Evolution of the network structure and voltage loss of anode electrode with the polymeric dispersion in PEM water electrolyzer

Exploring the intrinsic relationship between the network structure and the performance of catalyst layer (CL) by rational design its structure is of paramount importance for proton exchange membrane (PEM) electrolyzers. This study reveals the relative effect of polymeric dispersion evolution on oxygen evolution reaction (OER) performance and cell voltage loss and linked to CL network structure. The results show that although the dispersed particle size of the ionomer and ink increases with increasing the solubility parameter (δ) difference between the mixed solvent and the ionomer, MeOH-cat (ink from MeOH aqueous solution) has the largest ionomer and ink particle size resulting in the poorest stability, but has comparable OER overpotential to that of IPA-cat (249 mV@10 mA cm⁻²), which has the smallest dispersed size. While at 100 mA cm⁻², the overpotential of the ink rises as the particle size increases, suggesting that the electrode structure becomes more influential as the current density increases. Quantitatively analyzed the electrolyzers’ voltage losses and determined that the CL from MeOH-cat has the lowest kinetic overpotential. However, its performance is the worst because of the insufficient network structure of CL, resulting in an output of 1.96 V at 1.5 A cm⁻². Comparatively, the CL from IPA-cat has the highest kinetic overpotential yet can achieve the greatest performance of 1.76 V at 2 A cm⁻² due to its homogeneous network structure and optimal mass transport. Furthermore, the performance variation becomes more pronounced as current density rises. Hence, this study highlights the significant impact of CL structure on electrolyzer’s performance. To improve performance in PEM water electrolysis technology, especially for large work current density, it is crucial to enhance the CL’s network structure.