The significant role of the cathodic binder in modulating mass transport within the catalyst layer (CL) of fuel cells is essential for optimizing cell performance. This investigation focuses on enhancing the membrane electrode assembly (MEA) through the utilization of a short-side-chain perfluoro-sulfonic acid (SSC-PFSA) ionomer as the cathode binder, referred to as SSC-MEA. This study meticulously visualizes the distinctive interpenetrating networks of ionomers and catalysts, and explicitly clarifies the triple-phase interface, unveiling the transport-friendly microstructure and transport mechanisms inherent in SSC-MEA. The SSC-MEA exhibits advantageous microstructural features, including a better-connected ionomer network and well-organized hierarchical porous structure, culminating in superior mass transfer properties. Relative to the MEA bonded by long-side-chain perfluoro-sulfonic acid (LSC-PFSA) ionomer, noted as LSC-MEA, SSC-MEA exhibits a notable peak power density (1.23 W cm-2), efficient O2 transport, and remarkable proton conductivity (65% improvement) at 65 °C and 70% relativity humidity (RH). These findings establish crucial insights into the intricate morphology-transport-performance relationship in the CL, thereby providing strategic guidance for developing highly efficient MEA.

The mass transport and ion conductivity in the catalyst layer are important for fuel cell performances. Here, we report an in situ-grown ultrathin catalyst layer (UTCL) to reduce the oxygen mass transport and a surface ionomer-coated gas diffusion layer method to reduce the ion conducting resistance. A significantly reduced catalyst layer thickness (ca. 1 μm) is achieved, and coupled with the ionomer introduction method, the ultrathin catalyst layer is in good contact with the membrane, resulting in high ion conductivity and high Pt utilization. This ultrathin catalyst layer is suitable for both proton exchange membrane fuel cells and anion exchange membrane fuel cells, giving peak power densities of 2.24 and 1.11 W cm-2, respectively, which represent an increase of more than 30% compared with the membrane electrode assembly (MEA) fabricated by using traditional Pt/C power catalysts. Electrochemical impedance spectra and limiting current tests demonstrate the reduced charge transfer, mass transfer, and ohmic resistances in the ultrathin catalyst layer membrane electrode assembly, resulting in the promoted fuel cell performances.

In light of the intensifying global energy crisis and the mounting demand for environmental protection, it is of vital importance to develop advanced hydrogen energy conversion systems. Electrolysis cells for hydrogen production and fuel cell devices for hydrogen utilization are indispensable in hydrogen energy conversion. As one of the electrolysis cells, water splitting involves two electrochemical reactions, hydrogen evolution reaction and oxygen evolution reaction. And oxygen reduction reaction coupled with hydrogen oxidation reaction, represent the core electrocatalytic reactions in fuel cell devices. However, the inherent complexity and the lack of a clear understanding of the structure-performance relationship of these electrocatalytic reactions, have posed significant challenges to the advancement of research in this field. In this work, the recent development in revealing the mechanism of electrocatalytic reactions in hydrogen energy conversion systems is reviewed, including in situ characterization and theoretical calculation. First, the working principles and applications of operando measurements in unveiling the reaction mechanism are systematically introduced. Then the application of theoretical calculations in the design of catalysts and the investigation of the reaction mechanism are discussed. Furthermore, the challenges and opportunities are also summarized and discussed for paving the development of hydrogen energy conversion systems.

Alkaline anion exchange membrane (AEM)-based fuel cells (AEMFCs) and water electrolyzers (AEMWEs) are vital for enabling the efficient and large-scale utilization of hydrogen energy. However, the performance of such energy devices is impeded by the relatively low conductivity of AEMs. The conventional trial-and-error approach to designing membrane structures has proven to be both inefficient and costly. To address this challenge, a fully connected neural network (FCNN) model is developed based on acid-catalyzed AEMs to analyze the relationship between structure and conductivity among 180,000 AEM variations. Under machine learning guidance, anilinium cation-type membranes are designed and synthesized. Molecular dynamics simulations and Mulliken charge population analysis validated that the presence of a large anilinium cation domain is a result of the inductive effect of N+ and benzene rings. The interconnected anilinium cation domains facilitated the formation of a continuous ion transport channel within the AEMs. Additionally, the incorporation of the benzyl electron-withdrawing group heightened the inductive effect, leading to high conductivity AEM variant as screened by the machine learning model. Furthermore, based on the highly active and low-cost monomers given by machine learning, the large-scale synthesis of anilinium-based AEMs confirms the potential for commercial applications.

