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A battery is a galvanic cell that is used as a source of electrical power for specific applications. Modern batteries exist in a multitude of forms to accommodate various applications, from tiny button batteries such as those that power wristwatches to the very large batteries used to supply backup energy to municipal power grids. Some batteries are designed for single-use applications and cannot be recharged (primary cells), while others are based on conveniently reversible cell reactions that...
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Designer diffusion media microstructures enhance polymer electrolyte fuel cell performance.

Rens J Horst1, Ralph van der Linde1, Rémy R Jacquemond1

  • 1Electrochemical Materials and Systems, Department of Chemical Engineering and Chemistry, Eindhoven University of Technology PO Box 513 5600 MB Eindhoven Netherlands a.forner.cuenca@tue.nl r.j.horst@tue.nl ralphvanderlinde92@gmail.com r.r.jacquemond@tue.nl b.liu@tue.nl.

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|November 3, 2025
PubMed
Summary
This summary is machine-generated.

Researchers developed a new, scalable method using non-solvent induced phase separation (NIPS) to create advanced carbon-based gas diffusion media for fuel cells. This technique allows precise control over microstructure, enhancing performance and reducing costs.

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Area of Science:

  • Materials Science
  • Electrochemistry
  • Chemical Engineering

Background:

  • Gas diffusion media are critical for fuel cell performance, enabling gas/liquid transport and conductivity.
  • Current methods offer limited control over microstructure, hindering optimization for advanced architectures.
  • There is a need for scalable, cost-effective fabrication of diffusion media with tailored porosity.

Purpose of the Study:

  • To introduce a scalable, bottom-up fabrication method for carbon-based diffusion media using non-solvent induced phase separation (NIPS).
  • To demonstrate tunable microstructures, including isoporous and bimodal porosity, for improved multiphase transport.
  • To correlate microstructural features with fuel cell performance and assess economic viability.

Main Methods:

  • Non-solvent induced phase separation (NIPS) for fabricating carbon-based diffusion media.
  • Systematic variation of processing parameters to control microstructure.
  • Microscopy, porosimetry, electrochemical diagnostics, and techno-economic analysis for characterization and benchmarking.

Main Results:

  • Successfully produced mechanically robust diffusion media with tunable in-plane and through-plane porosity.
  • Demonstrated correlation between microstructural features and improved water management and gas transport in fuel cells.
  • NIPS fabrication shows potential for cost-effectiveness and scalability compared to conventional methods.

Conclusions:

  • NIPS is a versatile and industrially relevant method for next-generation gas diffusion media.
  • Tailored microstructures via NIPS can significantly optimize fuel cell performance.
  • This approach offers new design freedoms to reduce fuel cell system costs.