Effect of membrane deposition methods on the performance of membrane electrode assemblies

The performance of proton exchange membrane fuel cells (PEMFCs) is closely related to the preparation process of the membrane electrode assemblies (MEAs). The direct membrane deposition approach can achieve excellent interfacial connection between functional layer, as well as simplifying the MEA manufacturing process. Nevertheless, it has been recognized that for this approach, the permeation of the electrolyte solution into the catalyst layer is a challenge, and it is associated with the deposition method. In this study, three MEAs are prepared by spraying, blade coating, and a combination of the two. The effect of the electrolyte solution deposition methods on the properties of the MEAs is analyzed. The MEA prepared using the combination of spraying and blade coating delivers the highest performance of up to 0.618 W cm−2 (80°C with H2/air conditions at normal pressure). In this method, the spraying layer can alleviate the negative effect of cracks on the gas diffusion electrode surface, and the blade‐coating layer can improve the membrane uniformity. The MEA prepared by this method exhibits excellent cell performance compared to the traditional catalyst coated membrane type MEA, particularly in low‐humidity conditions. This work provides guidance for the preparation of high‐performance MEAs for PEMFCs.