Platinum
supported on mixed-metal oxides (MMOs) are a class of
active and durable cathode catalysts for proton exchange membrane
fuel cell (PEMFC) due to a combination of the high oxidative stability
of the supports and strong metal–support interactions (SMSI)
that enable them to exceed the activity of Pt/C. Herein, we solve
a significant remaining challenge with Pt/MMO systems, namely, the
relatively low surface area and porosity. This is achieved by dispersing
nearly uniform Pt clusters by using atomic layer deposition (ALD)
on highly conductive (6.2 S/cm) and stable antimony-doped tin dioxide
(ATO) support. ALD-Pt/ATO exhibited a significantly higher electrochemically
active surface area (ECSA) (74 m2/g) and oxygen reduction
reaction (ORR) catalytic activity (102 mA/mgPt at 0.9 V
vs RHE) compared to Pt/ATO synthesized by using ethylene glycol (ECSA
= 31 m2/gPt, mass activity = 52 mA/mgPt at 0.9 V vs RHE) and formic acid reduction methods (ECSA = 28 m2/gPt, mass activity = 46 mA/mgPt at
0.9 V vs RHE). Further characterization showed that wet chemical methods
resulted in poorer Pt particle dispersion, poor control over Pt particle
size distribution, and chemical degradation of the support (during
Pt deposition). Given the near-ideal Pt particle size distribution
of the ALD-Pt/ATO, particle size growth and loss of ECSA was found
to be minimal over the course of rigorous potential cycling. Thus,
after 10000 potential cycles between 1 and 1.5 V vs RHE, ALD-Pt/ATO
and other Pt/ATOs were found to retain 100% of their initial ECSA
compared to 57.6% retention for Pt/C. Upon testing in a H2/air PEMFC, following 1000 potential cycles, the change in ALD-Pt/ATO
performance was negligible while Pt/C exhibited a 68.2% loss of initial
peak power density. Thus, ALD-Pt/ATO is an active and highly durable
ORR electrocatalyst in PEMFCs under start-up–shut-down conditions.