A phosphorus-doped carbon nanotube (CNT) aerogel as the support material was loaded with Pt nanoparticles in fuel cell-type gas sensors for ultrasensitive H2 detection. The high surface area of the CNT scaffold is favorable to providing abundant active sites, and the high electrical conductivity facilitates the transport of carriers generated by electrochemical reactions. In addition, the CNT aerogel was doped with phosphorus (P) to further enhance the conductivity and electrochemical catalytic activity. As a result, the fuel cell-type gas sensor using the Pt/CNT aerogel doped with the optimal P content as the sensing material shows considerable performance for H2 detection at room temperature. The sensor exhibits an ultrahigh response of -921.9 μA to 15,000 ppm of H2. The sensitivity is -0.063 μA/ppm, which is 21 times higher than that of the conventional Pt/CF counterpart. The sensor also exhibits excellent repeatability and humidity resistance, as well as fast response/recovery; the response/recovery times are 31 and 4 s to 3000 ppm of H2, respectively. The modulation of the structure and catalytic properties of the support material is responsible for the improvement of the sensor performance, thus providing a feasible solution for optimizing the performance of fuel cell-type gas sensors.

As a central component for anion exchange membrane fuel cells (AEMFCs), the anion exchange membrane is now facing the challenge of further improving its conductivity and alkali stability. Herein, a twisted all-carbon backbone is designed by introducing stereo-contorted units with piperidinium groups dangled at the twisted sites. The rigid and twisted backbone improves the conduction of hydroxide and brings down the squeezing effect of the backbone on piperidine rings. Accordingly, an anion exchange membrane prepared through this method exhibits adapted OH- conductivity, low swelling ratio and excellent alkali stability, even in high alkali concentrations. Further, a fuel cell assembled with a such-prepared membrane can reach a power density of 904.2 mW/cm2 and be capable of continuous operation for over 50 h. These results demonstrate that the designed membrane has good potential for applications in AEMFCs.

Conventional electrochemical sensors use voltammetric and amperometric methods with external power supply and modulation systems, which hinder the flexibility and application of the sensors. To avoid the use of an external power system and to minimize the number of electrochemical cell components, a self-powered electrochemical sensor (SPES) for hydrogen peroxide was investigated here. Iron phthalocyanine, an enzyme mimetic material, and Ni were used as a cathode catalyst and an anode material, respectively. The properties of the iron phthalocyanine catalyst modified by graphene nanoplatelets (GNPs) were investigated. Open circuit potential tests demonstrated the feasibility of this system. The GNP-modulated interface helped to solve the problems of aggregation and poor conductivity of iron phthalocyanine and allowed for the achievement of the best analytical characteristics of the self-powered H2O2 sensor with a low detection limit of 0.6 µM and significantly higher sensitivity of 0.198 A/(M·cm2) due to the enhanced electrochemical properties. The SPES demonstrated the best performance at pH 3.0 compared to pH 7.4 and 12.0. The sensor characteristics under the control of external variable load resistances are discussed and the cell showed the highest power density of 65.9 μW/cm2 with a 20 kOhm resistor. The practical applicability of this method was verified by the determination of H2O2 in blood serum.

