Achieving high platinum utilization in proton exchange membrane fuel cell through synergistic engineering of carbon support structure and ionomer content

To address the critical challenge of reducing Platinum (Pt) consumption in proton exchange membrane fuel cells (PEMFCs), we demonstrate a dual-parameter engineering strategy that synergistically enhances Pt utilization in PEMFCs through coordinated optimization of carbon support structure and ionomer content. We first engineer carbon supports with tunable specific surface areas (SSA: 200–1050 m 2 /g), achieving precise control of Pt nanoparticle size from 3.26 nm (low SSA) to 1.76 nm (high SSA). Concurrently, we optimize the ionomer-to-carbon (I/C) ratios in catalyst layer (CL) fabrication, ranging from 0.1 to 1.1. We established a volcano-type dependence of Pt utilization on both carbon support SSA and I/C ratio, peaking at SSA of 550 m 2 /g and I/C ratio of 0.6 owing to the balance between Pt nanoparticle size and ionomer/carbon support-mediated transport limitations. This optimal dual-parameter configuration achieves peak utilization of 37 W/mg Pt , significantly exceeding previously reported values. Our dual-parameter optimization strategy provides a systematic investigation for maximizing Pt utilization in next-generation PEMFCs, offering valuable insights into the interfacial engineering of supported catalysts. • Tuning carbon surface area controls platinum size and ionomer distribution. • Proper ionomer-to-carbon ratio balances proton and gas transport pathways. • Platinum utilization shows volcano trend with support area and ionomer content. • Highest platinum utilization of 37 W/mg at 550 m 2 /g and ratio of 0.6.