Optimal fabrication of carbon paper by different lengths of chopped carbon fibers and its enhanced performance in proton exchange membrane fuel cell

Carbon paper as a macroporous substrate of gas diffusion layer in proton exchange membrane fuel cells directly impacts the output performance of cells. In this study, we present a straightforward strategy to improve the overall performance of carbon paper by mixing short/long (6mm/10 mm) chopped carbon fibers at an optimal concentration of phenolic resin. The results show that incorporating longer carbon fibers can increase the porosity, conductivity, gas flux, and mechanical properties of carbon paper. The membrane electrode assembly achieved a peak power density of 1182.61 mW cm−2 at 60% RH using carbon paper with a long carbon fiber content of 40 wt% and an impregnation concentration of 10 wt%. This outperforms commercially available carbon paper. Based on electrochemical impedance spectroscopy results, it was confirmed that our carbon paper had a lower mass transfer resistance of only 32.17 mΩ cm−2 under conditions of 2 A cm−2 and 60% RH. This was due to its sparser three−dimensional network-like pore structure which was created by mixing different lengths (6mm/10 mm) of carbon fibers. This work provides new insights into preparing high−performance carbon papers.