The thin-film rotating disk electrode
(TF-RDE) is a well-developed,
conventional ex situ electrochemical method that
is limited by poor mass transport in the dissolved phase and hence
can only measure the kinetic response for Pt-based catalysts in a
narrow overpotential range. Thus, the applicability of TF-RDE results
in assessing how catalysts perform in fuel cells has been questioned.
To address this problem, we use the floating electrode (FE) technique,
which can facilitate high-mass transport to a catalyst layer composed
of an ultralow loading of catalyst (1–15 μgPt cmgeo
–2) at the gas/electrolyte interface.
In this paper, the aspects that have critical effects on the performance
of the FE system are measured and parametrized. We find that, in order
to obtain reproducible results with high performance, the following
factors need to be taken into account: system cleanliness, break-in
procedure, hydrophobic agent, ionomer type, and the measurements of
catalyst surface area and loading. For some of these parameters, we
examined a range of different approaches/materials and determined
the optimum configuration. We find that the gas permeability of the
hydrophobic agent is an important factor for improving the hydrogen
oxidation reaction (HOR) and oxygen reduction reaction (ORR) performance.
We provide evidence that the suppression of the HOR and ORR introduced
by the Nafion ionomers is more than a local mass transport barrier
but that a mechanism involving the adsorption of the sulfonate on
Pt also plays a significant role. The work provides intriguing insights
into how to manufacture and optimize electrocatalyst systems that
must function at the gas/electrolyte interface.