A Highly Order‐Structured Membrane Electrode Assembly with Vertically Aligned Carbon Nanotubes for Ultra‐Low Pt Loading PEM Fuel Cells

A simple method was developed to prepare ultra‐low Pt loading membrane electrode assembly (MEA) using vertically aligned carbon nanotubes (VACNTs) as highly ordered catalyst support for PEM fuel cells application. In the method, VACNTs were directly grown on the cheap household aluminum foil by plasma enhanced chemical vapor deposition (PECVD), using Fe/Co bimetallic catalyst. By depositing a Pt thin layer on VACNTs/Al and subsequent hot pressing, Pt/VACNTs can be 100% transferred from Al foil onto polymer electrolyte membrane for the fabrication of MEA. The whole transfer process does not need any chemical removal and destroy membrane. The PEM fuel cell with the MEA fabricated using this method showed an excellent performance with ultra‐low Pt loading down to 35 μg cm^?2 which was comparable to that of the commercial Pt catalyst on carbon powder with 400 μg cm^?2. To the best of our knowledge, for the first time, we identified that it is possible to substantially reduce the Pt loading one order by application of order‐structured electrode based on VACNTs as Pt catalysts support, compared with the traditional random electrode at a comparable performance through experimental and mathematical methods.     

Electrocatalysts for PEM Fuel Cells

Degradation phenomena of electrocatalysts for proton‐exchange membrane fuel cells and their mechanisms are reviewed. Platinum dissolution and redeposition, carbon‐support corrosion, inhomogeneity during start‐up and cell reversal are discussed as factors that influence the degradation of electrocatalysts with relation to electrode potential. Early research findings at the National Institute of Advanced Industrial Science and Technology (AIST), Japan, are mainly used as a basis of discussion. The development of highly durable electrocatalysts using an oxide support based on the results of degradation studies to suppress electrocatalyst degradation is summarized with a main focus on Pt‐deposited Ti₄O₇ catalysts developed at AIST. The development of high‐CO‐concentration durable anode electrocatalysts is also reviewed. In particular, an electrocatalyst that uses an organic complex as a co‐electrocatalyst with a platinum ruthenium alloy anode electrocatalyst developed at AIST is included as a novel high‐CO‐concentration durable anode electrocatalyst.     

Nitrogen‐Doped Porous Molybdenum Carbide and Phosphide Hybrids on a Carbon Matrix as Highly Effective Electrocatalysts for the Hydrogen Evolution Reaction

The efficient evolution of hydrogen through electrocatalysis is considered a promising approach to the production of clean hydrogen fuel. Platinum (Pt)‐based materials are regarded as the most active hydrogen evolution reaction (HER) catalysts. However, the low abundance and high cost of Pt hinders the large‐scale application of these catalysts. Active, inexpensive, and earth‐abundant electrocatalysts to replace Pt‐based materials would be highly beneficial to the production of cost‐effective hydrogen energy. Herein, a novel organoimido‐derivatized heteropolyoxometalate, Mo4‐CNP, is designed as a precursor for electrocatalysts of the HER. It is demonstrated that the carbon, nitrogen, and phosphorus sources derived from the Mo4‐CNP molecules lead to in situ confined carburization, phosphorization, and chemical doping on an atomic scale, thus forming nitrogen‐doped porous molybdenum carbide and phosphide hybrids, which exhibit remarkable electrocatalytic activity for the HER. Such an organically functionalized polyoxometalate‐assisted strategy described here provides a new perspective for the development of highly active non‐noble metal electrocatalysts for hydrogen evolution.     

