CARBON SUPPORTS, CATALYSTS, MEMBRANE ELECTRODE ASSEMBLIES, POLYMER ELECTROLYTE MEMBRANE FUEL CELLS, AND RELATED METHODS
20240413354 ยท 2024-12-12
Inventors
Cpc classification
Y02E60/50
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
H01M4/8817
ELECTRICITY
H01M2250/20
ELECTRICITY
International classification
Abstract
A method of forming a catalyst on a catalyst support, combination of catalysts and carbon supports produced thereby, and applications therefor, including catalyst layers, electrodes, membrane electrode assemblies (MEAs), polymer electrolyte membrane fuel cells, and vehicles. Such a method includes guiding ions of a precursor of a catalyst to land uniformly on an NH.sub.2-modified surface of a catalyst support, and depositing fine monodisperse nanoparticles on the NH.sub.2-modified surface. Ultrafine noble metal-transitional metal intermetallic nanoparticles (e.g., PtM) can be directly synthesized on catalyst supports (e.g., carbon supports). Noble metal nanoparticles (e.g., Pt) are monodispersed on a catalyst support through electrostatic attraction established between a precursor of the intermetallic nanoparticles and protonated ammonium ions (NH.sub.3.sup.+) immobilized over surfaces of the catalyst support. The monodisperse noble metal nanoparticles are then used as seeds to form the intermetallic nanoparticles.
Claims
1. A method of forming a catalyst on a catalyst support, the method comprising: guiding ions of a precursor of the catalyst to land uniformly on an NH.sub.2-modified surface of the catalyst support; and depositing fine monodisperse nanoparticles on the NH.sub.2-modified surface with the ions of the precursor thereon.
2. The method of claim 1, further comprising: heat treating the fine monodisperse nanoparticles to form intermetallic nanoparticles of the catalyst.
3. The method of claim 2, wherein the intermetallic nanoparticles have an intermetallic core and one or more atomic noble metal layers over the intermetallic core.
4. The method of claim 2, wherein the intermetallic nanoparticles comprise noble metal atoms.
5. The method of claim 2, wherein the intermetallic nanoparticles comprise transition metal atoms.
6. The method of claim 2, wherein the intermetallic nanoparticles contain platinum and at least one of cobalt, nickel, iron, and zinc.
7. The method of claim 1, wherein in the step of guiding, the ions of the precursor and protonated ammonium ions (NH.sub.3.sup.+) on the NH.sub.2-modified surface have opposite charges resulting in a strong electrostatic attraction therebetween.
8. The method of claim 1, wherein the fine monodisperse nanoparticles have an average size of less than 2 nm.
9. The method of claim 8, wherein the fine monodisperse nanoparticles have an average size of 1.50.3 nm.
10. The method of claim 1, wherein the fine monodisperse nanoparticles are present on the NH.sub.2-modified surface of the catalyst support and within mesopores in the NH.sub.2-modified surface of the catalyst support.
11. The method of claim 1, wherein the ions of the precursor are Pt complex ions.
12. The method of claim 1, wherein the catalyst support is a carbon support.
13. The method of claim 1, further comprising: treating the catalyst support to form the NH.sub.2-modified surface thereon.
14. The method of claim 13, wherein treating the catalyst support comprises treating the catalyst support with a source of p-benzene amino (NH.sub.2) groups.
15. The method of claim 13, wherein the catalyst support contains micropores prior to being treated, and wherein treating the catalyst support decreases the specific volume of the micropores.
