A fuel cell catalyst material includes metal catalyst particles formed of a metal material and a carbon-based coating composition at least partially coating at least some of the metal catalyst particles. The carbon-based coating composition includes a carbon network. The carbon-based coating composition is doped with a dopant. The carbon-based coating composition includes a number of defects formed by one or more vacated carbon atoms in the carbon network. The carbon-based coating composition is made from a non-aromatic carbon molecule.

A process for preparing a catalyst material, said catalyst material comprising a support material, a first metal and one or more second metals, wherein the first metal and the second metal(s) are alloyed and wherein the first metal is a platinum group metal and the second metal(s) is selected from the group of transition metals and tin provided the second metal(s) is different to the first metal is disclosed. The process comprises depositing a silicon oxide before or after deposition of the second metal(s), alloying the first and second metals and subsequently removing silicon oxide. A catalyst material prepared by this process is also disclosed.

A catalyst comprising a functionalized substrate having a first charged functional group, a metal dispersed on the substrate, wherein the metal comprises at least one of Pt, Rh, Pd, Ag, Au, Ni, Os, Ir, Mn, Co, alloys thereof, oxides thereof, or mixtures thereof, and an ionomer are disclosed. Methods manufacturing a functionalized catalyst comprising catalyzing a substrate with a metal, functionalizing the catalyzed substrate with a first charged functional group, and add an ionomer to the loaded functionalized catalyst are also disclosed. Also, methods comprising catalyzing a substrate with a metal, functionalizing the substrate with a first charged functional group, and adding an ionomer to the loaded functionalized catalyst are disclosed.

A cathode, a membrane electrode assembly, and a battery, each has excellent durability. The cathode is a cathode of a battery including an electrolyte membrane, the cathode including: a first layer which contains 0.3 mg/cm.sup.2 or more and 9.0 mg/cm.sup.2 or less of a carbon catalyst; and a second layer which is arranged between the electrolyte membrane and the first layer in the battery, and which contains 0.002 mg/cm.sup.2 or more and 0.190 mg/cm.sup.2 or less of platinum.

Provided herein are catalyst materials comprising a catalyst support; and PtM′ nanowires affixed to the catalyst support, wherein the PtM′ nanowires include single atomic species of M′ at exterior surfaces of the PtM′ nanowires, and M′ represents at least one metal, e.g., a metal different from Pt. Also disclosed are manufacturing methods comprising: providing initial MM′ nanowires having an initial molar ratio of M:M′, wherein M is a noble metal, and M′ is a metal different from M; subjecting the initial MM′ nanowires to electrochemical dealloying to partially remove M′ and form partially dealloyed MM′ nanowires having a subsequent molar ratio of M:M′, wherein the subsequent molar ratio of M:M′ is greater than the initial molar ratio of M:M′; and affixing the partially dealloyed MM′ nanowires to a catalyst support.

Disclosed are single atom dispersions and multi-atom dispersions, and systems and methods for synthesizing the atomic dispersions. An exemplary method of synthesizing atomic dispersions includes: positioning a loaded substrate which includes a substrate in which is loaded with at least one of: a precursor of an element or a cluster of an element, applying one or more temperature pulses to the loaded substrate where a pulse of the temperature pulse(s) applies a target temperature for a duration, maintaining a cooling period after the pulse, and providing single atoms of the element dispersed on the substrate after the one or more temperature pulses. The target temperature applied by the pulse is between 500 K and 4000 K, inclusive, and the duration is between 1 millisecond and 1 minute, inclusive.

Provided is a highly reliable fuel cell that improves power generation efficiency of the fuel cell and that is less likely to cause damage to an electrode and an electrolyte film. The fuel cell includes a support substrate (2, 3) having a region in which a support portion having a mesh-like shape in a plan view is provided, a first electrode 4 on the support substrate, an electrolyte film 5 on the first electrode, and a second electrode 6 on the electrolyte film. The first electrode includes a first thin film electrode 4A formed in a manner of covering at least the region, and a first mesh-like electrode 4B connected to the first thin film electrode and provided corresponding to the support portion. The first mesh-like electrode 4B has a film thickness larger than that of the first thin film electrode and has a mesh-like shape in a plan view.

A method of forming a fuel cell catalyst system, the method includes providing an anticorrosive, conductive catalyst support material having oxygen vacancies and a formula (I):
MgTi.sub.2O.sub.5-δ  (I),
where .sub.δ is any number between 0 and 3 optionally including a fractional part denoting the oxygen vacancies, coating the catalyst support material with a polymeric film, attaching a catalyst material onto the polymeric film, removing the polymeric film, and providing additional material onto the support material to increase physical, electrical, and/or mechanical contact between the catalyst material and the catalyst support material.

A fuel cell electrode catalyst includes catalyst metal particles and electrically conductive support particles supporting the catalyst metal particles. In the fuel cell electrode catalyst, a proportion of a surface area occupied by the catalyst metal particles with particle sizes of 4.5 nm or less to a surface area of the catalyst metal particles calculated from a transmission electron microscope image is 5% or less.

The present disclosure relates to a fuel cell catalyst, a fuel cell electrode including the same, and a membrane-electrode assembly including the same. In one embodiment, the fuel cell catalyst includes: a support including a titanium oxynitride represented by the following Formula 1: TiO.sub.1-yN.sub.y, wherein 0.05<y<0.9; and an active material supported on the support.