Tailored Electron Transfer Pathways in Aucore/Ptshell–Graphene Nanocatalysts for Fuel Cells

Au_core/Pt_shell–graphene catalysts (G‐Cys‐Au@Pt) are prepared through chemical and surface chemical reactions. Au–Pt core–shell nanoparticles (Au@Pt NPs) covalently immobilized on graphene (G) are efficient electrocatalysts in low‐temperature polymer electrolyte membrane fuel cells. The 9.5 ± 2 nm Au@Pt NPs with atomically thin Pt shells are attached on graphene via l ‐cysteine (Cys), which serves as linkers controlling NP loading and dispersion, enhancing the Au@Pt NP stability, and facilitating interfacial electron transfer. The increased activity of G‐Cys‐Au@Pt, compared to non‐chemically immobilized G‐Au@Pt and commercial platinum NPs catalyst (C‐Pt), is a result of (1) the tailored electron transfer pathways of covalent bonds integrating Au@Pt NPs into the graphene framework, and (2) synergetic electronic effects of atomically thin Pt shells on Au cores. Enhanced electrocatalytic oxidation of formic acid, methanol, and ethanol is observed as higher specific currents and increased stability of G‐Cys‐Au@Pt compared to G‐Au@Pt and C–Pt. Oxygen reduction on G‐Cys‐Au@Pt occurs at 25 mV lower potential and 43 A g_Pt^?1 higher current (at 0.9 V vs reversible hydrogen electrode) than for C–Pt. Functional tests in direct fomic acid, methanol and ethanol fuel cells exhibit 95%, 53%, and 107% increased power densities for G‐Cys‐Au@Pt over C–Pt, respectively.     

Intrinsically Stretchable Fuel Cell Based on Enokitake‐Like Standing Gold Nanowires

Conventional fuel cells are based on rigid electrodes, limiting their applications in wearable and implantable electronics. Here, it is demonstrated that enokitake‐like vertically‐aligned standing gold nanowires (v‐AuNWs) can also serve as powerful platform for stretchable fuel cells by using ethanol as model system. Unlike traditional fuel cell electrodes, the v‐AuNWs have “Janus Morphology” on both sides of the film and also are highly stretchable. The comparative studies demonstrate that tail side exposed v‐AuNWs based stretchable electrodes outperform the head‐side exposed v‐AuNWs toward the electro‐oxidation of ethanol due to the direct exposure of high‐surface‐area nanowires to the fuels. Therefore, a stretchable fuel cell is fabricated utilizing tail side based interdigitated electrodes, where v‐AuNWs and Pt black modified v‐AuNWs serve as the anode and cathode, respectively. The as‐prepared stretchable fuel cell exhibits good overall performance, including high power density, current density, open‐circuit voltage, stretchability, and durability. Most importantly, a wearable fuel cell is also achieved by integrating tattoo‐like interdigitated electrodes with a thin layer of sponge as a fuel container, exhibiting good performance under various deformations (compression, stretching, and twisting). Such attractive performance in conjunction with skin‐like in‐plane design indicates its great potential to power the next‐generation of wearable and implantable devices.     

Unravelling Degradation Pathways of Oxide‐Supported Pt Fuel Cell Nanocatalysts under In Situ Operating Conditions

Knowledge of degradation pathways of catalyst/support ensembles aids the development of rational strategies to improve their stability. Here, this is exemplified using indium tin oxide (ITO)‐supported Platinum nanoparticles as electrocatalysts at fuel cell (FC) cathodes under degradation protocols to mimic operating conditions in two potential regimes. The evolution of crystal structure, composition, crystallite and particle size is tracked by in situ X‐ray techniques (small and wide angle scattering), metal dissolution by in situ scanning flow cell coupled with mass spectrometry (SFC ICP‐MS) and Pt surface morphology by advanced electron microscopy. In a regular FC operation regime, Pt poisoning rather than Pt particle growth, agglomeration, dissolution or detachment was found to be the likely origin of the observed degradation and ORR activity losses. In the start‐up regime degradation is actually suppressed and only minor losses in catalytic activity are observed. The presented data thus highlight the excellent nanoparticle stabilization and corrosion resistance of the ITO support, yet point to a degradation pathway involving Pt surface modifications by deposition of sub‐monolayers of support metal ions. The identified degradation pathway of the Pt/oxide catalyst/support couple contributes to our understanding of cathode electrocatalysts for polymer electrolyte fuel cells (PEFC).     