16. The combination catalyst and catalyst support formed by the method of claim 1.
17. A catalyst layer comprising the combination catalyst and catalyst support formed by the method of claim 1.
18. An electrode comprising the catalyst layer of claim 17.
19. A membrane electrode assembly comprising the electrode of claim 18.
20. A polymer electrolyte membrane fuel cell comprising the membrane electrode assembly of claim 19.
21. A vehicle comprising the polymer electrolyte membrane fuel cell of claim 20 installed in the vehicle.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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[0020]
DETAILED DESCRIPTION OF THE INVENTION
[0021] The intended purpose of the following detailed description of the invention and the phraseology and terminology employed therein is to describe what is shown in the drawings, which include the depiction of and/or relate to one or more nonlimiting embodiments of the invention, and to describe certain but not all aspects of what is depicted in the drawings, including the embodiment(s) to which the drawings relate. The following detailed description also describes certain investigations relating to the embodiment(s) depicted in the drawings, and identifies certain but not all alternatives of the embodiment(s) depicted in the drawings. As nonlimiting examples, the invention encompasses additional or alternative embodiments in which one or more features or aspects shown and/or described as part of a particular embodiment could be eliminated, and also encompasses additional or alternative embodiments that combine two or more features or aspects shown and/or described as part of different embodiments. Therefore, the appended claims, and not the detailed description, are intended to particularly point out subject matter regarded to be aspects of the invention, including certain but not necessarily all of the aspects and alternatives described in the detailed description.
[0022] Nonlimiting aspects and embodiments of the invention are described below in reference to experimental investigations leading up to the invention. The investigations involved the preparation of ultrafine (sub-3 nm) L1.sub.0-PtCo intermetallic nanoparticles supported on NH.sub.2-modified electroconductive carbon black, abbreviated herein as PtCo/KBNH.sub.2. The PtCo/KBNH.sub.2 exhibited excellent ORR activity and durability, originating from a favorable structure of Pt layers of about 2 to 3 atoms formed over a L1.sub.0-PtCo core. Benefitting from the high accessibility of PtCo/KBNH.sub.2 nanoparticles, MEA produced therewith delivered enhanced Pt utilization and lower mass transport resistance, resulting in breakthrough fuel cell performance. While the investigations reported below were directed to PtCo/KBNH.sub.2 structures, it will be appreciated that the teachings of the invention may also be generally applicable to the creation of catalyst supports on which catalyst nanoparticles are supported, including other PtM intermetallics and carbon supports for various applications, including but not limited to electrolyzers and other energy conversion and storage devices. Such carbon supports may include, but are not limited to, carbon blacks with high structure and low structure, graphites, graphenes, and other carbon support materials.
[0023] The present application discloses, among other aspects, a new method of synthesizing platinum alloy catalysts (including PtCo, PtNi, PtFe, PtZn, etc.) with the ordering intermetallic structure. The methods can result in uniformly distributing accessible ultrafine PtM intermetallic nanoparticles on carbon supports. In some nonlimiting aspect, the method includes using NH.sub.2 functionalized carbon support to synthesize Pt based intermetallic catalysts in order to achieve (1) the guided landing of Pt precursor ions to form uniformly distributed Pt seeds over the carbon surface. This guided landing helps later-formed Pt based intermetallic catalyst nanoparticles to realize uniform particle distribution. The method may also achieve (2) engineering the pore structure of the carbon support to fill the micropores so that all Pt based nanoparticles will be on the external surface of carbon support as well as in the mesopores. The method can cause the resulting ordered intermetallic Pt alloy catalyst nanoparticles to be completely accessible for oxygen, which, in turn, significantly increases the mass activity, ECSA, power density of the catalyst in both a RDE and a MEA.
[0024] In some nonlimiting aspects, methods are disclosed herein for directly synthesizing highly accessible sub-3 nm L1.sub.0-PtM intermetallic nanoparticles on carbon supports. The synthesis of such L1.sub.0-PtM intermetallic nanoparticles uses monodisperse Pt nanoparticles supported on NH.sub.2-modified carbon as seeds, which is achieved through a strong electrostatic attraction established between the Pt-precursor (PtCl.sub.6.sup.2) and protonated ammonium ions (NH.sub.3.sup.+) immobilized over carbon surfaces. The NH.sub.2 modification tailors the pore structure of carbon supports, enabling the deposition of L1.sub.0-PtM intermetallic nanoparticles mainly in the opened mesopores of carbon surfaces, which are highly accessible to reactants of oxygen and protons in MEAs. In some nonlimiting examples, sub-3 nm L1.sub.0-PtCo nanoparticles supported on NH.sub.2-modified ketjenblack (PtCo/KBNH.sub.2) prepared using this method exhibited excellent ORR activity and durability, which it is believed originated from the favorable structure of 23 atomic Pt layers formed over the L1.sub.0-PtCo core. Benefitting from the high accessibility of PtCo/KBNH.sub.2 nanoparticles, the MEA delivered enhanced Pt utilization and lowered mass transport resistance, resulting in breakthrough fuel cell performance.
