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Degradation occurs in catalyst inks because of the catalytic oxidation of the solvent. Identification of the generation process of impurities and their effects on the properties of HSC ink and LSC ink is crucial in mitigating them. In this study, gas chromatography-mass spectrometry (GC-MS) and cyclic voltammetry (CV) showed that oxidation of NPA and EA was the primary cause of impurities such as acetic acid, aldehyde, propionic acid, propanal, 1,1-dipropoxypropane, and propyl propionate. After the degassing treatment, the degradation of the HSC ink was suppressed, and the concentrations of acetic acid, propionic acid, and propyl propionate plummeted from 0.0898 wt.%, 0.00224 wt.%, and 0.00046 wt.% to 0.0025 wt.%, 0.0126 wt.%, and 0.0003 wt.%, respectively. The smaller particle size and higher zeta potential in the degassed HSC ink indicated the higher utilization of Pt, thus leading to optimized mass transfer in the catalyst layer (CL) during working conditions. The electrochemical performance test result shows that the MEA fabricated from the degassed HSC ink had a peak power density of 0.84 W cm−2, which was 0.21 W cm−2 higher than that fabricated from the normal HSC ink. However, the introduction of propionic acid in the LSC ink caused the Marangoni flux to inhibit the coffee ring effect and promote the uniform deposition of the catalyst. The RDE tests indicated that the electrode deposited from the LSC ink with propionic acid possessed a mass activity of 84.4 mA∙mgPt−1, which was higher than the 60.5 mA∙mgPt−1 of the electrode deposited from the normal LSC ink.

Graphitized black pearl (GBP) 2000 supported Pt nanoparticle catalysts is synthesized by a formic acid reduction method. The results of a half-cell accelerated degradation test (ADT) of two protocols and a single-cell ADT show that, Pt/GBP catalyst has excellent stability and durability compared with commercial Pt/C. Especially, the survival time of Pt/GBP-membrane electrode assembly (MEA) reaches 205 min, indicating that it has better reversal tolerance. After the 1003-hour durability test, the proton exchange membrane fuel cell (PEMFC) stack with Pt/GBP presents a slow voltage degradation rate of 5.19% and 36 μV h−1 at 1000 mA cm−2. The durability of the stack is improved because of the durability and stability of the catalyst. In addition, the post morphology characterizations indicate that the structure and particle size of the Pt/GBP catalyst remain unchanged during the dynamic testing protocol, implying its better stability under dynamic load cycles. Therefore, Pt/GBP is a valuable and promising catalyst for PEMFC, and considered as an alternative to classical Pt/C.

As the core component of a proton exchange fuel cell (PEMFC), a membrane electrode assembly (MEA) consists of function region (active area), structure region, and transition region. Situated between the function and structure regions, the transition region influences the reliability and durability of the MEA. The degradation of the electrolyte membrane in this region can be induced by mechanical stress and chemical aggression. Therefore, prudent design, reliable and robust structure of the transition region can greatly help avoid early failure of MEAs. This review begins with the summarization of current structural concepts of MEAs, focusing on the transition region structures. It can be seen that aiming at better repeatability and robustness, partly or total integration of the materials in the transition region is becoming a development trend. Next the degradation problem at the transition region is introduced, which can be attributed to the hygro-thermal environment, free radical aggression, air pressure shock, and seal material decomposition. Finally, the mitigation approaches for the deterioration at this region are summarized, with a principle of avoiding the exposure of the membrane at the edge of the catalyst-coated membrane (CCM). Besides, durability test methods of the transition region are included in this review, among which temperature and humidity cycling are frequently used.

In this paper, the composition, function and structure of the catalyst layer (CL) of a proton exchange membrane fuel cell (PEMFC) are summarized. The hydrogen reduction reaction (HOR) and oxygen reduction reaction (ORR) processes and their mechanisms and the main interfaces of CL (PEM|CL and CL|MPL) are described briefly. The process of mass transfer (hydrogen, oxygen and water), proton and electron transfer in MEA are described in detail, including their influencing factors. The failure mechanism of CL (Pt particles, CL crack, CL flooding, etc.) and the degradation mechanism of the main components in CL are studied. On the basis of the existing problems, a structure optimization strategy for a high-performance CL is proposed. The commonly used preparation processes of CL are introduced. Based on the classical drying theory, the drying process of a wet CL is explained. Finally, the research direction and future challenges of CL are pointed out, hoping to provide a new perspective for the design and selection of CL materials and preparation equipment.