The
ordered membrane electrode assembly (MEA) is currently the
frontier research field of proton exchange membrane fuel cells (PEMFCs).
The ordered MEA is effective in increasing the utilization of the
Pt catalyst and reducing the Pt catalyst loading and cost. Due to
a larger specific surface area and faster rate of proton transfer,
a Nafion array was used to prepare a high-performance MEA. In order
to realize the ideal performance, the critical mission is to make
a well-dispersed Nafion array. However, the pillars in the Nafion
array are prone to form bundles induced by surface tension of water,
resulting in a severe reduction in the specific surface area. In this
work, we successfully prepared a well-dispersed Nafion array by the
freeze-drying method, which greatly improved the performance of the
ordered MEA of a PEMFC. The percentage of isolated pillars in the
Nafion array is improved from about 0.8% after natural drying to about
90% after freeze-drying. The specific surface area of the Nafion array
membrane after freeze-drying increases to 4.74, which is 2.1 times
that after natural drying, and is close to the theoretical value of
4.99, indicating that the well-isolated array possesses a larger specific
surface area to load a catalyst. Consequently, the electrochemical
surface area of the catalyst layer reaches as high as 131.5 m2 gPt
–1, which is 1.6 or 2.5 times
that with the Nafion array after natural drying or without the Nafion
array. For the ordered MEA, a long-term stability is vital for PEMFC
operation. In this work, the lifetime of the ordered MEA with the
Nafion array after freeze-drying is excellent compared to the Nafion
array after natural drying and without the array. Besides, the scanning
electron microscopy characterization clearly shows that the Nafion
array remains a well-dispersed structure even after hot-pressing and
plays a pivotal role in PEMFC operation. Therefore, this research
proves that the freeze-drying method can effectively solve the aggregation
of the Nafion array during drying and further proves that the well-dispersed
Nafion array could show much higher performance. More importantly,
this work provides an ideal basic material for the preparation of
the ordered MEA.