Development of ultra-low highly active and durable hybrid compressive platinum lattice cathode catalysts for polymer electrolyte membrane fuel cells

A highly active and stable catalyst/support system is developed by using a two-step process. In the first step, activated carbon composite support (ACCS) is synthesized that retains its activity after accelerated stress test (AST). A 30% Pt/ACCS catalyst shows no loss of mass activity and power density after 5000 cycles at 1.0-1.5 V while the commercial Pt/C and Pt/290G catalysts show drastic mass activity losses (57.5% and 66.2%, respectively) and power density losses (88.7% and 84.0%, respectively). In the second step, Pt catalyst with a compressive Pt lattice (Pt∗) is synthesized through a USC-developed annealing procedure in which Co atoms previously embedded in the support diffuse into Pt. The 30% Pt∗/ACCS shows high initial power density (rated) of 0.174 gPt kW−1 and high stability of 24 mV loss at 0.8 A cm−2 with an electrochemical active surface area (ECSA) loss of 42% after 30,000 cycles (0.6-1.0 V). The support stability under 1.0-1.5 V potential cycling shows potential loss of 8 mV at 1.5 A cm−2 and ECSA loss of 22% after 5000 cycles. Improved stability and activity of Pt*/ACCS catalyst are due to synergistic effect of catalytic activity and stability of ACCS and formation of compressive Pt lattice catalyst.