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Atomically thin CVD graphene-integrated proton exchange membrane electrode assemblies: fabrication parameter space
Xiaozong Fan1, Aman Tamboli1, Pavan Chaturvedi1
1Department of Chemical and Biomolecular Engineering, Vanderbilt University, Nashville, TN, USA.
Nanoscale
|May 22, 2026
Summary
Fabrication methods significantly impact two-dimensional (2D) material integration in proton exchange membranes (PEMs). The decal transfer method effectively reduces hydrogen crossover in PEM fuel cells without compromising proton conductivity, enhancing durability and efficiency.
Area of Science:
- Materials Science
- Electrochemistry
- Nanotechnology
Background:
- Proton exchange membranes (PEMs) face a trade-off between proton conductivity and gas crossover.
- Two-dimensional (2D) materials, like graphene, offer potential to mitigate this trade-off.
- Integrating 2D materials into PEMs requires optimized fabrication processes for membrane-electrode assemblies (MEAs).
Purpose of the Study:
- To investigate the influence of different MEA fabrication methods on monolayer graphene-integrated PEMs.
- To evaluate the impact of these methods on proton conductance and hydrogen (H2) crossover.
- To identify the most effective fabrication strategy for enhancing PEM fuel cell performance and durability.
Main Methods:
- Systematic investigation of three MEA fabrication processes: gas diffusion electrode (GDE), directly sprayed catalyst-coated membrane (DS-CCM), and decal transfer catalyst-coated membrane (DT-CCM).
- Utilized monolayer chemical vapor deposition (CVD) graphene interfaced with perfluorosulfonic acid (PFSA) PEMs (12-25 μm thick).
- Analyzed H2 crossover and proton conductance for each fabrication method.
Main Results:
- GDE method showed limited H2 crossover suppression due to potential graphene damage from its rough surface.
- DS-CCM approach led to PEM degradation and reduced performance due to solvent exposure.
- DT-CCM method demonstrated minimal graphene damage, achieving a 25-44% reduction in H2 crossover without affecting proton conductance.
- The decal transfer approach proved effective even with thinner PEMs, improving durability and efficiency.
Conclusions:
- Fabrication method is critical for successful 2D material integration in PEMs.
- The decal transfer method is superior for fabricating MEAs with graphene-integrated PEMs, offering significant H2 crossover reduction.
- This approach enables enhanced membrane durability and fuel cell efficiency, paving the way for next-generation PEM technologies.
