Porous carbon microparticles with controlled channel structure for high-performance fuel cell

Abstract

Developing a highly efficient and durable proton exchange membrane fuel cell (PEMFC) using a low amount of platinum (Pt) is essential for minimizing the cost of the PEMFC. Herein, we demonstrate the development of high-performance PEMFC catalysts based on ultra-low Pt loaded (1 wt%) porous carbon with controlled channel diameter (Dch = 13-63 nm), produced from crosslinked block copolymer particles. The maximum power density and durability are achieved from the porous carbon particles with large Dch = 63 nm, due to their open-porosity and highest surface area. The single cell based on the catalysts with 1 wt% Pt yields a high initial power density of 1230 mW cm-2 and the power density was still very high as 1120 mW cm-2 after 30,000 cycles under H2/O2 flow, which significantly outperforms those of the commercial 20 wt% Pt/C catalyst in spite of 1/20 Pt usage. Furthermore, the catalyst shows outstanding performance and durability with 53 kW/gPt after 30,000 cycles in H2/air flow. under H2/air flow, which is the highest performance reported to date. It is found that the channel structure and Dch of the porous particles are the keys to enhance the power density by increasing the surface area and improving the proton and mass transport. Our work provides an important guideline for the design of high-performance PEMFCs with ultra-low Pt usage