Polyamide/polystyrene blend compatibilisation by montmorillonite nanoclay and its effect on macroporosity of gas diffusion layers for proton exchange membrane fuel cells

This work deals with a new route to modify polymer blend morphology in order to improve the porosity of gas diffusion layers (GDLs) for proton exchange membrane fuel cells (PEMFCs). First, electrically conductive polymer-based blends were carefully formulated using a twin-screw extrusion process. Blend electrical conductivity was ensured by the addition of high specific surface area carbon black and synthetic graphite flakes. Final GDL porosity, in particular its macroporosity, was generated by melt blending polyamide 11 (PA11) matrix with polystyrene (PS) followed by PS extraction with tetrahydrofuran (THF) solvent at room temperature. In order to improve GDL porosity by the optimisation of PS dispersion in the PA11 matrix, PA11/PS blends were compatibilised by the addition of 2 wt.-% of clay. It was observed that both macroporosity and pore size distribution were beneficially modified after blend compatibilisation. Final GDL conductivity of about 1.25 S cm(-1), a porosity of 53% and a specific pore surface area of 75 m(2) g(-1) were achieved.