2D arrays of hollow carbon nanoboxes: outward contraction-induced hollowing mechanism in Fe–N–C catalysts

Abstract

Maximizing the utilization efficiency of monatomic Fe sites in Fe–N–C catalysts poses a significant challenge for their commercial applications. Herein, a structural and electronic dual-modulation is achieved on a Fe–N–C catalyst to substantially enhance its catalytic performance. We develop a facile multi-component ice-templating co-assembly (MIC) strategy to construct two-dimensional (2D) arrays of monatomic Fe-anchored hollow carbon nanoboxes (Fe-HCBA) via a novel dual-outward interfacial contraction hollowing mechanism. The pore engineering not only enlarges the physical surface area and pore volume but also doubles the electrochemically active specific surface area. Additionally, the unique 2D carbon array structure reduces interfacial resistance and promotes electron/mass transfer. Consequently, the Fe-HCBA catalysts exhibit superior oxygen reduction performance with a six-fold enhancement in both mass activity (1.84 A cm⁻²) and turnover frequency (0.048 e⁻ site⁻¹ s⁻¹), compared to microporous Fe–N–C catalysts. Moreover, the incorporation of phosphorus further enhances the total electrocatalytic performance by three times by regulating the electron structure of Fe–N₄ sites. Benefitting from these outstanding characteristics, the optimal 2D P/Fe-HCBA catalyst exhibits great applicability in rechargeable liquid- and solid-state zinc–air batteries with peak power densities of 186 and 44.5 mW cm⁻², respectively.