Synthesis of ordered, uniform, macroporous carbons with mesoporous walls templated by aggregates of polystyrene spheres and silica particles for use as catalyst supports in direct methanol fuel cells

Porous carbons with mesoporous walls (see Figure) are produced by template replication of aggregates of small silica particles, which were themselves templated by a self-assembled lattice of larger monodisperse polystyrene spheres. A direct methanol fuel cell using the new material as a catalyst support shows significantly improved performance due to the combination of high surface area and facile fuel and product diffusion.