<p>Catalyst layers (CL) as an active component
of the catalyst coated membrane (CCM) form the heart of proton electrolyte
membrane fuel cells (PEMFC). For optimum performance of the fuel cell, obtaining
suitable structural and functional characteristics for the CL is crucial.
Direct tuning of the microstructure and morphology of the CL is non-trivial;
hence catalyst inks as catalyst layer precursors need to be modulated, which
are then applied onto a membrane, to form the CCM. Obtaining favorable
dispersion characteristics forms an important prerequisite in engineering
catalyst inks for large scale manufacturing. In order to facilitate a
knowledge-based approach for developing fuel cell inks, this work introduces
new tools and methods to study both the dispersion state and stability
characteristics, simultaneously. Catalyst inks were prepared using different processing
methods which include stirring and ultrasonication. The proposed tools are used
to characterize and elucidate the effects of the processing method. Structural characterization
of the dispersed particles and their assemblages was carried out by means of
transmission electron microscopy. Analytical centrifugation (AC) was used to
study the state and stability of inks. Herein, we introduce new concepts, <i>S
score</i> and <i>stability trajectory</i>, for a time-resolved assessment of inks in their native state using AC. The
findings were validated and rationalized using transmittograms as a direct
visualization technique. The flowability of inks was investigated by
rheological measurements. It was found that probe sonication only up to an optimum
amplitude leads to a highly stable colloidal ink.</p>