PEFC catalyst layers: Effect of support microstructure on both distributions of Pt and ionomer and cell performance and durability

In order to improve the performance and durability of polymer electrolyte fuel cells (PEFCs), various improvements in the microstructures of cathode catalyst layers (CLs) were initiated in the early 1990s. More recent advances in CL materials are highlighted, including carbon supports for improved accessibility of Pt nanoparticles (NPs), adsorption of ionomer on the Pt surface, high-oxygen-permeability ionomers, corrosion resistance of mesoporous and microporous carbons, and conductive ceramic supports with a fused-aggregate network structure. These approaches are summarized as stepwise improvements. The influences of the support structure on the distribution of Pt NPs and ionomer are reviewed, as well as their effects on performance and durability. These approaches for carbon supports are extended to conductive ceramic supports and the unique advantages are discussed.