Predicting Particle-Size Distributions in Fuel-Cell Inks

Prediction of the catalyst-activated carbon particle sizes of fuel-cell inks remains a critical challenge in enhancing the performance and durability of fuel cells. The performance and structural integrity of the catalyst layers in the cell depend not only on the properties of the ionomer, but also on the carbon supports that host the catalyst. To investigate how these carbon aggregate structures form, we present a model that calculates the cooperative size distributions of ionomer and carbon aggregates in various water/alcohol mixtures and compares those results to available experimental data. Aggregation of both the suspended ionomers and the carbon particles is interwoven as the carbon aggregation depends heavily on the ionic strength of its environment, namely protons dissociating from the ionomer’s sulfonic-acid-group side chains. We demonstrate that the surrounding mixed solvent as well as Nafion TM binder concentration strongly influence the degree of aggregation for carbon particles. The validated model provides a framework for exploring aggregation under a wide range of conditions for various electrochemical-technology inks.