Effect of Pt Loading Percentage on Carbon Blacks with Large Interior Nanopore Volume on the Performance and Durability of Polymer Electrolyte Fuel Cells

Achieving high performance and durability at low Pt loads is an important challenge for polymer electrolyte fuel cells (PEFCs). We investigated the effect of catalyst Pt loading percentage (wt % Pt) on the performance and durability of an ultrahigh surface area carbon black (CB) with a large nanopore volume using morphological observations, nitrogen adsorption, and electrochemical performance measurements. The ratio of the surface areas of Pt on the interior and exterior surfaces of the CB affects the penetration of the ionomer into the nanosized pores. When the exterior Pt surface area is larger than that of the interior, the oxygen diffusion resistance in the ionomer increases and the performance deteriorates due to the thick covering of the ionomer on the exterior Pt. Based on durability testing that combines startup, shutdown, and galvanostatic load cycling, the main deterioration factors are dependent upon the Pt interparticle distance and the thickness of the catalyst layer, which vary with the wt % Pt. The advanced characterization and optimization of the various wt % Pt on an ultrahigh surface area CB, combined with the extensive performance and durability testing, have provided an unprecedented understanding of the reaction sites, mass transport characteristics, and stability, which are crucial for their practical application in PEFCs.