Dataset for Influence of PTFE content in catalyst layer of gas diffusion electrode on performance of alkaline zinc–air flow battery

This dataset contains data from a systematic study on the effect of polytetrafluoroethylene (PTFE) content in the catalyst layer of gas diffusion electrodes (GDEs) for alkaline zinc–air flow batteries (ZAFBs). To address performance limitations under highly alkaline, flowing-electrolyte conditions, GDEs with 5–80 wt.% PTFE were fabricated on an optimal SGL 28BC substrate and evaluated across multiple cell types. The measurements show that low PTFE contents (<30 wt.%) lead to severe flooding, while high contents (>70 wt.%) restrict electronic and ionic transport. Optimal electrochemical performance and stable hydrophobicity were achieved at 50 wt.% PTFE, enabling stable ZAFB single-cell operation at 100 mA cm–2 with negligible capacity decay. These findings demonstrate that ZAFB systems require significantly higher PTFE loadings than typically reported to withstand harsh hydrodynamic environments.