The problem of the performance decay and the factors affecting on the DMFC performance for long-term operation are studied in this thesis. First, the influence of the initial treatments of MEA and the exposure of MEA in the atmosphere on the water content are measured. In addition, the effects of the pressure of the MEA hot press conditions, the treatments and preservation of MEA, and the operative conditions on the performance are also examined. Eventually, we expect that the best way to increase the DMFC performance and avoid the performance can be found. These can provide for references when a portable DMFC need to be designed and manufactured in future. In order to solve the problem of methanol crossover leading to the cathode poisoned, cells are operated only under the proper methanol concentration and discharged thoroughly before finishing the whole experiment. It is also necessary to maintain MEAs in proper wetness so that the performance of stack will not decay too quickly. In the initial treatment, firstly, a MEA is immersed in 3M MeOH and then boiled with 80oC DI water for an hour, respectively. The experimental conditions of this passive single-cell DMFC are pumpless in anode chamber, air-breathing, and room temperature. The power density of this DMFC with these test conditions can reach a value about 33mW/cm2. This value is about 106% higher than that of the untreated MEA. If MEA boiled with 0.5M H2SO4 for an hour and then boiled with 80oC DI water for an hour, its power density is about 75% higher than that of the untreated MEA.

Abstract Traditional unipolar/bipolar plates, such as the metal and the graphite unipolar/bipolar plates, are expensive, weight heavy and volume large, so that it is hard to be used in the portable application. A high efficiency, low cost and lightweight portable proton exchange membrane fuel cell (called PEMFC or called HFC when using pure hydrogen fuel), which is made with a new heterogeneous composite carbon fiber bipolar plate and a MEA, is developed in our lab. There are many advantages of the new carbon fiber unipolar/bipolar plates, such as low contact resistance, low cost, lightweight and small volume. We hope that the new unipolar/bipolar plate will be able to replace the conventional metal and graphite unipolar/bipolar plates in the future. The characteristics of a portable PEMFC in different operational conditions are studied in this research. From our experimental result, we find that the factors which affect the HFC performance include the gas temperature, humidity ratio, inlet gas pressure in anode, the geometry of inlet ports, the flow channels within cell, and the oxidant flow rate etc. In addition, the contact resistances between different materials within each cell all strongly influence HFC performance. The ribs of the carbon fiber unipolar/bipolar plates is pored structure, and the gas diffusion layer is no deformation because of only slight compression in stack assembly; therefore, the reactive gas can easily flow into the most of active area. In addition, the contact resistance between the carbon fiber unipolar plate and the gas diffusion layer is lower than that between the traditional unipolar plate and the gas diffusion layer, so that the electrons in active layer is easily to exit or enter this region. The experimental result at 1.15 atm and 40 oC displays that the current density with the new unipolar plate is about twice higher than that with the graphite unipolar plate at overpotential 0.6 V. With air as an oxidizer, we find that increasing the fan rotation speed can avoid output-voltage decay in high current density, but the design with fan is unfavorable for portable application. So a front open unipolar plate and air-breathing design is adopted on the cathode. The power density of this design is slightly lower than that with fan, but it still can reach a value 160 mW/cm2 without any heating and humidification in the anode. Because this design needs little supplement device, the application in portable fuel cells of the new design will be wider than that of a traditional design.

The effects of the structure of new carbon fiber bunch heterogeneous unipolar plates on the performance of PEMFC are studied in this thesis. Internal structure of carbon fiber bunches can be modified by embedding different thickness or number of copper plates in the glue bonding area to increase the air permeability of carbon fiber bunches in its soft end. We can add different thickness or amount of coppers at the middle of bonding area, making the carbon fiber bunches soft side to form parallel to the longitudinal fiber bunch with a small flow channel. We can also make a trench at the appropriate place of the soft side of the carbon fiber bunches to form an extra air passage. In order to make the above flow channel, a new process for making the carbon fiber bunches is developed also. This process will be easier to produce a variety of different structures of carbon fiber bunch. Finally, several different experiments are performed to help us to understand the effect of the carbon fiber bunch structure on the performance and find out the best structure of the carbon fiber bunches. The carbon fiber bunch structures of the test cells on the anode side are all the same, but the carbon fiber bunch structures of on cathode side are all different. Experiments show that there are two structures among all test structures displayed better gas permeability. The first one is two 0.2 mm copper plates embedded within both sides of the glue ends of a cathode carbon fiber bunch, so that a small longitudinal flow channel are formed in soft end of the cathode carbon fiber bunch. When the HFC operates at room temperature and by air-breathing, the highest performance of the HFC can reach a value of 185 mW/cm2. The second one is a 0.2 mm copper plate embedded in the center of the glue end of a carbon fiber bunch, and then three 2 mm wide serrated slots are cut on the soft end of the carbon fiber bunch. The highest performance of the HFC can reach a value of 190 mW/cm2. The highest performance of the HFC with no copper plate and no slot structure can only reach a value 160 mW/cm2. The second design can increase the no structure cell performance 18.8%. Therefore, the internal structures of carbon fiber bunches are significant to affect on the fuel cell performance, and its internal design must be considered.

A new type of heterogeneous carbon fiber bunch bipolar plate developed in our lab is applied to portable pure hydrogen proton exchange membrane fuel cell stacks. Several different types of bipolar plate structures have been designed, and the voltages and currents of these fuel cell stacks are measured to compare their performance. The new type of heterogeneous carbon fiber bunch bipolar plate is well in low contact resistance, weight low, small volume and the flexible geometry shape. Due to its flexible structure of carbon fiber bunch, the compressing pressure is small while assembling stack so that the electrode can not be over compressed and out of shape. Therefore the high porosity of diffusion layer can be keep and reaction gas can enter and distribute to all reaction areas easily. For using to portable equipments, a small 6-cell flat type of fuel cell stack are developed firstly. The total weight is about 75g and the total volume is about 68cm . The second stack is cylinder-type(I) fuel cell stack. The total weight is about 60g and the total volume is about 71cm . The third stack is cylinder-type (II). The total weight has been reduced to about 20g and the total volume has been reduced to about 30cm . Above three kinds of the 6-cell stacks the total electrode area is 13.5cm . Using Nafion, the catalyst content anode Pt 0.4mg/cm , cathode Pt 1.0mg/cm , On room temperature and inlet hydrogen gauge pressure 0.15atm air-breathing, total output power of the cylinder (II) can reach 1.85W, and the power density of unit area can reach about 137mW/cm^2.