Investigating the Impact of Catalyst Penetration into Gas Diffusion Layer on the Performance of High-Temperature Polymer Electrolyte Membrane Fuel Cells

The catalyst fabrication method, cell assembly, and operating conditions in polymer electrolyte membrane fuel cells (PEMFC) impact the catalyst penetration into the gas diffusion layer (GDL), alter its porous structure, and, consequently, the overall cell performance. This study investigates the effect of the catalyst layer (CL) penetration thickness, catalyst loading amount, and cell compression during assembly on species and current distributions, and overall cell performance. GDLs with large penetration thickness show a substantial resistance to reactant and proton transport, particularly at high current densities resulting in a drop in the cell performance. For zero, 50%, and 100% penetrations, the average current densities at an operating voltage of 0.4 V are 0.8329, 0.7920, and 0.71112 A cm-2, respectively. This indicates a performance loss of 5% and 15% for 50% and 100% penetrations in comparison to zero penetration. Higher catalyst loading results in greater penetration, negating the benefit of enhanced kinetics. Performance typically decreases by 3%-5% for 50% penetration and 12%-15% for 100% penetration when penetration levels increase for a certain Pt loading. An attempt is made to investigate the interplay between the effect of reactant and proton transport limitations on their distributions and cell performance. The combined effect of catalyst penetration and cell compression during the assembly has a crucial impact on cell performance with the starvation of reactants at high-density regions. The study highlights the necessity of optimizing the penetration thickness, catalyst loading, and cell assembly to achieve maximum cell performance.