The gas diffusion layer (GDL), as an important structure of the membrane electrode assembly (MEA) of the direct methanol fuel cell (DMFC), provides a support layer for the catalyst and the fuel and the product channel. Traditionally, the material of GDL is generally carbon paper (CP). In this paper, a new material, namely three-dimensional graphene (3DG) is used as GDL for micro DMFC. The experimental results reveal that the performance of the DMFC has been improved significantly by application of 3DG. The peak powers increase from 25 mW to 31.2 mW and 32 mW by using 3DG as the anode and cathode GDL instead of CP, respectively. The reason may be the decrease of charge and mass transfer resistance of the cell. This means that the unique 3D porous architecture of the 3DG can provide lower contact resistance and sufficient fuel diffusion paths. The output performance of the cell will be further improved when porous metal current collectors is used.
In order to solve the problem that bolts in traditional packaged direct methanol fuel cells (DMFCs) take up a large area and reduce the specific energy (energy per unit weight) and power density (power per unit area), a new button-type micro direct methanol fuel cell (B-μDMFC) is designed, assembled, and packaged. The cell with four different structures was tested before and after packaging. The results indicate that the button cell with three-dimensional graphene and springs has the best performance. The equivalent circuit and methanol diffusion model was applied to explain the experimental results. The peak volumetric specific power density of the cell is 11.85 mW cm−3. This is much higher than traditional packaged DMFC, because the novel B-μDMFC eliminates bolts in the structure and improves the effective area ratio of the cell.
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