Perovskite Membranes with Vertically Aligned Microchannels for All‐Solid‐State Lithium Batteries

Perovskite‐type solid‐state electrolytes exhibit great potential for the development of all‐solid‐state lithium batteries due to their high Li‐ion conductivity (approaching 10^?3 S cm^?1), wide potential window, and excellent thermal/chemical stability. However, the large solid–solid interfacial resistance between perovskite electrolytes and electrode materials is still a great challenge that hinders the development of high‐performance all‐solid‐state lithium batteries. In this work, a perovskite‐type Li_0.34La_0.51TiO₃ (LLTO) membrane with vertically aligned microchannels is constructed by a phase‐inversion method. The 3D vertically aligned microchannel framework membrane enables more effective Li‐ion transport between the cathode and solid‐state electrolyte than a planar LLTO membrane. A significant decrease in the perovskite/cathode interfacial resistance, from 853 to 133 Ω cm², is observed. It is also demonstrated that full cells utilizing LLTO with vertically aligned microchannels as the electrolyte exhibit a high specific capacity and improved rate performance.     

Incorporation of Indium Tin Oxide Nanoparticles in PEMFC Electrodes

Carbon materials suffer from corrosion at the cathode of polymer electrolyte membrane fuel cells (PEMFCs). In the presence of water, carbon support materials are oxidized to carbon dioxide even at low potentials. Hence, nowadays it is very fashionable to look for alternative support materials, like oxides or conductive polymers. To gain the maximum performance for a new material one should also consider an appropriate electrode structure. This study shows the results for the incorporation of nanosized alternative support materials into advanced electrode architectures. Commercially available indium tin oxide (ITO) nanoparticles (<50 nm) are used as support for Pt nanoparticles in combination with Nafion‐coated multi‐walled carbon nanotubes (MWCNTs) on the cathode side of a PEMFC. The MWCNTs promote a high electronic conductivity and help to form a porous network, which could accommodate the Pt/ITO nanoparticles. The microscopic investigations show a homogeneous electrode structure composed of Pt/ITO and MWCNT/Nafion multilayer. Single cell measurements show a maximum power density of 73 mW cm^?2 and a Pt utilization of 1468 mW mg_Pt^?1 for the cathode. The performance data and the Pt utilization are comparable to a standard Pt/carbon black electrode possessing the same Pt loading in the electrode. Beside this, it is shown for the first time that ITO serves as support material under real fuel cell conditions.     

Tuning Multimetallic Ordered Intermetallic Nanocrystals for Efficient Energy Electrocatalysis

Ordered intermetallic alloys have attracted extensive attention as advanced electrocatalysts for polymer electrolyte membrane fuel cells (PEMFCs) reactions with much improved activity and stability. Here, latest progress in tuning intermetallic Pt‐ and Pd‐based nanocrystals with tunable morphology and structure for catalyzing both the cathodic reduction of oxygen and anodic oxidation of fuels (e.g., methanol, ethanol and formic acid) in PEMFCs is highlighted. Making/tuning interesting intermetallic PtM (M = Fe, Co, Pb, Cu, etc.)‐based nanocrystals for boosting oxygen reduction reaction with high activity and stability by using/controlling high‐temperature annealing treatment is discussed. In all the reported Pt‐based intermetallic nanocrystals, controlling the degree of ordering under the proper high temperature treatment is the key for achieving the optimized electrocatalysis. In order to search for cheaper catalysts, the progress on making Pd‐based intermetallic nanocrystals is also discussed. Furthermore, future research directions are proposed and discussed to further enhance the efficiency of such unique intermetallic multimetallic nanocatalysts. This report aims to demonstrate the potential of ordered intermetallic strategy for boosting electrocatalysis and stimulating more research efforts in this field.     

