Effect of air flow on liquid water transport through a hydrophobic gas diffusion layer of a polymer electrolyte membrane fuel cell

The transport of liquid water through an idealized 2-D reconstructed gas diffusion layer (GDL) of a polymer electrolyte membrane (PEM) fuel cell is computed subject to hydrophobic boundary condition at the fibre–fluid interface. The effect of air flow, as would occur in parallel/serpentine/interdigitated type of flow fields, on the liquid water transport through the GDL, ejection into the channel in the form of water droplets and subsequent removal of the droplets has been simulated. Results show that typically water flow through the fibrous GDL occurs through a fingering and channelling type of mechanism. The presence of cross-flow of air has an effect both on the path created within the GDL and on the ejection of water into the channel in the form of droplets. A faster rate of liquid water evacuation through the GDL (i.e., more frequent ejection of water droplets) as well as less flooding of the void space results from the presence of cross-flow. These results agree qualitatively with experimental observations reported in the literature.     

The impact of rib structure on the water transport behavior in gas diffusion layer of polymer electrolyte membrane fuel cells

Using the multiphase lattice Boltzmann method (LBM), the liquid water transport dynamics is simulated in a gas diffusion layer (GDL) of polymer electrolyte membrane fuel cells (PEMFCs). The effect of rib structure on the water invasion process in the micro-porous GDL is explored by comparing the two cases, i.e., with rib and without rib structures. The liquid water distribution and water saturation profile are presented to determine the wetting mechanism in the GDL. The results show that the liquid water transport in the GDL is strongly governed by capillary force and the rib structure plays a significant role on water distribution and water transport behavior in the GDL. Comparison of two cases confirms that the rib structure influences on the location of water breakthrough. The liquid water distribution and water saturation profile indicate that the high resistance force underneath the rib suppresses the growth of water cluster, resulting in the change of flow path. After water breakthrough, the liquid water distribution under the channel has little variation, whereas that under the rib continues to change. The predicted value of effective permeability is in good agreement with Carman-Kozeny correlation and experimental results in the literature. The results suggest that the LBM approach is an effective tool to investigate the water transport behavior in the GDL.     

On the effectiveness of Leverett approach for describing the water transport in fuel cell diffusion media

This paper investigates the effectiveness of employing the traditional Leverett approach for describing the capillary-induced flow in thin-film fuel cell diffusion media (DM) with mixed wettability. A one-dimensional steady-state analytical model is developed to analyze the capillary transport of liquid water through the thin-film DM. A capillary pressure–liquid saturation relation is derived based on the experimental data reported by Gostick et al. [J.T. Gostick, M.W. Fowler, M.A. Ioannidis, M.D. Pritzker, Y.M. Volfkovich, A. Sakars, J. Power Sources, 156 (2006) 375]. The empirical fit is applicable to the fuel cell DMs tested by reference [J.T. Gostick, M.W. Fowler, M.A. Ioannidis, M.D. Pritzker, Y.M. Volfkovich, A. Sakars, J. Power Sources, 156 (2006) 375] under a limited set of conditions, providing a means to evaluate the effectiveness of the traditional Leverett approach. Furthermore, a new characteristic relative permeability correlation appropriate for the tested DMs under the given conditions was obtained by fitting the experimental capillary pressure data [J.T. Gostick, M.W. Fowler, M.A. Ioannidis, M.D. Pritzker, Y.M. Volfkovich, A. Sakars, J. Power Sources, 156 (2006) 375] into four well-established empirical models. The empirically-derived relationships are then integrated into an analytical model framework in order to compare the liquid saturation profiles predicted by both approaches. The results show that use of the standard Leverett approach equipped with Leverett J-function can lead to significant errors; therefore, an extension of this approach appropriate for fuel cell DM with mixed wettability is needed for reliable model predictions. Finally, a sensitivity analysis is performed to assess the relative significance of the various input parameters on the predicted saturation profiles.     

Effect of PTFE content in microporous layer on water management in PEM fuel cells

The effect of hydrophobic agent (PTFE) concentration in the microporous layer on the PEM fuel cell performance was investigated using mercury porosimetry, water permeation experiment, and electrochemical polarization technique. The mercury porosimetry and water permeation experiments indicated that PTFE increases the resistance of the water flow through the GDL due to a decrease of the MPL porosity and an increase of the volume fraction of hydrophobic pores. When air was used as an oxidant, a maximum fuel cell performance was obtained for a PTFE loading of 20 wt.%. The experimental polarization curves were quantitatively analyzed to determine the polarization resistances resulting from different physical and electrochemical processes in the PEM fuel cell. The polarization analysis indicated that the optimized PTFE content results in an effective water management (i.e., a balancing of water saturations in the catalyst layer and the gas diffusion layer), thereby improving the oxygen diffusion kinetics in the membrane-electrode assembly.     

