Production of a Catalyst-Coated Membrane

Abstract

This work was carried out in the framework of research activities at the University of Applied Sciences Upper Austria and provides a comprehensive overview of the production of a catalyst coated membrane (CCM). This core component plays a pivotal role in promising technologies such as proton exchange membrane (PEM) fuel cells and water electrolyzers, making the understanding of CCMs vital for the future development of hydrogen solutions in energy systems. In the theoretical part, PEM fuel cells and their core components are described in depth. Additionally, hydrogen production and water electrolyzers are briefly discussed throughout the work to contextualize the role of PEM technology within the broader hydrogen economy. Furthermore, a detailed analysis of CCMs manufacturing and characterization processes, using both established and experimental methods, is presented. In the applied part, besides the in-house fabrication of the entire spraying system, the experimental work behind the production of various CCMs is described thoroughly. Particular attention is given to the catalyst ink preparation, including the influences of the various chemical, spraying, and drying parameters on the result. The CCM microstructure is carefully examined to highlight the correlation between materials, electrical performance, and production procedure. All the produced CCMs are described, subdividing them according to the employed catalyst. This resulted in three main CCM types, i.e. carbon-based, platinum-based, and platinum-iridium-based. After successful fabrication and achieving a well-crafted quality level, the membranes were tested in a water electrolysis benchmark using electrochemical impedance spectroscopy. They produced hydrogen and withstood electrical loads of up to 5 A. Given the complexity and experimental variability involved in CCM production, the results are robust, albeit not comparable to those achieved by industrially manufactured products. This offers potential future research and optimization opportunities.

Date of Award	2025
Original language	English
Supervisor	Michael Steinbatz (Supervisor)