CATALYST, ELECTRODE, AND METHOD OF PREPARING THE SAME FOR PEM FUEL CELLS

1 . A catalyst for a fuel cell, comprising:

a carbon support including a high surface area porous carbon, a low surface area graphitized carbon, and a low surface area nonporous carbon; and

a metal selected from a group consisting of platinum, a platinum alloy, and combinations thereof, wherein the metal is deposited onto the carbon support.

2 . The catalyst of claim 1 , wherein the high surface area porous carbon has a surface area from about 300 m 2 /g to about 1200 m 2 /g.

3 . The catalyst of claim 1 , wherein the low surface area graphitized carbon has a surface area from about 125 m 2 /g to about 300 m 2 /g.

4 . The catalyst of claim 1 , wherein the low surface area nonporous carbon has a surface area from about 50 m 2 /g to about 125 m 2 /g.

5 . The catalyst of claim 1 , wherein the platinum alloy includes a member selected from a group consisting of: platinum-cobalt (Pt—Co), platinum-nickel (Pt—Ni), platinum-iron (Pt—Fe), platinum-manganese (Pt—Mn), and combinations thereof.

6 . A catalyst slurry or ink comprising the catalyst of claim 1 and a liquid vehicle.

7 . An electrode for a fuel cell, comprising:

a carbon support including a high surface area porous carbon, a low surface area graphitized carbon, and a low surface area nonporous carbon;

a metal selected from a group consisting of platinum, a platinum alloy, and combinations thereof, wherein the metal is deposited onto the carbon support; and

an ionomer.

8 . The electrode of claim 7 , wherein the ionomer includes perfluorosulfonic acid.

9 . A membrane electrode assembly comprising the electrode according to claim 7 and a proton exchange membrane.

10 . A method of making a catalyst, comprising:

blending a high surface area porous carbon, a low surface area graphitized carbon, and a low surface area nonporous carbon to form a carbon blend;

depositing a catalyst precursor onto the carbon blend to form a post-deposition carbon blend, wherein the catalyst precursor is selected from a group consisting of a platinum precursor, a platinum alloy precursor, and combinations thereof; and

heating the post-deposition carbon blend to form a carbon supported catalyst, wherein the carbon supported catalyst includes a metal deposition product selected from a group consisting of platinum, platinum alloy, and combinations thereof.

11 . The method of claim 10 , further comprising ascertaining a particle size of the carbon blend following the blending step and repeating the blending step until a predetermined particle size is obtained for the carbon blend.

12 . The method of claim 10 , further comprising chemically treating the carbon blend with one of an oxidizing agent and an acidic condition prior to the depositing step.

13 . The method of claim 10 , further comprising heat treating the carbon blend in one of an inert atmosphere and air prior to the depositing step.

14 . The method of claim 10 , further comprising washing the post-deposition carbon blend prior to the heating step.

15 . The method of claim 14 , further comprising repeating the washing of the post-deposition carbon blend prior to the heating step.

16 . The method of claim 14 , wherein washing the post-deposition carbon blend is followed by drying the post-deposition carbon blend prior to the heating step.

17 . A method of making an electrode, comprising:

making the catalyst according to the method of claim 10 ;

mixing the catalyst, a solvent, and an ionomer to form a slurry or ink;

depositing the slurry or ink onto a surface; and

removing the solvent to form the electrode.

18 . The method of claim 17 , wherein the surface includes a member selected from a group consisting of a proton exchange membrane, a gas diffusion layer, and combinations thereof.

19 . The method of claim 17 , further comprising transferring the electrode from the surface to a proton exchange membrane.

20 . The method of claim 17 , wherein removing the solvent includes volatilizing the solvent.