[0025] Various materials and chemicals utilized in the investigations are generally summarized as follows. Materials used included Ketjenblack (KB) carbon black EC300J (AkzoNobel Surface Chemistry), Vulcan (VC) XC-72 (Cabot Corporation), phenylenediamine (97%, Alfa Aesar) as a source of p-benzene amino (NH.sub.2) groups, chloroplatinic acid hexahydrate (H.sub.2PtCl.sub.6.Math.6H.sub.2O, 38-40% Pt, Strem Chemicals) as a platinum (Pt) precursor, anhydrous cobalt chloride (CoCl.sub.2, 97%, Thermo Scientific) as a cobalt (Co) precursor, sulfuric acid (ACS reagent grade, Sigma-Aldrich), sodium nitrite (NaNO.sub.2, 98%, Alfa Aesar), deionized water (18.2 M.Math.cm), filtration membrane (0.025 m, Millipore Corporation), ethylene glycol (certified grade, Fisher Chemical), n-propanol (certified ACS, Fisher Scientific), ionomer solution (NAFION D520, Ion Power), ionomer solution (720 EW, Aquivion D72-25BS), Gore membrane (15 m, M820.15), NAFION membrane (NR211, Ion Power), 46.4 wt. % Pt/C (TEC10E50E, Tanaka Kikinzoku Kogyo), 30 wt. % Pt/C (Jiping New Energy), and gas diffusion layers (Sigracet 22BB, SGL Global).
[0026] The investigations evaluated amino (NH.sub.2) surface modifications (NH.sub.2-modified) to carbon supports (hereinafter sometimes referred to as an NH.sub.2-modified carbon support, or simply NH.sub.2-modified carbon). For these nonlimiting investigations, the NH.sub.2-modified carbon supports were prepared using a diazonium reaction method. Briefly, 100 mg KB or 300 mg VC was dispersed into 100 mL of deionized water, followed by the addition of 56 mg phenylenediamine and 30 L of concentrated sulfuric acid. After sonication for 30 minutes, 36 mL of a 1.0 mg.Math.mL.sup.1 NaNO.sub.2 aqueous solution were added dropwise into the suspension above. The reaction product was collected after magnetic stirring for 16 hours at 60 C. by filtering using deionized water on a 0.025 m filtration membrane. The resulting carbon was dried in a vacuum oven at 65 C. for 12 hours and then ground in an agate mortar. The amount of phenylenediamine introduced was calculated based on the surface area of carbon supports, and an excess of phenylenediamine was used to ensure maximum surface coverage of p-benzene-NH.sub.2 on the carbon supports.
[0027] For use in the nonlimiting investigations, Pt/KBNH.sub.2, PtCo/KBNH.sub.2, PtCo/KB, and traditional PtCo/KB (prepared without seed mediation and carbon modification) were synthesized as outlined below.
[0028] Pt/KBNH.sub.2 was synthesized by depositing Pt nanoparticles on NH.sub.2-modified KB (KBNH.sub.2) by reducing a Pt-precursor in an ethylene glycol aqueous solution (60 vol. % EG/40 vol. % H.sub.2O). Briefly, KBNH.sub.2 was dispersed in the ethylene glycol aqueous solution, followed by the addition of a certain amount of H.sub.2PtCl.sub.6.Math.6H.sub.2O used as the Pt precursor. The suspension was refluxed at 140 C. for 6 hours, then filtrated with deionized water and ethanol. Finally, Pt/KBNH.sub.2 was obtained after drying the product at 65 C. for 12 hours in a vacuum oven. For comparison, Pt/KB was also prepared using the same procedure, except that unmodified KB was used as support material. The nominal Pt loading was set at 8.0 wt. %, and the detailed loading was determined using thermogravimetric analysis (TGA).
