Fig. 1: Schematic comparison of conventional and particulate-packed CL structures and their impact on TPI formation.

a Conventional CL structure of a fused and segregated electrode (FSE), showing large agglomerated PTFE hydrophobic islands and extensive CB regions flooded with electrolyte. b Magnified side view of (a), illustrating a fused PTFE domain covering CB particles, while surrounding CB is immersed in the electrolyte and relies solely on dissolved oxygen for 2e– ORR, severely limiting TPI formation. c Catalyst layer with a non-fused particulate-packed interface (PPE), where PTFE and CB particles form a porous and interspersed network. d Magnified side view of c, where discrete PTFE particles create localized hydrophobic microenvironments that enable nearby CB to participate in 2e– ORR, resulting in abundant and uniformly distributed TPIs.