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Summary: An ultrathin layer composed of carbon nanotubes (CNTs) was deposited on the cathodic catalyst layer to boost performance of polymer electrolyte membrane fuel cell (PEMFC) under low to mid relative humidity (RH) conditions. The CNT‐deposited layer (CDL) was formed without modifying the PEMFC components. To investigate the behavior of water and reactants at the inner interface of the membrane electrode assembly (MEA), we characterized the morphology of the CDL (contact angle, pore size distribution, specific surface area, field emission scanning electron microscopy, and energy dispersive spectroscopy images). The CDL in PEMFCs was used as a contributor to enhance the membrane hydration. Thereby performances have been significantly enhanced. Additionally, the three‐dimensional nanostructure of the CDL expanded the active area by uniform dispersion of the reactants. The polarization curves of the conventional MEA and MEA with CDL were evaluated under diverse RH (100%, 70%, 50%, and 30% RH). In the low to mid RH conditions, the maximum power densities were increased by 29.7% (70% RH), 26.6% (50% RH), and 25.5% (30% RH) compared with the conventional MEA. Especially, the maximum power density of the MEA with CDL (0.547 W/cm2 at 70% RH) was higher than that of the conventional MEA (0.482 W/cm2 at 100% RH). Thus, MEA with CDL demonstrated excellent performance enhancement under low to mid RH conditions. [ABSTRACT FROM AUTHOR]

In proton exchange membrane fuel cells (PEMFCs), securing sufficient hydration in perfluorosulfonic acid (PFSA) membrane is considered an indicator of performance and durability. Here, we present a straightforward yet effective strategy that sandwiches the nanoporous carbon nanotube (CNT) sheet between the cathodic gas diffusion backing layer (GDBL) and bipolar plate (BP) of a conventional membrane electrode assembly (MEA). CNT sheets are synthesized through the cost-effective direct spinning method. The carbon source, winding rates, and the number of layers are varied to tailor the thickness and nanoporous morphology of the CNT sheets (5, 15, and 30 μm). CNT interlayer MEAs are evaluated for their performance in various temperature and relative humidity (RH), ranges of 80–120 °C and 25–100% RH. With these nanoporous CNT sheets, reactants disperse homogeneously, enhancing membrane hydration and interfacial contact, thereby fulfilling superior performance compared to conventional under entire conditions. Among CNT interlayers, the 30 μm records a 115.4% enhanced peak power density (0.28 W cm−2) and 89.2% extended durability (∼187 h) than conventional under 120 °C and 25% RH. Our strategy delivers a broader perspective of PEMFCs and other fuel cell types based on their ease of production and reproducibility. [Display omitted] • Nanoporous CNT functional interlayers were prepared by direct spinning. • CNT interlayer notably boosts the performance of PEFMCs under all test conditions. • CNT interlayer also achieves 89.2% extended durability of PEMFCs. • These promising boosting mechanisms were demonstrated and optimized. [ABSTRACT FROM AUTHOR]

Carbon nanotubes (CNT) based nanoporous layer contacting the catalyst layer in polymer electrolyte membrane fuel cells (PEMFCs) is investigated. Nanoporous CNT-5, CNT-15, and CNT-40 sheets are prepared via direct spinning method with thicknesses is 5, 15, and 40 μm, respectively. The ethanol-derived CNT-5 possess sparse pore networks, whereas CNT-15 and CNT-40 derived from acetone exhibit fine networks, and CNT-15 and CNT-40 differ only in thickness. The CNTs are employed as either standalone nanoporous layer or as an additional layer with carbon-black microporous layer (MPL). Scanning electron microscopy and sessile drop method are utilized for CNT characterization. Current-voltage polarization curve and electrochemical impedance spectroscopy are recorded for the PEMFC characterization. The best performance is obtained when CNT-15 is adopted as an additional nanoporous layer with MPL in the dry operation. The current densities at a cell voltage of 0.6 V are 0.454 and 0.743 A cm−2 in dry and wet operations, respectively, corresponding to an increase of 28.5% and 57.1%, respectively, compared to carbon-black MPL. Enhancements in water management and reaction kinetics lead to this performance increase. In particular, the enhanced water storage and expulsion are benefits differentiated from employing CNT as the single nanoporous layer. [Display omitted] ∙ CNT-based nanoporous layers were employed to GDL of PEMFC. ∙CNTs were fabricated via cost-effective direct spinning method. ∙Additional nanoporous layer (w/ MPL) increased current density by 57% (at 0.6 V). ∙Mitigated charge transfer and ohmic resistances led to performance enhancements. ∙The correlation between the quality of CNT and fuel cell performance was subpar. [ABSTRACT FROM AUTHOR]