Characterisation of Novel and High Performing Double-Sided Microporous-Layers-Coated Gas Diffusion Layers for Polymer Electrolyte Membrane Fuel Cells

This study aims to experimentally evaluate the impact of a double-sided microporous layer coating on gas diffusion layers in terms of their key properties and fuel cell performance, in comparison to conventional single-sided coated gas diffusion layers (GDLs). Vulcan black and Ketjenblack were used as the carbon black materials. This was to investigate the sensitivity of the results with respect to the type of carbon black used. The results showed that the in-plane electrical conductivity is almost insensitive to microporous layer (MPL) loading and carbon black type. Furthermore, the electrical conductivity of all the MPL-coated GDLs are slightly lower than that of the uncoated GDL. The Ketjenblack black MPL samples were found to demonstrate higher gas permeability than the Vulcan black samples. The addition of the MPL resulted in a favourable shift in pore size distribution, with prominent micropores observed in both single- and double-sided MPL-coated GDLs. Contact angle measurements indicated a slight increase in the hydrophobicity with the addition of a microporous layer, but without significant differences between carbon black types or loading levels. Cross-sectional SEM images showed that there was a higher level of MPL penetration into the carbon substrate for the GDLs coated with Vulcan black as compared to a Ketjenblack coating. In situ fuel cell testing demonstrated the superior performance of the double-sided Vulcan black MPL-coated GDL under high humidity conditions, while the single-sided Vulcan black MPL-coated GDL exhibited better performance at low humidity conditions. All the above findings have been thoroughly discussed and justified.