Comparative study of three different catalyst coating methods for direct methanol fuel cells

The performance of direct methanol fuel cells (DMFCs) with membrane–electrode assemblies (MEAs) made separately by three different catalyst coating methods, namely, air-spray, electro-spray and dual-mode spray, is evaluated. Platinum–ruthenium (PtRu) is incorporated as a catalyst for the anode. Several techniques (XRD, FE-SEM, and TEM) are used to examine whether the coating method affects the morphological features of the PtRu catalyst, whereas cyclic voltammetry is used to evaluate the active surface area. The cell polarization curves attained for the three coating methods that use different methanol concentrations are compared to determine the best method. It is found that the PtRu catalyst coated by the dual-mode spray shows the most uniform nanoparticle distribution and the highest active surface area. The DMFC performance is best when the dual-mode spray is employed (165 mW cm−2 at 2 M methanol).