Fabrication and evaluation of micro-channel array for flexible on-chip PEMFC by new evaluation method and self-made hot embossing system

This paper succeeds to fabricate the micro-channel structure efficiently and accurately with our self-made small hot embossing system. Furthermore, a new evaluation method is proposed to obtain the optimal embossing condition parameters such as hot embossing temperature, embossing force, and force holding time, for fabricating the high-performance micro-channel for flexible proton exchange membrane fuel cell (PEMFC). With the optimal fabrication parameters, the fabricated micro-channel filling ratio can be realized by more than 95%. The results show that micro-pattern arrays can be directly fabricated on commercially available polymer substrate by metal master mold in hot embossing technology with self-made equipment. The fabricated micro-channel-based polymer substrate is capable of the application of PEMFC with a pillar structure to improve the power density of fuel cells.