Ensuring the consistency of electrode structure in proton exchange membrane fuel cells is highly desired yet challenging because of wide-existing and unguided cracks in the microporous layer (MPL). The first thing is to evaluate the homogeneity of MPL with cracks quantitatively. This paper proposes the homogeneity index of a full-scale MPL with an area of 50 cm2, which has yet to be reported in the literature to our knowledge. Besides, the effects of the carbon material and surfactant on the ink and resulting MPL structure have been studied. The ink with a high network development degree produces MPL with low crack density, but the ink with high PDI produces MPL with low crack homogeneity. The polarity of the surfactant and the non-polarity of PTFE are not mutually soluble, resulting in the heterogeneous PTFE distribution. The findings of this study provide guidelines for MPL fabrication.
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