-immobilized fluoropolymer derived from preformed PVDF-HFP (Generation III films) were synthesized and formed into membranes at 3M and characterized at 3M to exhibit conductivity reaching approximately 75mS/cm at 120°C/40%RH using a Bekktech sample fixture and TestEquity oven (optimized membrane, at close of program). Initial fuel cell fabrication and testing for this new class of membrane yielded negative results (no measureable proton conductivity); however, the specific early membrane that was used for the two 5cm2 MEAs was later determined to have <1 mS/cm at 80°C/80%RH using the Bekktech fixture, vs. ca. 200 mS/cm at 80°C/80%RH for samples of the later-optimized type described above. Future work in this area (beyond the presently reported contract) should include additional attempts to fabricate and test fuel cells based on the later-optimized Generation II and III polymer. A manufacturing study was performed which predicted no difficulties in any future scale up of the materials

Transport and Morphology of a Proton Exchange Membrane Based on a Doubly Functionalized Perfluorosulfonic Imide Side Chain Perflourinated Polymer

There is a critical need for higher performing proton exchange membranes for electrochemical energy conversion devices that would enable higher temperature and drier operating conditions to be utilized. A novel approach is to utilize multiacid side chains in a perfluorinated polymer, maintaining the mechanical properties of the material, while dramatically increasing the ion-exchange capacity; however, as we show in this paper, the more complex side chain gives rise to unexpected physical phenomena in the material. We have thoroughly investigated a doubly functionalized perfluorosulfonic imide acid side chain perfluorinated polymer (PFIA), the simplest of many possible multiacid side chains currently being developed. The material is compared to its simpler perfluorosulfonic acid (PFSA) analogue via a battery of characterization and modeling investigations. The doubly functional side chain profoundly influences the properties of the PFIA polymer as it gives rise to both inter- and intraside chain interactions. These affect the nature of thermal decomposition of the material but, more importantly, force the backbone of the polymer into an unusually highly ordered more crystalline configuration. Under water saturated conditions, the PFIA has the same proton conductivity as the PFSA material, indicating that the additional proton does not contribute to the ionic conductivity, but the PFIA shows higher proton conductivity at lower RH conditions owing to dynamic changes in its local molecular environment. A transition is observed between 30 and 60 \ub0C, indicating an order/disorder transition that is not present in the PFSA analogue. The mechanism of proton transport in the PFIA is due to more delocalized protons and more flexible side chains with better-dispersed, smaller water clusters forming the hydrophilic domains than in the PFSA analogue

A Small-Angle X‑ray Scattering Study of the Development of Morphology in Films Formed from the 3M Perfluorinated Sulfonic Acid Ionomer

An extensive SAXS investigation of the 3M perfluorinated sulfonic acid ionomer was performed to investigate the morphological changes that occur during and after annealing at temperatures above the <i>T</i>_α. The effect of film thickness in the range studied, 11–45 μm, was found to be negligible. These properties were studied as a function of equivalent weight from 700 to 1100 and correlated with the water uptake as measured by dynamic vapor sorption. Isoscattering points were observed in dynamic annealing experiments of the unboiled annealed films at <i>q</i> = 0.023, 0.096 Å^–1. On initial water uptake these films also showed isoscattering points at <i>q</i> = 0.024, 0.220 Å^–1; <i>q</i> = 0.029, 0.223 Å^–1; and <i>q</i> = 0.030, 0.211 Å^–1 at 50, 80, or 95 °C, respectively, indicating a decrease in the symmetry of the scattering objects in these size regimes. Isoscattering points were absent in similar water uptake experiment for the films after boiling

Fast Proton Conduction Facilitated by Minimum Water in a Series of Divinylsilyl-11-silicotungstic Acid-<i>co</i>-Butyl Acrylate-<i>co</i>-Hexanediol Diacrylate Polymers

Studies of proton transport in novel materials are important to enable a large array of electrochemical devices. In this study, we show that heteropoly acids (HPAs) when immobilized in polymer matrixes have highly mobile protons. Divinyl-11-silicotungstic acid, an HPA, was copolymerized with butyl acrylate and hexanediol diacrylate at various weight percentage loadings from 25% to 85% using UV initiated polymerizations. The resultant films were tan colored flexible sheets of ca. 120 μm thickness. The morphology of these films varied with loading, showing phase separation into clustered HPA above a 50 wt % loading and lamella morphologies above an 80 wt % loading. Water uptake was strongly associated with the HPA clusters, which facilitated transport of protons. This was realized by proton conductivities as high as 0.4 S cm^–1 at 95 °C and 95% RH and 0.1 S cm^–1 at 85 °C and 50% RH. Pulse field gradient spin echo NMR measurements indicated that water self-diffusion was fast (1.4 × 10^–5 and 4.4 × 10^–5 cm² s^–1 for 50% and 100% RH, respectively) at 80 °C. We show that the water in these systems is highly associated with the HPA clusters and that fast proton transport is facilitated by as few as 3 water molecules per proton