Composite-supported Pt catalyst and electrosprayed cathode catalyst layer for polymer electrolyte membrane fuel cell

A major limitation of the conventional polymer electrolyte membrane fuel cell (PEMFC) catalysts is the fast oxidative degradation of their carbon black supports. Complete replacement of carbon black is difficult because of its low-cost and high electrical conductivity. Reported here are the development and optimization of composite-supported Pt catalysts and the electrosprayed cathode catalyst layer with these catalysts for PEMFC. These catalysts are supported by a composite of carbon black (Vulcan XC-72R) and the electrochemically much more stable carbon-embedded niobium-doped titanium dioxide nanofibers (C/Nb0.1Ti0.9O2). Four different catalyst supports with 20 wt.% Pt were prepared by air spraying and electrospraying to compare their activity and stability. Vulcan XC-72R and C/Nb0.1Ti0.9O2 were tested as pristine support materials for comparison as well as 1:3 and 3:1 mixtures by weight of the two pristine support materials (composite supports). The amount of Nafion in the catalyst ink was optimized for each catalyst layer by a volumetric method. An increase in carbon black content of the support layer from 0% to 100% increases the performance of these catalysts in H-2/air PEMFCs but also increases the loss of oxygen reduction reaction mass activity. The best balance between PEMFC performance and durability was obtained for the Pt catalyst with 25% carbon black in the support layer, while the highest initial oxygen reduction reaction mass activity was obtained for the catalyst with 75% carbon black content. Copyright (C) 2017 John Wiley & Sons, Ltd.