Methods and compositions for making fuel cell components are described. In one embodiment, the method comprises providing a substrate, and forming or adhering an electrode on the substrate, wherein the forming includes depositing an aqueous mixture comprising water, a water-insoluble component, a catalyst, and an ionomer. The water-insoluble component comprises a water-insoluble alcohol, a water-insoluble carboxylic acid, or a combination thereof. The use of such water-insoluble components results in a stable liquid medium with reduced reticulation upon drying, reduced dissolution of the substrate, and reduced penetration of the pores of the substrate.

An electrochemical electrode comprising a tin-based catalyst, method of making, and method of use are provided. Catalyst particles are prepared which comprise tin deposits of about 0.1 nm to about 10 nm deposited onto carbon support. Preparing an ink comprising the catalyst particles and a binder enable an electrode to be prepared comprising the catalyst particles bound to an electrode substrate. The electrode may then be used in an apparatus and process to reduce carbon dioxide to products such as formate and formic acid at Faradaic Efficiencies up to 95 percent.

Provided is a catalytically active particle comprising an alloy, said alloy comprising: greater than or equal to 50 atomic % ruthenium (Ru); and 1 to 50 atomic % of one or more transition metals (M) selected from cobalt (Co), nickel (Ni), and iron (Fe), wherein the sum of the atomic percentages of Ru and M is greater than 65 atomic % of the alloy, and wherein, in the particle, the alloy is not fully or partially encapsulated by a layer of platinum atoms. Devices and processes employing the catalytically active particle are also provided.

The present invention is a carbon material for a catalyst carrier of a polymer electrolyte fuel cell, which has a three-dimensional dendritic structure, and simultaneously satisfies the following (A), (B), and (C). (A) By a laser Raman spectroscopic analysis with a wavelength of 532 nm, a standard deviation δ(R) of an intensity ratio (R value) of an intensity of a D-band (near 1360 cm.sup.−1) to an intensity of a G-band (near 1580 cm.sup.−1) measured with a beam diameter of 1 μm at 50 measurement points is from 0.01 to 0.07. (B) A BET specific surface area S.sub.BET is from 400 to 1520 m.sup.2/g. (C) A nitrogen gas adsorption amount V.sub.N:0.4-0.8 during a relative pressure (p/p.sub.0) from 0.4 to 0.8 is from 100 to 300 cc(STP)/g. A method of producing such a carbon material for a catalyst carrier is also included.

A nanocarbon material aggregate excellent as a catalyst in an electrochemical reaction can be provided. The present invention relates to a nanocarbon material aggregate, comprising: a fibrous carbon nanohorn aggregate constituted by a plurality of carbon nanohorns including a carbon nanohorn having a hole-opening; and a first particle encapsulated in the carbon nanohorn having a hole-opening and partially exposed to the outside from the carbon nanohorn.

A method for producing a noble metal-free catalyst comprises providing a catalyst support comprising organic heterocycles as catalyst, and applying an oxidation-inhibiting protective layer. Embodiments further relate to a noble metal-free catalyst, a fuel cell, and a motor vehicle.

A porous carbon-based metal catalyst, a preparation method and application thereof are provided. The preparation method includes: successively performing activation, surface corrosion, nitrogen-doping treatment and graphitization treatment on washed micro-grade porous carbon, then performing sensitization treatment, and subsequently carrying out loading, reduction and other treatments of catalytic metal, so as to finally obtain the porous carbon-based metal catalyst. The porous carbon-based metal catalyst provided by the present application has excellent catalytic performance, is especially suitable for producing hydrogen by efficiently catalytically decomposing ammonia borane, is not prone to inactivation, and is easy to regenerate after inactivation. Meanwhile, the preparation method is environmental-friendly, is suitable for large-scale production and has a wide application prospect in the fields such as hydrogen fuel batteries.

Prussian blue analog derived catalysts having a composition of highly porous transition metal (“TM”) oxides with nano particle size. Such OER catalysts are synthesized from the PBA, containing cobalt, iron, nickel, copper, manganese, zinc, magnesium etc., as secondary building units (“SBUs”) coordinated by hexacyano-based ligands. Furthermore, the PBA-derived catalysts may also integrated into a highly graphitized carbon network to further improve the conductivity, mass transport and durability against oxidative corrosion.

Improved catalyst layers for use in fuel cell membrane electrode assemblies, and methods for making such catalyst layers, are provided. Catalyst layers can comprise structured units of catalyst, catalyst support, and ionomer. The structured units can provide for more efficient electrical energy production and/or increased lifespan of fuel cells utilizing such membrane electrode assemblies. Catalyst layers can be directly deposited on exchange membranes, such as proton exchange membranes.

A membrane electrode assembly (MEA) includes a membrane, a cathode catalyst layer, a cathode co-catalyst layer including a hydrogen reservoir, an anode catalyst layer, and an anode co-catalyst layer including a hydrogen reservoir. The anode co-catalyst layer and the cathode co-catalyst layer cap a cathode potential at lower than 1.5V and an anode potential at lower than 1.0V. The anode co-catalyst layer and the cathode co-catalyst layer can include a platinum doped rare earth oxide, such as platinum doped cerium oxide.