Ordered Catalyst Layer Design for Proton Exchange Membrane Fuel Cells: Principle and Methods

Proton exchange membrane fuel cell is an ideal energy conversion technology that owns unique advantages including zero emission, high efficiency, and high power density. However, the cost issue caused by the use of Pt-based catalysts limits the widespread application of PEMFC. When lowering the Pt loading in cathode catalyst layer, an increase in concentration polarization occurs that limits the cell performance. To address this issue, the improvement in catalyst layer structure is required to enhance transport process, especially for low-loading and ultralow-loading PEMFCs. This chapter focuses on the effects of ordered catalyst layer structures on multicomponent transport and the different designs of ordered catalyst layers. The designs of ordered catalyst layer are illustrated respectively, including the supporting material-based one, the catalyst-based one, and the proton conductor-based one. Each design of the ordered catalyst layer is concluded with the fabrication process, structure characterization, and performance improvement.