Vertical CoP Nanoarray Wrapped by N,P‐Doped Carbon for Hydrogen Evolution Reaction in Both Acidic and Alkaline Conditions

Hydrogen evolution reaction (HER) is a key reaction in water splitting, and developing efficient and robust non‐noble electrocatalysts for HER is still a great challenge for large‐scale hydrogen production. Herein, a vertically aligned core–shell structure grown on Ti foil with CoP nanoarray as a core and N,P‐doped carbon (NPC) as a shell (CoP/NPC/TF) is first reported as an efficient electrocatalyst for HER. Results indicate that CoP/NPC/TF only demands the overpotentials of 91 and 80 mV to drive the current density of 10 mA cm^?2 in acidic and alkaline solutions. The electrochemical measurements and theoretical calculations show that the synergy of CoP nanorod core and porous NPC shell enhances HER performance significantly, because the introduction of porous NPC shell not only offers more active sites but also improves the electrical conductivity and durability of the sample in acidic and alkaline solutions. Density functional theory calculation further reveals that all the C atoms between N and P atoms in CoP/NPC are the most efficient active sites, which greatly improve the HER performance. The identification of active species in this work provides an effective strategy to design and synthesize the low‐cost, high‐efficient, and robust CoP‐based electrocatalysts.     

Carbon Nanodot Surface Modifications Initiate Highly Efficient,Stable Catalysts for Both Oxygen Evolution and Reduction Reactions

Efficient, stable, and low‐cost electrocatalysts for the oxygen evolution and reduction reactions (OER and ORR) are essential components of energy conversion. Although much progress has been achieved in the development of platinum‐based electrocatalysts for ORR and iridium‐based electrocatalysts for OER, they are still not yet viable for large‐scale commercialization because of the high cost and scanty supply of the noble metals. Here, it is demonstrated that carbon nanodots surface‐modified with either phosphorus or amidogen can respectively achieve electrocatalytic activity approaching that of the benchmark Pt/C and IrO₂ /C catalysts for ORR and OER. Furthermore, phosphorus (amidogen)‐modified carbon nanodots with attached Au nanoparticles exhibit superior ORR (OER) activity better than commercial Pt/C (IrO₂/C) catalysts as well as excellent electrochemical stability under visible light.     

Mesoporous Decoration of Freestanding Palladium Nanotube Arrays Boosts the Electrocatalysis Capabilities toward Formic Acid and Formate Oxidation

Fabricating high‐performance electrocatalysts is the most critical step in commercializing direct formic acid or formate fuel cells. In this work, a dual‐template electrodeposition method is used to create freestanding mesoporosity decorated palladium nanotube arrays (P‐PdNTA) as a bifunctional electrocatalyst toward formic acid and formate oxidation (FAO/FOR). The phytantriol‐based soft template modifies the superficial chemistry of aluminum anodic oxide inner surfaces, thereby facilitating the regulated electrodeposition of highly stable palladium nanotubes. The sacrifice of the soft template generates substantial mesoporosity on the nanotubes, resulting in a 189% increase in the electrochemically active surface area with respect to the mesopore‐free PdNTA baseline. In addition, the soft template significantly increases the density of catalytically active sites per unit area via perturbation on routine nanotube growth, as evidenced by the doubled areal catalytic activity of P‐PdNTA versus PdNTA. Remarkably, the P‐PdNTA delivered gravimetric catalytic currents of 3.65 and 3.87 A mg^?1 for FAO and FOR, which are 8.5 and 6.5 times higher, respectively, than those of commercial Pt/C. These values are among the most favorable reported and benefit from the unique synergy of fast substance transport, large electrochemical active surface area and high areal population of catalytically active sites.     

Monolayer formation of human osteoblastic cells on vertically aligned multiwalled carbon nanotube scaffolds

Monolayer formation of SaOS‐2 (human osteoblast‐like cells) was observed on VACNT (vertically aligned multiwalled carbon nanotubes) scaffolds without purification or functionalization. The VACNT were produced by a microwave plasma chemical vapour deposition on titanium surfaces with nickel or iron as catalyst. Cell viability and morphology studies were evaluated by LDH (lactate dehydrogenase) release assay and SEM (scanning electron microscopy), respectively. The non‐toxicity and the flat spreading with monolayer formation of the SaOs‐2 on VACNT scaffolds surface indicate that they can be used for biomedical applications.     

