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<p>The advancement of membrane electrode assemblies (MEAs) relies strongly on controlling the structural properties of the catalyst layer, particularly porosity, adhesion, and uniformity. This study develops and systematically optimizes a fully water-based catalyst ink formulation for fabricating porous electrodes suitable for fuel cells and electrolyzers. By tailoring the binder (40 wt% PTFE), pore former (63 wt% ammonium carbonate), and deposition parameters, the study establishes how ink composition and coating conditions govern pore formation and film integrity. Rheological analysis reveals pronounced non-Newtonian shear-thinning behaviour, which enables uniform spray deposition and minimizes defects. Optimization of PTFE and pore-former content resulted in catalyst layers with porosity values up to 80%, enhancing gas-accessible pathways and supporting efficient water management. Comparative evaluation of spray and pour coating methods shows that spray coating yields superior adhesion, microstructural uniformity, and process consistency. The findings underscore the importance of controlled ink formulation and deposition strategy in mitigating mass-transport limitations and improving mechanical stability in MEAs. This work provides a scalable and eco-friendly fabrication approach that supports the development of next-generation hydrogen-energy devices.</p><p></p>

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Optimization of the porosity of membrane electrode assembly

  • 期刊论文

  • 发表日期：

    2026年2月25日

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  • Ayushi Rastogi,
  • Hemant S. Sodaye,
  • Asis Kumar Adak

摘要

The advancement of membrane electrode assemblies (MEAs) relies strongly on controlling the structural properties of the catalyst layer, particularly porosity, adhesion, and uniformity. This study develops and systematically optimizes a fully water-based catalyst ink formulation for fabricating porous electrodes suitable for fuel cells and electrolyzers. By tailoring the binder (40 wt% PTFE), pore former (63 wt% ammonium carbonate), and deposition parameters, the study establishes how ink composition and coating conditions govern pore formation and film integrity. Rheological analysis reveals pronounced non-Newtonian shear-thinning behaviour, which enables uniform spray deposition and minimizes defects. Optimization of PTFE and pore-former content resulted in catalyst layers with porosity values up to 80%, enhancing gas-accessible pathways and supporting efficient water management. Comparative evaluation of spray and pour coating methods shows that spray coating yields superior adhesion, microstructural uniformity, and process consistency. The findings underscore the importance of controlled ink formulation and deposition strategy in mitigating mass-transport limitations and improving mechanical stability in MEAs. This work provides a scalable and eco-friendly fabrication approach that supports the development of next-generation hydrogen-energy devices.