Using a dual plasma process to produce cobalt--polypyrrole catalysts for the oxygen reduction reaction in fuel cells -- part I: characterisation of the catalytic activity and surface structure

A new dual plasma coating process to produce platinum-free catalysts for the oxygen reduction reaction in a fuel cell is introduced. The catalysts thus produced were analysed with various methods. Electrochemical characterisation was carried out by cyclic voltammetry, rotating ring- and rotating ring-disk electrode. The surface porosity of the different catalysts thus obtained was characterised with the nitrogen gas adsorption technique and scanning electron microscopy was used to determine the growth mechanisms of the films. It is shown that catalytically active compounds can be produced with this dual plasma process. Furthermore, the catalytic activity can be varied significantly by changing the plasma process parameters. The amount of H$_2$O$_2$ produced was calculated and shows that a 2 electron mechanism is predominant. The plasma coating mechanism does not significantly change the surface BET area and pore size distribution of the carbon support used. Furthermore, scanning electron microscopy pictures of the produced films are presented and show the preference of columnar growth mechanisms. By using different carbons as the support it is shown that there is a strong dependence of the catalytic activity that is probably related to the chemical properties of the carbon.