[0029] PtCo/KBNH.sub.2 was synthesized by initially dispersing 100 mg of 8.0 wt. % Pt/KBNH.sub.2 in 50 mL of deionized water, followed by adding 0.077 mmol of H.sub.2PtCl.sub.6.Math.6H.sub.2O and 0.153 mmol of CoCl.sub.2 used as the Co precursor. After sonication for 30 minutes, the suspension was then subjected to magnetic stirring at 60 C. until the water fully evaporated to form a thick slurry. The slurry was dried in a vacuum oven at 65 C. for 12 hours and then ground in an agate mortar. The grounded powder was heated in a tube furnace at 400 C. for 2 hours and then at 650 C. for another 6 hours under flowing forming gas (5 vol. % H.sub.2/95 vol. % Ar). The heating rate was maintained at 8 C.Math.min.sup.1. The product was then treated in a 0.1 mol.Math.L.sup.1 HClO.sub.4 solution at 60 C. for 6 hours in air, followed by a heat treatment at 400 C. for 1 hour under flowing forming gas. The Pt loading for PtCo/KBNH.sub.2 was determined to be 24.0 wt. % using inductively coupled plasma atomic emission spectroscopy (ICP-AES).
[0030] PtCo/KB was synthesized by initially dispersing 100 mg of 8.0 wt. % Pt/KB in 50 mL of deionized water, followed by the addition of 0.128 mmol of H.sub.2PtCl.sub.6.Math.6H.sub.2O and 0.220 mmol of CoCl.sub.2, and then the same subsequent procedure as that described above for synthesizing PtCo/KBNH.sub.2. The Pt loading for PtCo/KB was determined to be 23.5 wt. % using ICP-AES.
[0031] As noted above, traditional PtCo/KB was prepared utilizing a traditional impregnation method without seed mediation and carbon modification. The method entailed initially dispersing 85 mg KB in 50 mL of deionized water, followed by the addition of 0.154 mmol of H.sub.2PtCl.sub.6.Math.6H.sub.2O and 0.201 mmol of CoCl.sub.2, and then the same subsequent procedure as that described above for synthesizing PtCo/KBNH.sub.2. The Pt loading of PtCo/KB-traditional was determined to be 24.6 wt. % using ICP-AES.
[0032]
[0033] For the subsequent Pt deposition, a modified ethylene glycol (EG) method was employed. The Pt complex ions (PtCl.sub.6.sup.2) 26 of the Pt precursor (H.sub.2PtCl.sub.6.Math.6H.sub.2O) in the EG aqueous solution and protonated ammonium ions (NH.sub.3) 28 on the KBNH.sub.2 surface exhibited opposite charges, resulting in a strong electrostatic attraction. Apparently, this attraction guided the Pt complex ions 26 to land uniformly on the NH.sub.2-modified carbon surface, enabling the deposition of fine monodisperse Pt nanoparticles 30 on the KBNH.sub.2 (
[0034] To obtain L1.sub.0-PtCo intermetallic nanoparticles supported on KBNH.sub.2, the Pt/KBNH.sub.2 was impregnated with the previously-noted Pt and Co precursors followed by heat treatment (annealing) under a forming gas atmosphere. The uniform and fine Pt nanoparticles on KBNH.sub.2 served as seeds to guide the impregnation (deposition) of the Pt and Co precursors and the subsequent formation/growth of PtCo alloy nanoparticles and the formation/growth of PtCo intermetallic nanoparticles following heat treatment. The formation and structure evolution of L1.sub.0-PtCo intermetallic nanoparticles during the heat treatment were investigated using in-situ synchrotron high energy X-ray diffraction (SHEXRD), which could be divided into three stages based on the heat treatment (annealing) process. The first stage was a heating process from room temperature to 400 C., which clearly revealed the reduction of the Co and Pt precursors (respectively, CoCl.sub.2.Math.2H.sub.2O and H.sub.2PtCl.sub.6.Math.6H.sub.2O), accompanied by slight alloying (the positive shifting of (111), (200), (220), and (311) peaks). The second stage was a two-hour hold at 400 C., which corresponded to further alloying as the Co atoms continuously diffused into the Pt fcc lattice. For the third stage, the heat treatment temperature was increased to 650 C., during which the characteristic peaks of the L1.sub.0-PtCo structure gradually appeared, accompanied by further alloying. The intensity of peaks indexed to (001), (110), and (201) planes for the L1.sub.0-PtCo structure gradually increased with heating time, which was attributed to the gradual structure transformation from a disordered PtCo alloy to an atomically ordered L1.sub.0-PtCo intermetallic. Although the presence of NH.sub.2 groups may improve the uniformity of ionomer distribution within the catalyst layers, their stability has been demonstrated to be insufficient to withstand harsh fuel cell testing conditions, resulting in decreased durability. The NH.sub.2 groups on the carbon surface were decomposed during the high-temperature heat treatment, as evidenced by the disappearance of the XPS N 1 s peak in the PtCo/KBNH.sub.2 in the XPS N 1 s spectra, which may be beneficial to maintain the durability of L1.sub.0-PtCo intermetallic nanoparticles.
