Single-Step Fabrication of a Multiscale Porous Catalyst Layer by the Emulsion Template Method for Low Pt-Loaded Proton Exchange Membrane Fuel Cells

Multiscale porosity assures better mass transport for a low Pt-loaded fuel cell; however, achieving a complex pore structure in a simple manner presents a major challenge. In this work, by using the emulsion template method, a multiscale porous catalyst layer with macro- and mesopores was fabricated in a single step. A stable high internal phase emulsion is achieved with catalyst layer components by exploiting a Nafion ionomer as a surfactant. The oil phase of the emulsion catalyst slurry induces the macropores, and the Pt/C and ionomer mixture in the hydrophilic solvent forms a mesoporous framework in the catalyst layer. Scanning electron microscopy and micro X-ray computed tomography confirmed the formation of uniform and well-interconnected macropores. The performance of the low Pt-loaded catalyst layer derived from the emulsion template method considerably improved the mass transport property due to the mitigation of water flooding. The fabrication of an emulsion-based catalyst layer provides an efficient platform to design high-performance low Pt-loaded fuel cells.