Effect of water distribution in gas diffusion layer on proton exchange membrane fuel cell performance

Water management of proton exchange membrane fuel cells remains a prominent issue in research concerning fuel cells. In this study, the gas diffusion layer (GDL) of a fuel cell is partially treated with a hydrophobic agent, and the effect of GDL hydrophobicity on the water distribution in the fuel cell is examined. First, the effect of the position of the cathode GDL hydrophobic area relative to the channel on the fuel cell performance is investigated. Then, the water distribution in the fuel cell cathode GDL is observed using X-ray imaging. The experimental results indicate that when the hybrid GDL's hydrophobic area lies on the channel, water tends to accumulate under the rib, and the water content in the channel is low; this improves the fuel cell performance. When the hydrophobic area is under the rib, the water distribution is more uniform, but the performance deteriorates.     

Study on water transport in hydrophilic gas diffusion layers for improving the flooding performance of polymer electrolyte fuel cells

For hydrogen-based polymer electrolyte fuel cells (PEFCs), water transport control in gas diffusion layers (GDLs) by wettability distribution is useful to suppress the flooding problem. In this study, the water transport of a novel GDL with hydrophilic-hydrophobic patterns was investigated. First, we clarified that the water motion in the hydrophilic GDL with microstructures could be reproduced by the enlarged scale model. The scale model experiment also showed that the same water behavior in hydrophilic GDL can be obtained from Capillary numbers (Ca) in a range of Ca ~ 10^?5 to 10^?3. As the computational load is inversely proportional to Ca, the computational load could be reduced by 1/100th by using Ca ~ 10^?3, which is 100 times higher than PEFC operation (Ca ~ 10^?5). Finally, the simulation with Ca ~ 10^?3 was performed, and we showed that the GDL with straight region of contact angle 50° minimized the water accumulation.     

The effect of through plane pore gradient GDL on the water distribution of PEMFC

The effect of through plane pore gradient of gas diffusion layer (GDL) on the performance of Polymer Electrolyte Membrane Fuel Cell is investigated experimentally. The performance with GDLs having no, medium and high pore gradient are compared at 2 different relative humidity (RH) conditions. The medium pore gradient GDL shows generally the best performance in both RH conditions. The performance difference is analyzed based on the water distribution. The water distribution is measured through the X-ray visualization. The amount of water is reduced with the pore gradient GDL. This change reduces the concentration over-potential, and thereby increases the performance at high RH condition. However, the reduction of liquid water results in dehydration of the membrane at low RH condition. This makes lower performance with high pore gradient. The highest performance is not matched with the highest pore gradient. The effect of pore gradient is distinct when water exists sufficiently.     

Prevention of the water flooding by micronizing the pore structure of gas diffusion layer for polymer electrolyte fuel cell

In polymer electrolyte fuel cells, high humidity must be established to maintain high proton conductivity in the polymer electrolyte. However, the water that is produced electrochemically at the cathode catalyst layer can condense in the cell and cause an obstruction to the diffusion of reaction gas in the gas diffusion layer and the gas channel. This leads to a sudden decrease of the cell voltage. To combat this, strict water management techniques are required, which usually focus on the gas diffusion layer. In this study, the use of specially treated carbon paper as a flood-proof gas diffusion layer under extremely high humidity conditions was investigated experimentally. The results indicated that flooding originates at the interface between the gas diffusion layer and the catalyst layer, and that such flooding could be eliminated by control of the pore size in the gas diffusion layer at this interface.     

Experimental study on mitigating the cathode flooding at low temperature by adding hydrogen to the cathode reactant gas in PEM fuel cell

Severe flooding can be critical in a fuel cell vehicle operating at a high current density, and in a fuel cell vehicle at the initial stage of start up. It is often difficult to remove the condensed water from the cathode gas diffusion layer (GDL) of the fuel cell because of the surface tension between the water and the GDL. In this research, in order to remove the condensed water from the cathode GDL, a small amount of hydrogen was injected into the cathode reactant gases. The results showed that the hydrogen addition method successfully removed the liquid water from the cathode GDL. Water removal was verified for various hydrogen flow rates and hydrogen addition durations. Furthermore, the dew point temperature of the outlet gas at the cathode was observed to determine the amount of water removed from the cathode GDL. In addition, the water droplet in the cathode gas flow channel was visualized by using a transparent cell. Furthermore, degradation tests are also performed. Considering the degradation test, the hydrogen addition method is expected to be effective in mitigating cathode flooding.     