[0035] To ensure the formation of the L1.sub.0-PtCo structure, a slight excess of the Co precursor was introduced during the impregnation step. After 6 hours at the heat treatment temperature of 650 C., a post acid treatment was performed to remove excess metallic Co on the carbon surface. Based on ICP-AES analyses, the Pt loading of the resulting PtCo/KBNH.sub.2 was determined to be 24.0 wt. %. As shown in
[0036] The location of Pt nanoparticles relative to the internal or external surfaces of a carbon support is known to affect the MEA performance of Pt/C catalysts. The Pt nanoparticles on the external surfaces of carbon supports are readily accessible to reactants of oxygen and protons, which is beneficial to maximizing the catalyst/ionomer interface and lowering the mass transport resistance in the catalyst layer. To understand the distribution of PtCo intermetallic nanoparticles on the internal and external surfaces of the carbon supports, scanning transmission electron microscopy (STEM) was used to simultaneously acquire secondary electron (SE) and high-angle annular dark-field (HAADF) images, as shown in
[0037] Atomic resolution STEM was employed to investigate the detailed structure of PtCo/KBNH.sub.2 nanoparticles. A representative PtCo intermetallic nanoparticle is illustrated in
[0038] The ORR performances of PtCo/KBNH.sub.2 and PtCo/KB catalysts were investigated using RDE technique in 0.1 mol.Math.L.sup.1 HClO.sub.4 electrolytes. For comparison, one of the most active commercial Pt/C catalysts (TEC10E50E, Tanaka Kikinzoku Kogyo) was also tested under the same conditions. As shown by CV curves in
[0039] For ORR polarization curves (
[0040] To understand the excellent activity and durability of PtCo/KBNH.sub.2, X-ray photoelectron spectroscopy (XPS) and X-ray adsorption spectroscopy (XAS) were employed to characterize these catalysts. As illustrated by XPS results (
[0041] The enhanced resistance against Pt oxidation agreed well with observations from the CV curves (
[0042] To gain a deep insight into the ORR reactivity of PtCo/KBNH.sub.2, density functional theory (DFT) calculations were performed to simulate a 2.6 nm sized L1.sub.0-PtCo@Pt.sub.3L (3 atomic Pt layers over a L1.sub.0-PtCo core) nanoparticle using a semispherical model (right insets in
[0043] To separate the influence of ligand effect and strain effect on E.sub.OH*, the same 3.42% compressive strain was applied to the Pt (111) surface. The E.sub.OH* varied dramatically from 1.401 eV on unstrained Pt (111) to 1.188 eV on 3.42% strained Pt (111), going from too strong to too weak compared to the theoretical optimum value, which indicated that the strain-induced variation reached as high as 0.213 eV. Additionally, the strain is positively correlated with E.sub.OH* on Pt (111) and L1.sub.0-PtCo@Pt.sub.3L (111); that is, the increased strain resulted in higher E.sub.OH*. Due to the presence of Co atoms deep in the core structure, the influence of the ligand effect on E.sub.OH* was subtle but not negligible compared to the strain effect. The E.sub.OH* on L1.sub.0-PtCo@Pt.sub.3L (111) was 0.053 eV lower than that on Pt (111) if the same 3.42% compressive strain is applied, indicating that the presence of the L1.sub.0-PtCo core (ligand effect) brings the E.sub.OH* closer to the theoretical optimum value. The synergy between strain and ligand effects tuned E.sub.OH* to a just-right level for optimum ORR activity, which explained the excellent activity of PtCo/KBNH.sub.2 from a theoretical point of view.
