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Potentiometry: Membrane Electrodes01:15

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Scalable Solution-Processed Electrolyte Membranes with Optimized Microstructure for High-Performance Protonic Ceramic

Anshu Kumari1, Shuanglin Zheng1, Saroj Karki1

  • 1School of Aerospace and Mechanical Engineering, University of Oklahoma, Norman, Oklahoma 73019, United States.

ACS Applied Materials & Interfaces
|December 1, 2025
PubMed
Summary
This summary is machine-generated.

A new solution-processed slurry enables dense, thin proton-conducting electrochemical cell (PCEC) electrolytes for efficient hydrogen production. This scalable method improves performance and durability in fuel cell and electrolysis modes.

Keywords:
dense microstructureproton-conducting electrochemical cellssolution optimizationthin-film depositionwet powder spraying

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Area of Science:

  • Electrochemistry
  • Materials Science
  • Chemical Engineering

Background:

  • Proton-conducting electrochemical cells (PCECs) offer efficient hydrogen production.
  • Scalable fabrication of dense, uniform, thin electrolyte layers is a significant challenge.

Purpose of the Study:

  • To develop a solution-processed deposition method for uniform electrolyte formation in PCECs.
  • To overcome limitations in scalable fabrication of high-performance PCEC electrolytes.

Main Methods:

  • Optimized electrolyte slurry by tailoring particle size, solid loading, and solvent/additives.
  • Controlled wetting behavior and evaporation kinetics for homogeneous particle packing.
  • Sintering process to eliminate porosity and enhance mechanical integrity.

Main Results:

  • Achieved a ~15 μm thick, dense electrolyte with high mechanical integrity and stable interfaces.
  • Demonstrated superior performance (31% improvement at 600 °C) compared to spray-based methods.
  • Single cells achieved 0.962 W cm⁻² (fuel cell) and 1.31 A cm⁻² (electrolysis) with >100 h stability.
  • Reproducible performance and geometric stability were confirmed on scaled-up substrates.

Conclusions:

  • The developed solution-processed approach offers a cost-effective and scalable route for high-performance PCEC electrolytes.
  • Control over particle-fluid interactions and drying dynamics is key to superior electrolyte microstructure.
  • This method enables robust and durable PCEC operation for hydrogen production and utilization.