Manufacturing and structural control of slurry-cast catalyst layers for AEMFC

Fabrication of the catalyst layer (CL) in a cost-effective and scalable manner is a critical step toward commercialization of anion exchange membrane fuel cells (AEMFCs). Herein, we present a CL manufactured by slurry-casting that is compatible with the roll-to-roll process. Careful control of the rheological properties of the catalyst slurry enables casting onto a gas diffusion layer. The slurry cast CL features uniform thickness and well-developed mesoporous structure. By adjusting the solid content and ionomer-to-carbon ratio of the slurry, the pore structure and ionomer connectivity in the CL are controlled and the power performance is enhanced. This work suggests a practical strategy for mass production of the CL and extends the understanding of the structure–property relationship for slurry-cast CLs.