A New Integrated GDL with Wavy Channel and Tunneled Rib for High Power Density PEMFC at Low Back Pressure and Wide Humidity.

Proton exchange membrane fuel cells (PEMFCs) have garnered significant attention due to their high efficiency and low emissions. However, PEMFC always suffers mass transfer and water management in performance improvement. Herein, an integrated gas diffusion layer (GDL) with wavy channel and micro-tunneled rib is designed and prepared to achieve faster and gentler mass transfer and excellent water management capability by laser engraving. Outstandingly, the new integrated GDL can use the back pressure of air as low as 0 and 50 kPa to respectively achieve 80% and 90% of fuel cell performance realized under pure oxygen. Such high performance is mainly due to the turbulent flow caused by wavy channel and express removing pathway of liquid water provided by micro-tunneled rib. Moreover, the new integrated GDL also shows wide humidity tolerance from 40% to 100% and a very high specific volume power density of 16,300 W L-1 due to the thin thickness of new integrated GDL. This new integrated GDL is expected to be widely used in PEMFC and other energy conversion devices.

Ordered Membrane Electrode Assembly with Drastically Enhanced Proton and Mass Transport for Proton Exchange Membrane Water Electrolysis.

In this work, an ordered membrane electrode assembly (MEA) based on a cone Nafion array with gradient Nafion distribution, tightly bonded catalytic layer/proton exchange membrane (CL/PEM) interface, and abundant vertical channels has been engineered by an anodic aluminum oxide template and magnetron sputtering method. Benefiting from a highly efficient CL/PEM interface, plentiful proton transfer highways, and rapid oxygen bubble release, this ordered MEA achieves an ultralow Ir loading of 20.0 µg cm-2 and a high electrochemical active area by 8.7 times compared to traditional MEA with Ir loading of 1.0 mg cm-2. It yields a mass activity of 168 000 mA mgIr-1 cm-2 at 2.0 V, which is superior to most reported PEM electrolyzers. Notably, this ordered MEA maintains excellent durability at a current density of 500 mA cm-2. This work opens a simple, cost-effective, and scalable route to design ordered MEAs for proton exchange membrane water electrolysis.

Multiscale Architectured Nafion Membrane Derived from Lotus Leaf for Fuel Cell Applications.

Hierarchically patterned proton-exchange membranes (PEMs) have the potential to significantly increase the specific surface area, thus improving the catalyst utilization rate and performance of proton-exchange membrane fuel cells (PEMFCs). In this study, we are inspired by the unique hierarchical structure of the lotus leaf and proposed a simple three-step strategy to prepare a multiscale structured PEM. Using the multilevel structure of the natural lotus leaf as the original template, and after structural imprinting, hot-pressing, and plasma-etching steps, we successfully constructed a multiscale structured PEM with a microscale pillar-like structure and a nanoscale needle-like structure. When applied in a fuel cell, the multiscale structured PEM resulted in a 1.96-fold increase in discharge performance and a significant improvement in mass transfer compared to the membrane electrode assembly (MEA) with a flat PEM. The multiscale structured PEM has the combined advantage of a nanoscale and a microscale structure, benefiting from the markedly reduced thickness, increased surface area, and improved water management inherited from the multiscale structured lotus leaf's superhydrophobic characteristic. Using a lotus leaf as a multilevel structure template avoids the complex and time-consuming preparation process required by commonly used multilevel structure templates. Moreover, the remarkable architecture of biological materials can inspire novel and innovative applications in many fields through nature's wisdom.

A Recyclable Standalone Microporous Layer with Interpenetrating Network for Sustainable Fuel Cells.

The commercialization of fuel cells inevitably brings recycling problems. Therefore, achieving high recyclability of fuel cells is particularly important for their sustainable development. In this work, a recyclable standalone microporous layer (standalone MPL) with interpenetrating network that can significantly enhance the recyclability and sustainability of fuel cells is prepared. The interpenetrating network enables the standalone MPL to have high strength (17.7 MPa), gas permeability (1.55 × 10-13  m2 ), and fuel-cell performance (peak power density 1.35 W cm-2 ), providing the basic guarantee for its application in high-performance and highly recyclable fuel cells. Additionally, the standalone MPL is highly adaptable to various gas-diffusion backings (GDBs), providing high possibility to select highly recyclable GDBs. Outstandingly, anode standalone MPLs and GDBs can be easily detached from the spent membrane electrode assembly (MEA). This not only saves >90 vol% solvent in the recovery of the catalyst-coated membrane (CCM), but also extends the service life of the GDBs and the anode standalone MPL at least 138 times (2 760 000 h assuming 20 000 h of CCM) comparing to CCM. Therefore, the standalone MPL significantly enhances the recyclability and sustainability of fuel cells and is promising to be an indispensable component in the next-generation fuel cells.

Integrated Gas Diffusion Electrode with High Conductivity Obtained by Skin Electroplating for High Specific Power Density Fuel Cell.

Smaller volume/weight and higher output power/energy density are always the goals of electrochemistry energy devices. Here, a simple strategy is proposed to prepare an integrated gas diffusion electrode (GDE) with high conductivity through skin electroplating. The skin electroplating is the combination of magnetron sputtering and spatial confinement electroplating. The electroplated metal obtained by skin electroplating is uniformly, continuously, and tightly attached to the surface of carbon paper like a layer of skin. Uniform and continuous electroplating metal layer endows the integrated electrode excellent conductivity with the square resistance as low as 27 mΩ sq-1 . In application, the self-breathing fuel cell with 1 cm2 active area can harvest ultrahigh volume specific power density (20.9 kW L-1 ). Additionally, the weight of the fuel cell stack (23 W) with the integrated electrode is only 20 g, which is only 7% of the commercial stack with the same power. The mass specific power density reaches 1150 W kg-1 , which is 15 times of the commercial stack. Outstandingly, the stack can charge 4 mobile phones at the same time. More importantly, the skin electroplating provides an effective strategy to improve the specific power density of other energy devices including Zn-air batteries, Li-air batteries, and so on.

Ultralight, Safe, Economical, and Portable Oxygen Generators with Low Energy Consumption Prepared by Air-Breathing Electrochemical Extraction.

Pure oxygen is vital in medical treatment, first aid, and chemical synthesis. Hypoxia can cause severe damage to the organ systems such as respiratory, digestive, and nervous systems and even directly cause death. Notably, the severe Coronavirus disease 2019 (COVID-19) pandemic has exacerbated the shortage of medical oxygen in the world. Hence, a safe, economical, and portable oxygen supply device is urgently needed. Here, we have successfully prepared a device with air-breathing electrochemical extraction of pure oxygen (ABEEPO) with light weight and high energy efficiency. By renovating the structure of the electrolytic cell, the components bipolar plate and end plate are replaced with a plastic membrane, and the component current collector is replaced with a highly conductive graphene composite membrane electrode. Due to the use of the plastic membrane and graphene composite membrane electrode, the weight of the electrolytic cell is reduced from 1319.4 to 1.6 g, and the flexibility of the electrolytic cell is successfully realized. Through optimizing anode catalysts, working area, and operating voltage, a high flow rate per mass (234 mL h-1 g-1) was achieved at a voltage of 1.2 V. The device exhibits high stability in 2 h. The new portable oxygen production device would be effective for hypoxia treatment.