To promote further commercialization of proton exchange
membrane
(PEM) fuel cells, developing a novel preparation method for high-performance
and durable membrane electrode assemblies (MEAs) is imperative. In
this study, we adopt the reverse membrane deposition process and expanded
polytetrafluoroethylene (ePTFE) reinforcing technology to optimize
the interface combination and durability of MEAs simultaneously for
the preparation of novel MEAs with double-layer ePTFE reinforcement
skeletons (DR-MEA). With the wet-contact between the liquid ionomer
solution and porous catalyst layers (CLs), a tight 3D PEM/CL interface
is formed in the DR-MEA. Based on this enhanced PEM/CL interface combination,
the DR-MEA exhibits a significantly increased electrochemical surface
area, reduced interfacial resistance, and improved power performance
compared with a conventional MEA (C-MEA) based on a catalyst-coated
membrane method. Furthermore, with the reinforcement of double-layer
ePTFE skeletons and the support of rigid electrodes for the membranes,
the DR-MEA demonstrates less mechanical degradation than the C-MEA
after wet/dry cycle test, reflected in lower increase in hydrogen
crossover current, interfacial resistance, and charge-transfer resistance
and reduced power performance attenuation. With less mechanical degradation,
the DR-MEA therefore shows less chemical degradation than the C-MEA
after an open-circuit voltage durability test.