Layer reduction method for fabricating Pd-coated Ni foams as high-performance ethanol electrode for anion-exchange membrane fuel cells

An ideal electrode architecture that boosts the performance of anion-exchange membrane direct liquid fuel cells needs the electrode design to meet all the requirements of electrochemical kinetics and mass and charge transport characteristics. In this regard, here we propose a facile, well-controlled, and binder-free layer reduction method for preparing a three-dimensional foam electrode, which enables the catalytic particles to be directly reduced on the surface of the metal foam. This innovative layer reduction method not only avoids the formation of large catalytic aggregation, but also promises a thin and porous catalyst film that presents a sponge-like morphology uniformly coated onto the skeleton, thus both improving the electrochemical kinetics and enhancing the mass and charge transport of species. The results demonstrate that the application of the layer-reduced Pd/Ni foam electrode in an anion-exchange membrane direct ethanol fuel cell enables a peak power density and the maximum current density as high as 164 mW cm(-2) and 1.34 A cm(-2) at 60 degrees C, respectively, which are 1.03 and 1.16 times higher than those of the conventional design.