Optimisation and characterisation of graphene-based microporous layers for polymer electrolyte membrane fuel cells

The viability of graphene-based microporous layers (MPLs) for polymer electrolyte membrane fuel cells is critically assessed through detailed characterisation of the morphology, microstructure, transport properties and electrochemical characterisation. Microporous layer composition was optimised by the fabrication of several hybrid MPLs produced from various ratios of graphene to Vulcan carbon black. Single cell tests were performed at various relative humidities between 25% and 100% at 80 °C, in order to provide a detailed understanding of the effect of the graphene-based MPL composition on the fuel cell performance. The inclusion of graphene in the MPL alters the pores size distribution of the layer and results in presence of higher amount of mesopores. Polarisation curves indicate that a small addition of graphene (i.e. 30 wt %) in the microporous layer improves the fuel cell performance under low humidity conditions (e.g. 25% relative humidity). On the other hand, under high humidity conditions (≥50% relative humidity), adding higher amounts of graphene (≥50 wt %) improves the fuel cell performance as it creates a good amount of mesopores required to drive excess water away from the cathode electrode, particularly when operating with high current densities.