[0044] Translating the excellent ORR activity into fuel cell performance remains a great challenge because of the insufficient Pt utilization and mass transport in the MEAs for traditional high-active Pt-based catalysts. Membrane electrode assembly (MEA) performance using PtCo/KBNH.sub.2 as the cathode catalyst was examined and compared with that using PtCo/KB and commercial Pt/C. THE MEA was fabricated by ultrasonically spraying cathode/anode catalyst inks onto a 15 m membrane (Gore M820.15) using an ExactCoat spray coating system (Sono-Tek, NY). The as-prepared PtCo/KBNH.sub.2, PtCo/KB, or commercial 46.4 wt. % Pt/C (TEC10E50E, Tanaka Kikinzoku Kogyo) was dispersed into an n-propanol aqueous solution (10 wt. % n-PA/90 wt. % H.sub.2O) with the ionomer solution (Aquivion D72-25BS, 720 EW) as cathode catalyst ink. The solid content was 2.0 mg.Math.mL.sup.1, and weight ratios of ionomer/carbon (I/C) for PtCo/KBNH.sub.2 and PtCo/KB were controlled to be 0.50 and 0.60, respectively. Commercial 30 wt. % Pt/C (Jiping New Energy) was used as an anode catalyst with an I/C ratio of 0.4 5. All catalyst inks were homogenized using an ultrasonic bath for 30 minutes and a sonic dismembrator for 4 minutes. Catalyst coated membranes (CCMs) were sandwiched between two gas diffusion layers without hot pressing.
[0045] In H.sub.2/air fuel cells using a cathode loading of 0.10 mg.sub.Pt.Math.cm.sup.2, the MEA of PtCo/KBNH.sub.2 showed the best performance over the entire range of polarization curves, particularly in the low voltage region dominated by mass transport resistance. The MEA of PtCo/KBNH.sub.2 delivered an excellent MA (at 0.90 V.sub.iR-free) of 0.691 A.Math.mg.sub.Pt.sup.1, which far exceeded that of PtCo/KB (0.583 A.Math.mg.sub.Pt.sup.1) and the U.S. DOE target (0.440 A.Math.mg.sub.Pt.sup.1). In contrast, the MEA of commercial Pt/C exhibited a relatively low MA of 0.241 A.Math.mg.sub.Pt.sup.1. An extremely high current density of 480 mA.Math.cm 2 at 0.80 V was achieved using the MEA of PtCo/KBNH.sub.2, which is 1.6 times the U.S. DOE target (300 mA.Math.cm 2).
[0046] It is well known that MEA performance in the high voltage region is dominated by the intrinsic activity of the cathode catalyst. The uniform and ultrafine L1.sub.0-PtCo@Pt.sub.3L structure of PtCo catalysts enabled the superior activities in both RDE and MEA tests. More importantly, at the operating voltage of 0.67 V for practical fuel cell application, where the performance is also limited by mass transport, the MEA of PtCo/KBNH.sub.2 exhibited a record-high power density of 0.96 W.Math.cm.sup.2. This rated power density closely approaches the U.S. DOE target of 1.0 W.Math.cm.sup.2, which outperformed that of PtCo/KB (0.89 W.Math.cm.sup.2), commercial Pt/C (0.78 W.Math.cm.sup.2), and other reported Pt-based catalysts. Furthermore, in H.sub.2/O.sub.2 fuel cells, a maximum power density of 2.65 W.Math.cm.sup.2 (at 0.45 V) was achieved using PtCo/KBNH.sub.2.
