Synergistic Carbon Support Engineering in Composite Catalyst Layer for High-Performance PEM Fuel Cells

Abstract

This study introduces an innovative composite cathode catalyst layer (CCL) design for proton exchange membrane fuel cells (PEMFCs), combining Pt-supported by Vulcan carbon (Pt/V) and Ketjenblack carbon (Pt/KB) to overcome mass transport limitations and ionomer-induced catalyst poisoning. The composite architecture strategically positions Pt/V layer with lower ionomer-to-carbon ratio (I/C = 0.6) near the proton exchange membrane to maximize surface Pt accessibility and oxygen transport efficiency, whereas Pt/KB layer (I/C = 0.9) adjacent to the gas diffusion layer leverages its porous structure to shield Pt from sulfonate group poisoning and enhance proton conduction under low-humidity conditions. This synergistic carbon support engineering achieves a balance between reactant accessibility and catalyst utilization, as demonstrated by improved power density, reduced transport resistance, and higher Pt utilization under dry conditions. These findings establish a new paradigm for low-Pt CCL design through rational carbon support hybridization and ionomer gradient engineering, offering a scalable solution for high-performance PEMFCs in energy-critical applications.

Keywords

composite catalyst layer / ionomer distribution / oxygen transport / platinum utilization / proton conduction

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