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<p>The utilization of iridium-based anode catalysts in proton exchange membrane water electrolyzers is largely limited by the presence of electrochemically inactive “dead zones” within the catalyst layer. Here, by combining in-situ visualization of gas bubble evolution with quantitative conductivity measurements and electrochemical analysis, we establish that the limited in-plane electronic conductivity, dictated by the ionomer disrupting the conductive network of IrO<sub>2</sub> nanocatalysts, is the dominant factor. A sequential spray-coating strategy is further developed, which decouples the deposition of a pristine conductive catalyst layer from the ionomer and thereby preserves continuous electron transport pathways. This approach effectively activates the in-plane dead zones, resulting in membrane electrode assemblies that exhibit over 30% higher activity (4.2 A cm<sup>−2</sup>@2.0 V@80 °C; membrane: Nafion 115) than those prepared by the conventional one-step method based on IrO<sub>2</sub>/ionomer mixed inks. Crucially, this approach achieves both low iridium loading (0.25 mg cm<sup>–2</sup>) with standard catalysts and demonstrates extended stability over 8300 hours under practical current densities.</p>

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Activating in-plane dead zones of anode catalyst layers in proton exchange membrane water electrolyzers

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年7月1日

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  • Zicheng Zhao,
  • Xiao Liang,
  • Nan Lin,
  • Zhenye Kang,
  • Yuchang Hou,
  • Yaoxin Wang,
  • Hui Chen,
  • Xiaoxin Zou

摘要

The utilization of iridium-based anode catalysts in proton exchange membrane water electrolyzers is largely limited by the presence of electrochemically inactive “dead zones” within the catalyst layer. Here, by combining in-situ visualization of gas bubble evolution with quantitative conductivity measurements and electrochemical analysis, we establish that the limited in-plane electronic conductivity, dictated by the ionomer disrupting the conductive network of IrO2 nanocatalysts, is the dominant factor. A sequential spray-coating strategy is further developed, which decouples the deposition of a pristine conductive catalyst layer from the ionomer and thereby preserves continuous electron transport pathways. This approach effectively activates the in-plane dead zones, resulting in membrane electrode assemblies that exhibit over 30% higher activity (4.2 A cm−2@2.0 V@80 °C; membrane: Nafion 115) than those prepared by the conventional one-step method based on IrO2/ionomer mixed inks. Crucially, this approach achieves both low iridium loading (0.25 mg cm–2) with standard catalysts and demonstrates extended stability over 8300 hours under practical current densities.