In recent decades, fuel cell technology has been undergoing revolutionary developments, with fundamental progress being the replacement of electrolyte solutions with polymer electrolytes, making the device more compact in size and higher in power density. Nowadays, acidic polymer electrolytes, typically Nafion, are widely used. Despite great success, fuel cells based on acidic polyelectrolyte still depend heavily on noble metal catalysts, predominantly platinum (Pt), thus increasing the cost and hampering the widespread application of fuel cells. Here, we report a type of polymer electrolyte fuel cells (PEFC) employing a hydroxide ion-conductive polymer, quaternary ammonium polysulphone, as alkaline electrolyte and nonprecious metals, chromium-decorated nickel and silver, as the catalyst for the negative and positive electrodes, respectively. In addition to the development of a high-performance alkaline polymer electrolyte particularly suitable for fuel cells, key progress has been achieved in catalyst tailoring: The surface electronic structure of nickel has been tuned to suppress selectively the surface oxidative passivation with retained activity toward hydrogen oxidation. This report of a H ₂ –O ₂ PEFC completely free from noble metal catalysts in both the positive and negative electrodes represents an important advancement in the research and development of fuel cells.

As one of the most effective synthesis tools, layer-by-layer (LbL) self-assembly technology can provide a strong non-covalent integration and accurate assembly between homo- or hetero-phase compounds or oppositely charged polyelectrolytes, resulting in highly-ordered nanoscale structures or patterns with excellent functionalities and activities. It has been widely used in the developments of novel materials and nanostructures or patterns from nanotechnologies to medical fields. However, the application of LbL self-assembly in the development of highly efficient electrocatalysts, specific functionalized membranes for proton exchange membrane fuel cells (PEMFCs) and electrode materials for supercapacitors is a relatively new phenomenon. In this review, the application of LbL self-assembly in the development and synthesis of key materials of PEMFCs including polyelectrolyte multilayered proton-exchange membranes, methanol-blocking Nafion membranes, highly uniform and efficient Pt-based electrocatalysts, self-assembled polyelectrolyte functionalized carbon nanotubes (CNTs) and graphenes will be reviewed. The application of LbL self-assembly for the development of multilayer nanostructured materials for use in electrochemical supercapacitors will also be reviewed and discussed (250 references).

Iron single atom catalysts (Fe SACs) are the best‐known nonprecious metal (NPM) catalysts for the oxygen reduction reaction (ORR) of polymer electrolyte membrane fuel cells (PEMFCs), but their practical application has been constrained by the low Fe SACs loading (<2 wt%). Here, a one‐pot pyrolysis method is reported for the synthesis of iron single atoms on graphene (FeSA‐G) with a high Fe SAC loading of ≈7.7 ± 1.3 wt%. The as‐synthesized FeSA‐G shows an onset potential of 0.950 V and a half‐wave potential of 0.804 V in acid electrolyte for the ORR, similar to that of Pt/C catalysts but with a much higher stability and higher phosphate anion tolerance. High temperature SiO₂ nanoparticle‐doped phosphoric acid/polybenzimidazole (PA/PBI/SiO₂) composite membrane cells utilizing a FeSA‐G cathode with Fe SAC loading of 0.3 mg cm⁻² delivers a peak power density of 325 mW cm⁻² at 230 °C, better than 313 mW cm⁻² obtained on the cell with a Pt/C cathode at a Pt loading of 1 mg cm⁻². The cell with FeSA‐G cathode exhibits superior stability at 230 °C, as compared to that with Pt/C cathode. Our results provide a new approach to developing practical NPM catalysts to replace Pt‐based catalysts for fuel cells.