UC Berkeley

Significant mass-transport resistances in polymer-electrolyte-fuel-cell catalyst layers (CLs) impose a lower limit on Pt-loading levels, hindering wide-spread fuel-cell commercialization. The origin of this resistance remains unclear. Minimization of CL mass-transport resistance is imperative to achieve better CL design and performance. In this paper, an operando method based on H2 limiting current is used to characterize and quantify CL resistance in traditional porous Pt/carbon-based electrodes. CL sub-resistances are isolated using continuum multiscale modeling and experiments, investigating the effects of reactant molecular weight, pressure, and ionomer to carbon weight ratio. The results expose CL resistance including both interfacial and transport components, although the majority of the CL resistance is ascribed to a local resistance close to the Pt reaction sites, which includes interfacial resistance and local transport resistance. Variations in temperature, humidity, and primary particle loading (Pt:C ratio) highlight the impact of operating conditions and CL design parameters on CL sub-resistances. The observed trends guide optimization of CL design to achieve novel low-loaded fuel-cell electrodes.