The
microporous layer (MPL) in membrane electrodes is critical
for mass transfer in proton-exchange membrane fuel cells (PEMFCs).
The mass transfer loss in electrodes is very serious when operating
in high-current-density and high-humidity environments, which greatly
reduces the output performance and durability of fuel cells. To address
these challenges, we designed an MPL with a graded pore structure.
By controlling the content of the pore former in the MPL slurry, conventional
MPLs with uniform pores are constructed, and then structural MPL with
ordered gradient pore distribution is formed through layered coating
and sintering. The capillary driving force provided by such a gradient
structure can effectively improve the cathode water management capability.
In this study, the MPL with the graded pore structure (G-MPL) shows
the highest output performance of 2.28 W cm–2 at
a high relative humidity of 100%. This is mainly due to its gradient
pore structure, which significantly facilitates water discharge and
gas diffusion, thereby upgrading the mass transfer capacity of fuel
cells. In addition to its outstanding electrochemical performance,
G-MPL also has the advantages of low production cost and a simplified
preparation process, making it an exceptional candidate to promote
the practical application of PEMFCs.