Abstract
The microporous layer (MPL) is of significance to the PEM fuel cell performance and durability through water management. It is essential to gain insights into the MPL nanoink, a critical state determining the resulting MPL porous structure and function. In this work, a comprehensive investigation of ink microstructure and rheology with different PTFE loadings and solvent compositions has been conducted from a theoretical and practical level. Two different CB/PTFE interaction modes (i.e., covering and bridging) were revealed and the latter dominates with increasing PTFE loading. It was found a PTFE loading of 30% produces homogeneous ink dispersion and best stability. Besides, larger aggregates were found with increased IPA/water ratio using cryo-SEM. Furthermore, rheological measurements revealed that less shear-thinning indicates stable inks. Combining the ink preparation and slot-die coating processes, an optimal formulation of 30% PTFE loading and 1/2 IPA/water weight ratio was proposed for a uniform ink dispersion.
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