Engineering Multimetallic Aerogels for pH‐Universal HER and ORR Electrocatalysis

The advent of noble metal aerogels (NMAs), that feature the high catalytic activity of noble metals and unique structural attributes of aerogels, has stimulated research on a new class of outstanding electrocatalysts. However, limited by the available compositions, the explored electrocatalytic reactions on NMAs are highly restricted and certain important electrochemical processes have not been investigated. Here, an effective gelation approach is demonstrated by using a strong salting‐out agent (i.e., NH₄F), thereby expanding the composition of NMAs to various multimetallic systems and providing a platform to investigate composition‐dependent electrocatalytic performance of NMAs. Combining structural features of aerogels and optimized chemical compositions, the Au–Pt and Au–Rh aerogel catalysts manifest remarkable pH‐universal (pH = 0–14) performance surpassing commercial Pt/C and many other nanoparticle (NP)‐based catalysts in the electrocatalytic oxygen reduction reaction, hydrogen evolution reaction, and water splitting, displaying enormous potential for the electrochemical hydrogen production, fuel cells, etc.     

Synergistically Tuning Water and Hydrogen Binding Abilities Over Co4N by Cr Doping for Exceptional Alkaline Hydrogen Evolution Electrocatalysis

Searching for highly efficient and cost‐effective electrocatalysts toward the hydrogen evolution reaction (HER) in alkaline electrolyte is highly desirable for the development of alkaline water splitting, but still remains a significant challenge. Herein, the rational design of Cr‐doped Co₄N nanorod arrays grown on carbon cloth (Cr–Co₄N/CC) that can efficiently catalyze the HER in alkaline media is reported. It displays outstanding performance, with the exceptionally small overpotential of 21 mV to obtain the current density of 10 mA cm^?2 and good stability in 1.0 m KOH, which is even better than the commercial Pt/C electrocatalyst, and much lower than most of the reported transition metal nitride‐based and other non‐noble metal‐based electrocatalysts toward the alkaline HER. Density functional theory (DFT) calculations and experimental results reveal that the Cr atoms not only act as oxophilic sites for boosting water adsorption and dissociation, but also modulate the electronic structure of Co₄N to endow optimized hydrogen binding abilities on Co atoms, thereby leading to accelerating both the alkaline Volmer and Heyrovsky reaction kinetics. In addition, this strategy can be extended to other metals (such as Mo, Mn, and Fe) doped Co₄N electrocatalysts, thus may open up a new avenue for the rational design of highly efficient transition metal nitride‐based HER catalysts and beyond.     

Activity Restoration of Pt–Ni Octahedron via Phase Recovery for Anion Exchange Membrane-Unitized Regenerative Fuel Cells

Unitized regenerative fuel cells (URFCs) offer a cost-effective solution for energy conversion by functioning as both fuel cells and electrolyzers. Anion-exchange membrane-based URFCs (AEM-URFCs) require bifunctional electrocatalysts, such as Pt–Ir alloys, for the oxygen evolution reaction (water electrolysis mode) and oxygen reduction reaction (fuel cell mode). However, the low stability of Pt in alkaline media and the high cost of Ir remain challenges for the widespread application of these URFCs. In this study, a Pt–Ni octahedral alloy is synthesized to replace Ir with Ni as the oxygen evolution reaction catalyst. The alloying effect of Pt–Ni inhibits the dissolution of Pt and transforms PtOx to metallic Pt via a recovery process, thereby providing a new operational strategy for improving the durability of AEM-URFCs. Remarkably, the performance of the AEM-URFC single cell is maintained over ten cycles after the recovery process, demonstrating the viability of this approach for long-term operations. These findings pave the way for broader applications and advancements of AEM-URFCs.     

Recent Development of Zeolitic Imidazolate Frameworks (ZIFs) Derived Porous Carbon Based Materials as Electrocatalysts

Development of effective, stable, and economic electrocatalysts is critical for further implementation of fuel cells, water electrolysis, and metal–air batteries in clean energy conversion technologies. As a subfamily of metal–organic frameworks (MOFs), zeolitic imidazolate frameworks (ZIFs) possess the characteristics of both MOFs and zeolites, showing highly porous structures, large surface area, and open catalytic active sites. This review presents materials design strategies for constructing improved electrocatalysts based on ZIF precursors/templates, with special emphasis on the varieties of derivatives, controllable building of active sites, the construction of macroscopic structure, and the favored electrocatalytic reactions based on these materials. These ZIF‐derived N‐doped carbon‐based composites or compounds have exhibited remarkable activity and stability for a broad electrocatalysis application, displaying great potential to replace noble‐metal‐based catalysts. The challenges and perspectives regarding ZIF‐derived electrocatalysts are also discussed for better development of ZIF‐derived electrocatalysts.     

