Enhanced performance of activated carbon-polytetrafluoroethylene air-cathode by avoidance of sintering on catalyst layer in microbial fuel cells

► The power density was increased by 35% when the catalyst layer was unsintered. ► The hydrophobicity of the catalyst layer was increased after sintering. ► The enhancement was due to the increase of pores in the unsintered catalyst layer. ► Three phase interface of catalyst layer could exist in 6 μm pores.