Surfactant doped polyaniline coatings for functionalized gas diffusion layers in low temperature fuel cells

Gas diffusion layers (GDLs) are essential for the proper distribution of the reaction gases, the removal of excess water as well as electrical contact in polymer electrolyte fuel cells (PEFCs). The production of state-of-the-art GDLs consists of many steps such as graphitization at high temperatures and hydrophobic treatments with polytetrafluoroethylene (PTFE) which increase the cost. In this study, an electrically conductive and hydrophobic polyaniline (PANI) coating was deposited on carbon paper via dip-coating and electropolymerization to fabricate PTFE-free GDLs. As a proof-of-concept, PANI-coated GDLs were tested as a cathodic GDL in a single cell PEFC and achieved a 42% higher maximum power compared to the reference measurement with a commercial GDL. Furthermore, these PTFE-free GDLs achieved contact angles up to 144° which is in the range of commercial GDLs. The chemical composition of the PANI-coating was investigated via infrared spectroscopy and energy dispersive X-ray spectroscopy (EDX) and the morphology was examined via scanning electron microscopy (SEM). Hence, the proposed method emerges as a possible strategy to simultaneously substitute PTFE and apply a protective and durable coating.