Hydrocarbon-based Pemion™ proton exchange membrane fuel cells with state-of-the-art performance

Non-fluorinated hydrocarbon ionomers feature distinct technical, cost, and environmental advantages over incumbent perfluorinated sulfonic acid (PFSA)-based ionomers: they offer improved thermo-mechanical properties at temperatures beyond 90 °C, likelihood of lower material cost, lower gas cross-over, and facile recycling of platinum group metals. In addition, fluorine-free hydrocarbon ionomers are less hazardous to the environment owing to the lack of (per)fluorinated precursors. Yet, the performance of hydrogen fuel cells with hydrocarbon-based ionomers and membranes has been historically largely inferior to the PFSA-based state of the art. In this study, we present wholly hydrocarbon fuel cells exceeding previous literature landmarks by a factor of nearly two, with peak power densities of 2.1 W cm−2 under H2/O2 (atmospheric pressure and 95% relative humidity), and 1.1 W cm−2 under H2/air (250 kPaabs and 50% relative humidity). This improvement was achieved by the use of Pemion™ – a sulfo-phenylated polyphenylene-based cation exchange material – as ionomer in the catalyst layer and as proton exchange membrane with a low thickness of 7 μm, and an optimization of cathode catalyst layer based on PtCo/C. Based on an in-depth study of electrochemical performance under various conditions vs. a state-of-the-art PFSA reference cell, the performances of Pemion™-based cells were found to be more sensitive to changes in relative humidity of inlet gases, but the detrimental influence of high temperatures on performance was significantly reduced. At an operation temperature of 110 °C, 250 kPaabs, and 50% relative humidity, the peak power density (0.96 W cm−2) was 8% higher than the short-side chain PFSA-based reference cell (0.89 W cm−2), highlighting the potential of Pemion™ for next-generation fuel cells for heavy-duty or aeronautic applications.