Production of Gas Diffusion Layers with Tunable Characteristics

Gas diffusion electrodes (GDEs) allow electrochemical reactions to occur at higher rates by enhancing the mass transport of gaseous reactants to the catalyst. These electrodes are made of two layers: the catalyst layer and the gas diffusion layer (GDL). The catalyst layer is frequently studied for gas diffusion electrodes, and the GDL is rarely a focus. Consequently, no studies investigate interaction effects that may be present between these two layers. To study such interactions, it must be possible to obtain GDLs with various characteristics. This study uses a design of experiments to understand how multiple factors in the production method for GDLs can be adjusted to tune the characteristics of the GDL. These GDLs are particularly intended for the electrochemical reduction of CO₂. The conductance through the GDL, surface conductivity, thickness, elasticity, hydrophobicity, and porosity are measured for the 26 synthesized electrodes, and the top influential production factors are identified for each characteristic.