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Lookup NU author(s): Dr Daniel NiblettORCiD
This work is licensed under a Creative Commons Attribution 4.0 International License (CC BY 4.0).
© 2026 The AuthorsLow-cost proton exchange membrane fuel cells are critical to the hydrogen economy. Despite their potential for major cost reductions, most low-platinum oxygen reduction reaction catalysts perform poorly in commercial fuel cells, operating with H2−Air, ambient pressure, and high current densities (> 1 A cm−2) due to severe gas diffusion limitations. Herein, we engineer a serpentine flow field with 100 µm lateral bypasses and 100 µm micro-ribs, or so-called lateral bypass flow field, to improve gas diffusion to the active sites for low-platinum fuel cells. The rationale behind this concept is to remove water saturating within the 100 µm pores of the gas diffusion electrode at the interface with the flow field ribs. Using cathode loadings of 0.1 mgPtCo cm−2, 0.1 mgPt cm−2, and 0.2 mgPt cm−2, the lateral bypass fuel cell achieves 0.63, 0.76, and 1.1 W cm−2 in H2−Air at ambient pressure, which is up to 75% higher than the conventional serpentine fuel cell. Advanced characterization and simulations are conducted to further elucidate the underlying mechanisms. Operando electrochemical impedance spectroscopy and operando neutron imaging, coupled with advanced two-phase flow simulations using computational fluid dynamics with the Volume of Fluid and the Lattice Boltzmann Methods, and a zero-dimensional analytical model, reveal that the lateral bypasses not only suppress water accumulation beneath the flow field ribs but also enhance water transport across adjacent channels and increase the oxygen content in the catalyst layer. This design also significantly improves the performance of platinum-free catalysts and paves the way for high-performance flood-free fuel cells.
Author(s): Meyer Q, Wang YD, Niblett D, Bin Mamtaz MR, Akbar M, Nie Y, Liu S, Lee J, Boillat P, Tang K, Tung P, Mostaghimi P, Armstrong RT, Zhao C
Publication type: Article
Publication status: Published
Journal: Applied Catalysis B: Environmental
Year: 2026
Volume: 393
Print publication date: 15/09/2026
Online publication date: 28/03/2026
Acceptance date: 22/03/2026
Date deposited: 21/04/2026
ISSN (print): 0926-3373
ISSN (electronic): 1873-3883
Publisher: Elsevier B.V.
URL: https://doi.org/10.1016/j.apcatb.2026.126713
DOI: 10.1016/j.apcatb.2026.126713
Data Access Statement: Data will be made available on request
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