Ultrasonic process for the manufacture of proton exchange membrane fuel cell electrode assembly
Year: 2025
Type: article
Abstract: The growing demand for clean energy underscores the importance of Proton Exchange Membrane Fuel Cells (PEMFCs) as a sustainable electricity generation solution. However, their widespread adoption faces challenges in performance, durability, cost, and manufacturing efficiency. This study investigates the ultrasonic process as a rapid alternative to traditional methods for manufacturing Membrane Electrode Assemblies (MEAs). Unlike the slow and complex hot pressing method, the ultrasonic process assembles MEAs in seconds without external heating. It transfers pre-coated layers to form the Catalyst Coated Membrane (CCM) and welds components like gas diffusion layers (GDL) without additional adhesives.This technique reduces assembly time by over 94 %, significantly enhancing production efficiency. Scanning Electron Microscope (SEM) analysis reveals that higher stress and energy input during the ultrasonic process decrease PTFE reinforcement thickness in the membrane. Additionally, thanks to SEM and X-ray tomography weld quality is optimized, ensuring defect-free interfaces.Initial fuel cell tests confirm that MEAs produced via the ultrasonic process perform similarly to those made with conventional techniques, in different test conditions. These results position ultrasonic process as a breakthrough in PEMFC manufacturing, offering a faster, more efficient process that supports the transition to clean energy.
Source: Journal of Power Sources
Authors: Claire Tougne, Thomas Cavoué, Arnaud Morin, Christine Nayoze-Coynel
Language: English
Subfield: Electrical and Electronic Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: hybrid
Estimated APC paid: $4,230
OpenAlex ID: W7077082124