This study numerically analyzed the gas diffusion layer (GDL) in proton exchange membrane fuel cells (PEMFCs). The GDL, composed of carbon fibers and binder, plays a critical role in facilitating electron, heat, gas, and water transport while cushioning under cell compression. Its microstructure significantly influences these properties, requiring precise design.
Using simulations, this study explored GDL designs by varying fiber and binder parameters and calculated gas diffusivity under wet conditions. Unlike previous studies, a novel model treated carbon fibers as beam elements with elastic binder connections, closely replicating structural changes under compression.
Key properties analyzed include permeability, electrical conductivity, and gas diffusion efficiency under wet conditions. The optimized designs enhanced these properties while balancing trade-offs between electrical conductivity and mass transport. These findings provide valuable guidelines for advancing PEMFC technology.