A Novel Dual-Gradient Patterned Wettability Current Collector for Passive DMFCs

Direct methanol fuel cells (DMFCs) offer significant advantages including high energy density and rapid refueling, making them promising power sources for portable electronic products. However, their practical application, particularly in passive systems, is hindered by critical mass transport limitations: water flooding in the cathode and CO2 bubble blockage in the anode. Herein, a novel dual-gradient patterned wettability current collector (CC) was designed to alleviate this mass transport impedance. The design uniquely integrates wedge-shaped gradients with surface energy gradients to create a unified, self-driven mechanism for efficient water and CO2 bubble transport at both electrodes. A mathematical model was developed to quantitatively evaluate the effects of the dual-gradient structure. The results confirm that water removal is enhanced when the cathode current collector features a hydrophobic periphery with a dual-gradient patterned wettability interior on the gas-diffusion-layer side and a fully hydrophilic air-side surface, whereas an inverted pattern facilitates anode CO2 removal. Optimal fabrication parameters on 316 L stainless steel were established by investigating laser scanning conditions and low-surface-energy agent concentrations. The experimental results show that the passive DMFCs incorporating the optimized current collectors delivered marked performance improvements. At 1 mol·L−1 methanol, the novel anode and cathode current collectors increased peak power density by 15.6% and 14.5%, respectively. Electrochemical impedance spectroscopy revealed a 31.4% and 31.9% reduction in mass transfer resistance of the cell with novel anode and cathode current collectors, respectively, confirming improved gas–liquid self-driven efficiency. Furthermore, the new cells exhibited substantially enhanced long-term stability over 18 h of continuous discharge, attributed to the robust wettability achieved via laser–silane modification. Overall, these findings suggest that the proposed dual-gradient wettability design is a promising method for improving internal mass transport, potentially supporting the development of more robust passive DMFCs.