Here, we comprehensively investigated methanol electrooxidation on Cu-based catalysts, allowing us to build the first microfluidic fuel cell (μFC) equipped with a Cu anode and a metal-free cathode that converts energy from methanol. We applied a simple, fast, small-scale, and surfactant-free strategy for synthesizing Cu-based nanoparticles at room temperature in steady state (ST), under mechanical stirring (MS), or under ultrasonication (US). The morphology evaluation of the Cu-based samples reveals that they have the same nanoparticle (NP) needle-like form. The elemental mapping composition spectra revealed that pure Cu or Cu oxides were obtained for all synthesized materials. In addition to having more Cu2O on the surface, sample US had more Cu(OH)2 than the others, according to X-ray diffractograms and X-ray photoelectron spectroscopy. The sample US is less carbon-contaminated because of the local heating of the sonic bath, which also enhances the cleanliness of the Cu surface. The activity of the Cu NPs was investigated for methanol electrooxidation in an alkaline medium through electrochemical and spectroelectrochemical measurements. The potentiodynamic and potentiostatic experiments showed higher current densities for the NPs synthesized in the US. In situ FTIR experiments revealed that the three synthesized NP materials eletcrooxidize methanol completely to carbonate through formate. Most importantly, all pathways were led without detectable CO, a poisoning molecule not found at high overpotentials. The reaction path using the US electrode experienced an additional round of formate formation and conversion into carbonate (or CO2 in the thin layer) after 1.0 V (vs. Ag/Ag/Cl), suggesting improved catalysis. The high activity of NPs synthesized in the US is attributed to effective dissociative adsorption of the fuel due to the site\'s availability and the presence of hydroxyl groups that may fasten the oxidation of adsorbates from the surface. After understanding the surface reaction, we built a mixed-media μFC fed by methanol in alkaline medium and sodium persulfate in acidic medium. The μFC was equipped with Cu NPs synthesized in ultrasonic-bath-modified carbon paper as the anode and metal-free carbon paper as the cathode. Since the onset potential for methanol electrooxidation was 0.45 V and the reduction reaction revealed 0.90 V, the theoretical OCV is 0.45 V, which provides a spontaneous coupled redox reaction to produce power. The μFC displayed 0.56 mA cm-2 of maximum current density and 26 μW cm-2 of peak power density at 100 μL min-1. This membraneless system optimizes each half-cell individually, making it possible to build fuel cells with noble metal-free anodes and metal-free cathodes.

Developing highly efficient and carbon monoxide (CO)-tolerant platinum (Pt) catalysts for the formic acid oxidation reaction (FAOR) is vital for direct formic acid fuel cells (DFAFCs), yet it is challenging due to the high energy barrier of direct intermediates (HCOO* and COOH*) as well as the CO poisoning issues associated with Pt alloy catalysts. Here we present a versatile biphasic strategy by creating a hexagonal/cubic crystalline-phase-synergistic PtPb/C (h/c-PtPb/C) catalyst to tackle the aforementioned issues. Detailed investigations reveal that h/c-PtPb/C can simultaneously facilitate the adsorption of direct intermediates while inhibiting CO adsorption, thereby significantly improving the activation and CO spillover. As a result, h/c-PtPb/C showcases an outstanding FAOR activity of 8.1 A mgPt-1, which is 64.5 times higher than that of commercial Pt/C and significantly surpasses monophasic PtPb. Moreover, the h/c-PtPb/C-based membrane electrode assembly exhibits an exceptional peak power density of 258.7 mW cm-2 for practical DFAFC applications.

High-temperature polymer-electrolyte membrane fuel cells (HT-PEMFCs) are a very important type of fuel cells since they operate at 150-200 °C, making it possible to use hydrogen contaminated with CO. However, the need to improve the stability and other properties of gas-diffusion electrodes still impedes their distribution. Self-supporting anodes based on carbon nanofibers (CNF) are prepared using the electrospinning method from a polyacrylonitrile solution containing zirconium salt, followed by pyrolysis. After the deposition of Pt nanoparticles on the CNF surface, the composite anodes are obtained. A new self-phosphorylating polybenzimidazole of the 6F family is applied to the Pt/CNF surface to improve the triple-phase boundary, gas transport, and proton conductivity of the anode. This polymer coating ensures a continuous interface between the anode and proton-conducting membrane. The polymer is investigated using CO2 adsorption, TGA, DTA, FTIR, GPC, and gas permeability measurements. The anodes are studied using SEM, HAADF STEM, and CV. The operation of the membrane-electrode assembly in the H2/air HT-PEMFC shows that the application of the new PBI of the 6F family with good gas permeability as a coating for the CNF anodes results in an enhancement of HT-PEMFC performance, reaching 500 mW/cm2 at 1.3 A/cm2 (at 180 °C), compared with the previously studied PBI-O-PhT-P polymer.