Integration of Pt3Ni Catalysts, Plasma-Etched Multiscale Membrane, and Flow Field with Micro-Channel for High-Performance Fuel Cell

To improve the performance and durability of polymer electrolyte membrane fuel cells, extensive research on each component has been performed, and there have been great advances for each part. However, no attempts have been made for the integration of all developed components into a PEMFC system. In this study, we successfully integrated a highly active Pt3Ni/C catalyst, a multiscale/multilevel membrane with a plasma etching process, and a flow-field bipolar plate with a micro-channel into a single-cell assembly, and achieved excellent PEMFC performance. Specifically, we obtained a maximum power density of more than 1.6 W/cm(2) with low catalyst loading of 0.125 mgPt/cm(2) (0.125 mgPtNi/cm(2)) at the anode (cathode) from the synergetic effects of the improved kinetics of oxygen reduction reaction, reduced ohmic resistance, and enhanced mass transport with the integration of each developed component. Furthermore, a current density of 2.61A/cm(2) at 0.6 V was achieved with catalyst loading of 0.2 mgPt/cm(2) (0.4 mgPtNi/cm(2)) at the anode (cathode).