The Space Confinement Approach Using Hollow Graphitic Spheres to Unveil Activity and Stability of Pt‐Co Nanocatalysts for PEMFC

The performance of polymer electrolyte fuel cells is strongly correlated to the electrocatalytic activity and stability. In particular, the latter is the result of an interplay between different degradation mechanisms. The essential high stability, demanded for real applications, requires the synthesis of advanced electrocatalysts that withstand the harsh operation conditions. In the first part of this study, the synthesis of oxygen reduction electrocatalysts consisting of Pt‐Co (i.e., Pt₅Co, Pt₃Co, and PtCo) alloyed nanoparticles encapsulated in the mesoporous shell of hollow graphitic spheres (HGS) is reported. The mass activities of the activated catalysts depend on the initial alloy composition and an activity increase on the order of two to threefold, compared to pure Pt@HGS, is achieved. The key point of the second part is the investigation of the degradation of PtCo@HGS (showing the highest activity). Thanks to pore confinement, the impact of dissolution/dealloying and carbon corrosion can be studied without the interplay of other degradation mechanisms that would induce a substantial change in the particle size distribution. Therefore, impact of the upper potential limit and the scan rates on the dealloying and electrochemical surface area evolution can be examined in detail.     

Sb‐Doped SnO2 Hollow Spheres Offering Micro‐ and Nanoporosity in Fuel Cell Electrode Structures

Sb‐doped SnO₂ (ATO) is used as an alternative support material to replace carbon in the highly corrosive environment of a fuel cell cathode. Two ATO powders with different morphologies are decorated with Pt nanoparticles and afterwards used as the cathode catalyst. The commercial ATO powder exhibits crystallites in the nanometer range, while the home‐made ATO powder, which was synthesized by ultrasonic spray pyrolysis, consists of polycrystalline hollow spheres. The spheres have diameters in the micrometer range and are composed of individual nanocrystallites. The unusual morphology of the home‐made ATO offers nano‐ and microporosity at the same time and opens up new possibilities for the controlled design of electrode structures in low‐temperature polymer electrolyte fuel cells. Both materials are characterized by XRD, SEM, and TEM and tested in a single cell set‐up. While almost no current is gained from the membrane electrode assembly with the commercial ATO support, the cell with the home‐made ATO achieves a mediocre performance. This higher activity, however, is obtained with approximately half the Pt content compared to the catalyst with the commercial support. The different behaviours of both ATO powders can therefore mainly be attributed to differences in the specific support morphology.     

Development of Highly Stable and Mass Transfer‐Enhanced Cathode Catalysts: Support‐Free Electrospun Intermetallic FePt Nanotubes for Polymer Electrolyte Membrane Fuel Cells

Proton exchange membrane fuel cells (PEMFCs) are an alternative clean energy source and they are attracting increased attention. However, several limitations such as degradation of the carbon support and Nafion ionomer in the cathode electrode must be overcome for practical applications of PEMFCs. Support‐free 1D‐ordered intermetallic nanotubes (NTs) are considered as promising candidates for highly active and durable cathode catalysts in PEMFCs. However, 1D nanotubes are difficult to produce at large scale because they have generally been synthesized using a template‐based method that requires multistep synthetic routes. Herein, a simple and scalable method to produce ordered‐intermetallic FePt nanotubes by electrospinning is reported. When tested as cathode catalysts, under the US Department of Energy's reference condition, the activity of face‐centered‐tetragonal (fct) FePt NTs surpasses that of commercial Pt/C. In an accelerated degradation test at 1.4 V for 3 h, the degradation activity rate of fct‐FePt NTs is only 10%, whereas that of commercial Pt/C catalysts is 65%. For practical PEMFCs, this approach would provide simple routes to support‐free intermetallic nanotube structures with superior kinetic activity and higher durability than those of commercial Pt/C catalyst.