[0047] To interpret the impressive MEA performance of PtCo/KBNH.sub.2 catalyst, electrochemical impedance spectra were recorded at 0.60 V in H.sub.2/air fuel cells and fitted using an equivalent circuit described previously.58 In Nyquist plots of these studied catalysts, the MEA of PtCo/KBNH.sub.2 had the smallest impedance arc, corresponding to the best MEA performance. The MEA performance was dominated by the cathode activation resistance (R.sub.cathode) and mass transport resistance (R.sub.mt), because they are much larger than ohmic resistance (R.sub.) and anode activation resistance (R.sub.anode). The R.sub.cathode of PtCo/KBNH.sub.2 (123.7 m.Math.cm.sup.2) was lower than that of PtCo/KB (232.7 m.Math.cm.sup.2) and commercial Pt/C (333.0 m.Math.cm.sup.2), which agreed well with the intrinsic activities revealed in
[0048] The Pt utilizations in MEAs were calculated by obtaining the relative values of the ECSA determined in the MEA to the ECSA determined in the RDE (
[0049] Accelerated durability tests (ADTs) were performed by cycling the MEAs between 0.60 and 0.95 V for 30,000 voltage cycles using the U.S. DOE testing protocol. The MEA of commercial Pt/C appeared to suffer a severe degradation after the ADT, showing a MA loss of 63.1% and a voltage drop of 170 mV (at 0.8 A.Math.cm.sup.2). Both MEAs of PtCo/KBNH.sub.2 and PtCo/KB demonstrated excellent durability with a voltage loss of 30 mV (at 0.8 A.Math.cm.sup.2) after the ADT, reaching the U.S. DOE target of 30 mV. The MA of PtCo/KBNH.sub.2 was maintained at a high level of 0.380 A.Math.mg.sub.Pt.sup.1 after the ADT, surpassing the U.S. DOE target of 0.264 A.Math.mg.sub.Pt.sup.1. The retained MEA performance of PtCo/KBNH.sub.2 after the ADT was comparable to the initial MEA performance of commercial Pt/C. The MEA performance of PtCo/KBNH.sub.2 reached nearly all U.S. DOE requirements for light-duty vehicles, indicating a great potential of PtCo/KBNH.sub.2 for fuel cell applications.
[0050] To investigate its potential application in heavy-duty vehicles, the long-term performance was further examined by cycling a MEA using a cathode loading of 0.20 mg.sub.Pt.Math.cm.sup.2 for 90,000 voltage cycles. The initial MEA performance was enhanced because of the higher Pt loading, showing a power density of 1.02 W.Math.cm.sub.2 (at 0.67 V). The MEA performance decayed significantly for the first 30,000 cycles and then slightly decayed over the subsequent cycles. The current density at 0.70 V dropped from 1.31 to 0.83 A.Math.cm.sup.2 after 90,000 cycles, indicating a current decay of 36.6%. Given the low testing pressure of 150 kPa.sub.abs, the retained current density of 0.83 A.Math.cm.sup.2 was a promising result, albeit below the U.S. DOE target of 1.07 A.Math.cm.sup.2 for heavy-duty vehicles testing at 250 kPa.sub.abs.
[0051] To gain insights into the catalyst degradation mechanisms, the microstructure of PtCo/KBNH.sub.2 in the MEA after 30,000 voltage cycles was examined in detail. The PtCo intermetallic nanoparticles remained well-dispersed on the carbon support after the ADT, although the average particle size increased from 2.71.0 nm to 5.92.5 nm. In contrast, severe coarsening of Pt nanoparticles was observed for commercial Pt/C after the ADT, resulting in the average particle size remarkably increasing from 2.61.0 nm to 7.23.0 nm. The enhanced sintering resistance has been reported in the literature for PtCo, PtNi, and PtFe alloys when compared with pure Pt catalysts, which may be offered by the alloying metal (i.e., the anchor effects of alloying metals on the carbon supports). Typical lattice fringes indexed to the (001) plane of the L1.sub.0-PtCo structure and alternating Z-contrasts could be clearly identified, indicating that the intermetallic structure was well-preserved after the ADT, which definitely contributed to the excellent durability. The L1.sub.0-PtCo intermetallic nanoparticles exhibited a more defined core-shell structure after the ADT, showing a shell thickness of 0.90 nm, which is about 4 atomic Pt layers. Although a large amount of Co was observed to remain in the core structure after the ADT, the Co content in L1.sub.0-PtCo intermetallic nanoparticles decreased from 28 at. % (initial value) to 20 at. % (after the ADT) due to inevitable Co dissolution. The structure change was further evidenced by a SHEXRD pattern after the ADT, showing both diffraction peaks corresponding to the L1.sub.0-PtCo structure and emerging splitting peaks belonging to pure Pt. The R.sub.106 remained almost unchanged at 31.1 m.Math.cm.sup.2 after the ADT, indicating that the dissolved Co did not lead to a significant increase in the proton conduction resistance of the ionomer and membrane, which is consistent with the previous observation of PtCo/C catalyst.
