Nonprecious metal oxygen reduction reaction catalysts have been prepared via a simple chemisorption-based methodology. First, an aminosilane was chemically attached to a carbon surface, followed by coordination of iron and subsequent high temperature pyrolysis. Catalysts were prepared from a series of mono, di, and triaminosilanes. Physical and electrochemical properties of these catalysts were studied using inductively coupled plasma optical emission spectroscopy, X-ray photoelectron spectroscopy, and rotating ring-disk electrode cells. Maximum catalytic activity was achieved for samples prepared from the triaminosilane combined with a more disordered carbon black.

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Sulfonic acid functionalities were grafted onto the surface of Pt/Vulcan XC72 electrocatalysts via the thermal decomposition of ammonium sulfate method. Electrochemical impedance spectroscopy was used to investigate its impact on catalyst utilization and proton conductivity as a function of depth within the catalyst layer. Catalysts prepared from sulfonated carbon supports displayed higher electrochemically active surface areas at lower Nafion contents than those prepared from untreated carbons. This enhanced conductivity and active area was explained in terms of an increased concentration and more effective deployment of sulfonic acid groups.

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