Evaluating Ink Structure Using Ultrasonic Spray Coating for PEMFC MEA

Abstract

From the standpoint of improving manufacturing productivity and performance/durability of PEMFC MEAs, there is an increasing interest in ink. Ink research is centered on comprehending the interplay between the components of the ink, including catalysts, ionomers, and solvents, to control the ink structure and evaluate its influence on ink properties, catalyst layer microstructure, and fuel cell performance. As a facet of this ink research, the current study proposes ultrasonic spray coating as a methodology to indirectly evaluate the ink structure.50 wt% Pt/C catalysts loaded on Ketjenblack (KB) and Vulcan carbon (VC) were separately incorporated to produce sprayable inks with a solid content of 4 wt% using an Aquivion ionomer (EW 720) and a mixture solvent composed of a 1:1 weight ratio of 1-propanol and water. The structural differences between the two catalyst inks were compared by quantifying the amount of adsorbed and free ionomers, as well as their rheological properties. Additionally, the advantages of ultrasonic spray coating, such as the formation of small droplets on the order of tens of micrometers and rapid drying, were utilized to coat each ink onto a silicon substrate. The structural characteristics of the resulting catalyst layers were compared through SEM images, as well as the distribution of constituent elements using EDS and Auger spectroscopy. The Pt/KB catalyst ink forms a gel-like structure due to its relatively high amount of adsorbed ionomer, resulting in a relatively uniform distribution of catalyst particles and ionomers in the catalyst layer formed from ultrasonic spray droplets. In contrast, the Pt/VC catalyst ink behaves as a liquid-like, mainly existing in the form of free ionomer, regardless of ionomer content. During the drying process of each droplet, they merge to form larger unit catalyst layers, which exhibit an uneven distribution where free ionomers tend to concentrate at the edges of the catalyst layer due to the coffee-ring effect. As a result, the catalyst and ionomers exist in a non-uniform distribution, which is observed to affect the performance and electrochemical characteristics of fuel cells. In this presentation, we will discuss in detail the series of characteristics of ink-catalyst layer-fuel cell performance that vary according to catalyst properties.