[0052] The effect of surface Co dissolution on the kinetic activity of L1.sub.0-PtCo intermetallic nanoparticles was further studied by calculating the E.sub.OH* on L1.sub.0-PtCo@Pt.sub.4L. Compared to L1.sub.0-PtCo@Pt.sub.3L (1.241 eV), the F.sub.OH* varied slightly on L1.sub.0-PtCo@Pt.sub.4L (1.237 eV) because the compressive strain remained almost unchanged at 3.42%, indicating that surface Co dissolution may not result in a significant reduction in ORR activity. The surface contraction induced by the PtCo lattice mismatch faded away on the nanoparticles with thicker shells, consistent with that observed on Pt@Pd nanoparticles. Therefore, the MEA performance degradation could be mainly attributed to the reduction in active area caused by the increase in particle size. Future work is underway to prepare Pt-based intermetallic nanoparticles on other types of functionalized carbon supports to improve the catalyst durability.
[0053] The investigations and procedures described above evidence an uncomplicated and effective approach was developed to directly synthesize ultrafine (sub-3 nm) noble metal-containing nanoparticles on external surfaces of carbon supports, as well as within mesopores at the external surfaces of the supports. The representative PtCo/KBNH.sub.2 nanoparticles exhibited atomic Pt layers of about 2 to 3 atomic thicknesses over the L1.sub.0-PtCo core, showing excellent ORR activity (MA of 1.82 A.Math.mg.sub.Pt.sup.1) and durability (13.0% MA loss after 30,000 cycles) in the RDE tests. DFT calculations revealed that a synergy of ligand effect and strain effect weakened the adsorption of oxygenated intermediates on PtCo/KBNH.sub.2 nanoparticles to a near-optimal value. The formation of a L1.sub.0-PtCo structure and enhanced resistance against surface Pt oxidation in PtCo/KBNH.sub.2 led to superior durability. More importantly, the excellent activity could be well translated into fuel cell performance because of the enhanced accessibility of PtCo/KBNH.sub.2 nanoparticles, resulting in high Pt utilization and low mass transport resistance in the MEA. Using a low cathode loading of 0.10 mg.sub.Pt.Math.cm.sup.2, the MEA of PtCo/KBNH.sub.2 delivered a superior MA of 0.691 A.Math.mg.sub.Pt.sup.1, a very high power density of 0.96 W.Math.cm.sup.2 at 0.67 V, and only a 30 mV drop at 0.80 A.Math.cm 2 after 30,000 voltage cycles. Furthermore, the current density could be maintained at a high level of 0.83 A.Math.cm.sup.2 at 0.70 V (under a reasonably low pressure testing condition of 150 kPa.sub.abs) after 90,000 cycles, suggesting a great potential application of PtCo/KBNH.sub.2 in heavy-duty vehicles. As such, the investigations not only evidenced a successful approach to preparing uniform and ultrafine Pt-based intermetallic electrocatalysts, but also provided an effective direction for overcoming the mass transport problem to achieve high-power fuel cells as well as other energy conversion and storage devices.
[0054] As previously noted above, though the foregoing detailed description describes certain aspects of one or more particular embodiments of the invention and investigations associated with the invention, alternatives could be adopted by one skilled in the art. For example, process parameters such as concentrations, temperatures, and durations could be modified, and appropriate materials could be substituted for those noted, as a nonlimiting example, other noble metals in addition to or instead of platinum, such as ruthenium, rhodium, palladium, osmium, and iridium, alloys thereof, and ordered intermetallics thereof. As such, and again as was previously noted, it should be understood that the invention is not necessarily limited to any particular investigation or embodiment described herein or illustrated in the drawings.