Paradigm-shifting catalyst layer design for high performance and low cost polymer electrolyte fuel cells

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Polymer electrolyte fuel cells (PEFCs) are at the forefront of technological solutions that are aimed at meeting the global challenge of developing highly efficient, cost competitive energy conversion systems that also have a low environmental footprint. PEFCs cleanly convert the chemical energy of hydrogen to electricity at high efficiency in their 'catalyst layers" (CLs), while generating only purewater and heat as by-products. PEFC technology will constitute nearly 25% of the global fuel cell market, projected to exceed $40B by 2022. Our industry partner, Ballard Power Systems in Burnaby, ranked #1 globally in PEFC technology, is thus poised to reap tremendous economic benefits in the future. To remain competitive and increase their market share, the cost of Ballard's PEFC system must be reduced and its performance enhanced. These issues arise partly because current PEFC CLs are made using an ink in which carbon powder particles that support expensive platinum (Pt) nanoparticles are mixed randomly with a disordered polymer binder. This results in poorly used Pt (adding to cost) or poorly accessible pores (resulting in poor performance) in the dried ink or CL.