Fuel cell catalyst and core–shell structure model (Image provided by the Korea Institute of Energy Research)
DAEJEON, Nov. 27 (Korea Bizwire) — South Korean scientists have developed a new method for producing fuel cell catalysts that dramatically cuts manufacturing time and improves durability, the Korea Institute of Energy Research (KIER) said Thursday.
The technique replaces conventional copper-based coating methods with a carbon monoxide–assisted process that allows researchers to form precise metal thin films far more quickly. KIER said the breakthrough could significantly accelerate industrial production of next-generation fuel cell components.
Traditional fuel cell catalysts rely on a core–shell structure in which platinum is deposited onto a base metal such as copper through an underpotential deposition (Cu-UPD) process. While effective, the method requires extremely fine atomic-layer coating and lengthy surface-treatment steps, often taking more than 24 hours to complete.
The KIER team instead used carbon monoxide — a gas that readily adsorbs onto metal surfaces — to form a molecular layer on the core material. Researchers then deposited platinum particles just 0.3 nanometers thick onto the coated surface. The entire synthesis process can now be completed in 30 minutes to two hours, reducing production time to as little as one-tenth of the previous standard.
Using the new approach, the team fabricated core–shell catalysts made of platinum layered onto metals such as palladium, gold and iridium. The palladium-based platinum catalyst developed with the carbon monoxide method demonstrated 1.5 times higher durability than existing commercial catalysts.
“This began with the idea of transforming carbon monoxide — typically seen as harmful — into a tool for nanoscale thin-film control,” said Park Gu-gon, a senior researcher at KIER. “The technology shows strong potential for commercialization.”
KIER expects the faster, more efficient process to support broader advances in the domestic fuel cell industry as demand grows for cleaner energy systems.
Kevin Lee (kevinlee@koreabizwire.com)
