An asymmetric membrane electrode assembly for high-performance proton exchange membrane fuel cells

The membrane electrode assembly (MEA) is a critical part of proton exchange membrane fuel cells (PEMFCs) and has a significant impact on their performance. A novel preparation method of MEA is proposed in this work to inhibit the swelling and deformation of the proton exchange membrane (PEM) during MEA preparation and improve the interface between the PEM and cathode catalyst layer (CL). Using this novel fabrication method, an asymmetric MEA is prepared, where the anode and cathode parts are fabricated separately and then integrated by a hot-pressing process. The cathode part is prepared by covering the gas diffusion electrode (GDE) onto a layer of a perfluorosulfonic acid dispersion to form a membrane-coated electrode according to a wet-contact interface design, thereby ensuring a tight and concave-convex PEM/CL interface on the cathode. The anode part is prepared by spraying the CL onto a commercial PEM with a substrate to form a CL-coated PEM. An MEA was also prepared according to the traditional catalyst-coated membrane (CCM) method for comparison. The asymmetric MEA based on the new manufacturing process performs better than the traditional CCM-type MEA under the same PEM thickness prerequisite. The peak power densities of the asymmetric MEA are verified to be 18% (H2/air) and 31% (H2/O2) higher than conventional CCM-type MEA. In addition, the asymmetric MEA shows less cell performance degradation after 3000 dry/wet test cycles than the CCM-type MEA.