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Figure 3-5 Multi-Cell Stack Performance on Dow Membrane (9) PEFCs were originally made with an unimpregnated electrode/Nafion electrolyte interface. This was later replaced by a proton conductor that was impregnated into the active layer of the electrode. This allowed reduced catalyst loading to 0.4 mg/cm2 while obtaining high power density (27). The standard "Prototech" electrodes contained 10 percent Pt on carbon supports. Using higher surface area carbon-supported catalysts, researchers have tested electrodes with even lower platinum loading, but having performance comparable to conventional electrodes. Los Alamos National Laboratory has tested a cathode with 0.12 mg Pt/cm2 loading, and Texas A&M University has tested a cathode with 0.05 mg Pt/cm2 loading. Another example of low catalyst loadings is the work carried out at DLR (43) in which loadings as low as 0.07 mg/cm2 were applied to the membrane using a dry process. The binder was a Teflon-like material. Another approach has been developed to fabricate electrodes with loading as low as 0.1 mg Pt/ cm2 (44). The electrode structure was improved by increasing the contact area between the electrolyte and the platinum clusters. The advantages of this approach were that a thinner catalyst layer of 2 to 3 microns and a uniform mix of catalyst and polymer were produced. For example, a cell with a Pt loading of 0.07 to 0.13 mg/cm2 was fabricated. The cell generated 3 A/cm2 at > 0.4V on pressurized O2, and 0.65 V at 1 A/cm2 on pressurized air (44, 45). Stable performance was demonstrated over 4,000 hours with Nafion membrane cells having 0.13 mg Pt/cm2 catalyst loading and cell conditions of 2.4 atmospheres H2, 5.1 atmospheres air, and 80 °C (4,000 hour performance was 0.5 V at 600 mA/cm2). Water management was stable, particularly after thinner membranes of somewhat lower equivalent weight became available. Some performance losses may have been caused by slow anode catalyst deactivation, but the platinum catalyst "ripening" phenomenon was not considered to contribute significantly to the long-term performance losses observed in PEFCs (1). 3-12PDF Image | Fuel Cell Handbook (Seventh Edition)
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