Liquid water transport mechanism in the gas diffusion layer

We developed an equivalent capillary model of a microscale fiber-fence structure to study the microscale evolution and transport of liquid in a porous media and to reveal the basic principles of water transport in gas diffusion layer (GDL). Analytical solutions using the model show that a positive hydraulic pressure is needed to drive the liquid water to penetrate through the porous GDL even consisting of the hydrophilic fibers. Several possible contributions for the water configuration, such as capillary pressure, gravity, vapor condensation, wettability and microstructures of the GDL, are discussed using the lattice Boltzmann method (LBM). It is found that the distribution manners of the fibers and the spatial mixed-wettability in the GDL also play an important role in the transport of liquid water.     

Development and impact of sandwich wettability structure for gas distribution media on PEM fuel cell performance

Water management is one of the key issues related to the performance, durability and cost of polymer electrolyte membrane fuel cells (PEMFCs); and the wettability of gas distribution media (GDM) is critical to the water management. In this study, a novel design is developed for GDM, referred to as sandwich wettability GDM. After being coated with a silica particle/poly(dimethylsiloxane) (PDMS) composite, the GDM has superhydrophobic surfaces with a contact angle of 162 ± 2°, but hydrophilic internal pores. Water droplets (10 μl) can roll off the tilted surface of the coated GDM at an angle of 5°, and can also be drawn into the pores of the coated GDM in 10 min when it is horizontal. The surface morphology, roughness and pore structures of GDMs are characterized by profilometry, scanning electron microscopy, and porosimetry. The measured internal pore size of the coated GDM is around 7.1 μm, and shows low energy resistance to gas transport. Performance testing indicates that the PEMFC equipped with sandwich wettability GDMs offers the best performance compared to those with raw GDM (untreated with surface coating), conventional GDM (with microporous layer) coated with PTFE or hydrophilic GDM (coated with silica particles).     

Microporous layer coated gas diffusion layers for enhanced performance of polymer electrolyte fuel cells

The influence of microporous layer (MPL) design parameters for gas diffusion layers (GDLs) on the performance of polymer electrolyte fuel cells (PEFCs) was clarified. Appropriate MPL design parameters vary depending on the humidification of the supplied gas. Under low humidification, decreasing both the MPL pore diameter and the content of polytetrafluoroethylene (PTFE) in the MPL is effective to prevent drying-up of the membrane electrode assembly (MEA) and enhance PEFC performance. Increasing the MPL thickness is also effective for maintaining the humidity of the MEA. However, when the MPL thickness becomes too large, oxygen transport to the electrode through the MPL is reduced, which lowers PEFC performance. Under high humidification, decreasing the MPL mean flow pore diameter to 3 μm is effective for the prevention of flooding and enhancement of PEFC performance. However, when the pore diameter becomes too small, the PEFC performance tends to decrease. Both reduction of the MPL thickness penetrated into the substrate and increase in the PTFE content to 20 mass% enhance the ability of the MPL to prevent flooding.     

Droplet pinning by PEM fuel cell GDL surfaces

In this work, side view images of liquid–gas–solid interfaces are observed during the evaporation of liquid water droplets on various commercially available untreated gas diffusion layers (GDLs). The change in contact diameter as a function of evaporative volume loss is measured to quantify the unpinning rates of micro-sized droplets. This contact diameter pinning behaviour during evaporation is correlated to the material topography, which is quantified through profilometry measurements. The carbon fibre paper with the smallest average roughness (15 μm) exhibits the strongest degree of pinning (unpinning at a rate of 0.13 mm/μL). Higher average surface roughnesses for felt (30 μm) and cloth yarn (32 μm) result in higher unpinning rates, 0.21 mm/μL and 0.19 mm/μL, respectively. These results indicate that common GDL materials exhibit Cassie–Baxter wetting behaviour, and reduced GDL roughness promotes droplet pinning. The material-specific droplet contact diameter progression should be considered during GDL selection for polymer electrolyte membrane (PEM) fuel cells. This work provides insight into the effect of GDL material properties on gas channel water management, as water droplets are expected to experience similar pinning to that observed in this work within the cathode gas channels of a PEM fuel cell.     

Liquid water distribution in hydrophobic gas-diffusion layers with interconnect rib geometry: An invasion-percolation pore network analysis

Water distribution in gas diffusion layers (GDLs) of polymer electrolyte membrane fuel cells (PEMFCs) is determined by the pore morphology of the GDL as well as the flow conditions between the GDL and the gas flow field, where interconnect ribs and gas channels are placed side-by-side. The present study employs a steady state pore network model based on the invasion-percolation (IP) process to investigate the water transport in the under-rib region, in the under-channel region, and in between those regions inside the GDL. The interconnect rib partially blocks the outlet surface of the GDL, which forces water transport paths from the under-rib region to grow towards the gas channel through an extra IP process. The pore network model predicts spatially non-uniform water distributions inside the GDL due to the interconnect ribs, especially with an increased saturation level in the under-rib region. Parametric studies are also conducted to investigate the effects of several geometrical factors, such as width of the rib and the channel, thickness of the GDL, and water intruding condition at the inlet surface of the GDL.     

