Scalable Design of Mesoporous Carbon Support Tailored for High-Performance PEM Fuel Cell Applications

Reducing the platinum (Pt) loading in proton exchange membrane fuel cell (PEMFC) cathodes generally results in substantial voltage losses, primarily due to increased overpotentials for the oxygen reduction reaction (ORR) and to oxygen transport limitations related to the structural constraints of conventional carbon supports. Here, we introduce a scalable synthesis for graphitic mesoporous carbons via pyrolysis of a resorcinol-formaldehyde gel (RFG) prepared via a modified sol–gel process. This method eliminates hydrothermal treatment, hard templating, solvent exchange, and supercritical drying, offering a simple and industrially viable approach. The RFG combines a well-connected mesoporous network for efficient oxygen transport, a high surface area for uniform Pt dispersion with minimized direct contact between the Pt nanoparticles and the proton-conducting ionomer, and a graphitic framework that can enhance the carbon corrosion resistance. Membrane electrode assemblies (MEAs) employing Pt/C with the RFG carbon support demonstrate superior performance to those using commercial carbons such as Vulcan and KetjenBlack in single-cell PEMFC tests. RFG’s hydrophilic surface allows for reduced ionomer usage without compromising H 2 /air performance, while the confinement of Pt within the mesopores mitigates ionomer-induced poisoning of the ORR. With demonstrated reproducibility and yields of up to 70 g l −1 , RFG shows strong practical potential for next-generation PEMFC electrodes.