Honeycomb-Structured IrO_x Foam Platelets as the Building Block of Anode Catalyst Layer in PEM Water Electrolyzer

Achieving robust long-term durability with high catalytic activity at low iridium loading remains one of great challenges for proton exchange membrane water electrolyzer (PEMWE). Herein, we report the low-temperature synthesis of iridium oxide foam platelets comprising edge-sharing IrO₆ octahedral honeycomb framework, and demonstrate the structural advantages of this material for multilevel tuning of anodic catalyst layer across atomic-to-microscopic scales for PEMWE. The integration of IrO₆ octahedral honeycomb framework, foam-like texture and platelet morphology into a single material system assures the generation and exposure of highly active and stable iridium catalytic sites for the oxygen evolution reaction (OER), while facilitating the reduction of both mass transport loss and electronic resistance of catalyst layer. As a proof of concept, the membrane electrode assembly in single-cell PEMWE based on honeycomb-structured IrO_x foam platelets, with a low iridium loading (~0.3 mg_Ir/cm²), is demonstrated to exhibit high catalytic activity at ampere-level current densities and to remain stable for more than 2000 hours.