Experimental study of the effect of dissolution on the gas diffusion layer in polymer electrolyte membrane fuel cells

The gas diffusion layer (GDL) is important for maintaining the performance of polymer electrolyte membrane (PEM) fuel cells, as its main function is to provide the cells with a path for fuel and water. In this study, the mechanical degradation process of the GDL was investigated using a leaching test to observe the effect of water dissolution. The amount of GDL degradation was measured using various methods, such as static contact angle measurements and scanning electron microscopy. After 2000 h of testing, the GDL showed structural damage and a loss of hydrophobicity. The carbon-paper-type GDL showed weaker characteristics than the carbon-felt-type GDL after dissolution because of the structural differences, and the fuel cell performance of the leached GDL showed a greater voltage drop than that of the fresh GDL. Contrary to what is generally believed, the hydrophobicity loss of GDL was not caused by the decomposition of polytetrafluoroethylene (PTFE).     

Development of a novel hydrophobic/hydrophilic double micro porous layer for use in a cathode gas diffusion layer in PEMFC

In this study, a gas diffusion layer (GDL) was modified to improve the water management ability of a proton exchange membrane fuel cell (PEMFC). We developed a novel hydrophobic/hydrophilic double micro porous layer (MPL) that was coated on a gas diffusion backing layer (GDBL). The water management properties, vapor and water permeability, of the GDL were measured and the performance of single cells was evaluated under two different humidification conditions, R.H. 100% and 50%. The modified GDL, which contained a hydrophilic MPL in the middle of the GDL and a hydrophobic MPL on the surface, performed better than the conventional GDL, which contained only a single hydrophobic MPL, regardless of humidity, where the performance of the single cell was significantly improved under the low humidification condition. The hydrophilic MPL, which was in the middle of the modified GDL, was shown to act as an internal humidifier due to its water absorption ability as assessed by measuring the vapor and water permeability of this layer.     

A design tool for predicting the capillary transport characteristics of fuel cell diffusion media using an artificial neural network

Developing a robust, intelligent design tool for multivariate optimization of multi-phase transport in fuel cell diffusion media (DM) is of utmost importance to develop advanced DM materials. This study explores the development of a DM design algorithm based on artificial neural network (ANN) that can be used as a powerful tool for predicting the capillary transport characteristics of fuel cell DM. Direct measurements of drainage capillary pressure–saturation curves of the differently engineered DMs (5, 10 and 20 wt.% PTFE) were performed at room temperature under three compressions (0, 0.6 and 1.4 MPa) [E.C. Kumbur, K.V. Sharp, M.M. Mench, J. Electrochem. Soc. 154(12) (2007) B1295–B1304; E.C. Kumbur, K.V. Sharp, M.M. Mench, J. Electrochem. Soc. 154(12) (2007) B1305–B1314; E.C. Kumbur, K.V. Sharp, M.M. Mench, J. Electrochem. Soc. 154(12) (2007) B1315–B1324]. The generated benchmark data were utilized to systematically train a three-layered ANN framework that processes the feed-forward error back propagation methodology. The designed ANN successfully predicts the measured capillary pressures within an average uncertainty of ±5.1% of the measured data, confirming that the present ANN model can be used as a design tool within the range of tested parameters. The ANN simulations reveal that tailoring the DM with high PTFE loading and applying high compression pressure lead to a higher capillary pressure, therefore promoting the liquid water transport within the pores of the DM. Any increase in hydrophobicity of the DM is found to amplify the compression effect, thus yielding a higher capillary pressure for the same saturation level and compression.     

Gas diffusion layer design focusing on the structure of the contact face with catalyst layer against water flooding in polymer electrolyte fuel cell

High humidity must be maintained inside polymer electrolyte fuel cells to achieve high ion conductivity. However, water condensation blocks the diffusion of the reaction gas in the gas diffusion layer under water saturation conditions which are produced by the product water. This effect is known as flooding and causes a sudden drop in the cell voltage. Therefore, advanced water management is required in such fuel cells. Internal water management is generally carried out by making adjustments to the gas diffusion layer. This study reports that the extremely highly flood-resistant gas diffusion layer has been developed, based on simple carbon paper. It was experimentally revealed that flooding is controlled by a gas diffusion layer with a smaller pore-structure facing the catalyst layer and it is one of the governing factors for flooding in the gas diffusion layer.