Controlled Porosity and Surface Coatings for Advanced Gas Diffusion Layers

Polymer electrolyte membrane fuel cells (PEMFCs) are a leading candidate for an alternative energy source for light duty vehicles, however, their current performance is inadequate for this application. Gas diffusion layers (GDLs) are a critical component of the PEMFC that contribute significantly to the overall performance. Improving the properties of GDLs will allow for wide scale adoption of the PEMFC and thus enhanced US energy security and reduced greenhouse gas emissions. The objective of this project is to develop a novel and cost-effective process to produce carbon-based GDLs. The Phase II will demonstrate scale-up of the process demonstrated in Phase I. This readily tailored process results in controllable transport properties, enhanced electrical conductivity, and durability that will enable enhanced PEMFC performance. During the Phase I effort, a carbon-based GDL with transport properties equivalent and electrical conductivity 2X superior to commercial Sigracet 10AA GDLs was demonstrated. The process developed facilitates tailoring of the transport properties and durability of the final product at 80% of the cost of current commercial GDLs. The objective of the Phase II project is to scale-up production of the GDLs and optimize performance based upon testing the component level and in fuel cell stacks. Fuel cell performance testing and demonstration of a cost effective, versatile production process will highlight the ability to use the advanced GDL in PEMFCs at a reduced cost. Commercial Applications and Other Benefits: The GDLs produced in this effort will be applied to light duty transportation applications providing enhanced durability and performance. Wide adoption of PEMFCs in transportation applications will reduce dependence on petroleum fuels and reduce greenhouse gas emissions.