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<p>Flexible and electrically conductive carbon papers (CPs) were fabricated via a low-temperature (≤ 350&#xa0;°C), resin-free wet-laying process, in which carbon nanotube (CNT) bundles function as multifunctional physical binders interconnecting individual carbon fibers to form a continuous percolating network, eliminating the need for conventional resin binders and high-temperature carbonization. By systematically varying the CNT bundle content, well-defined correlations are established among microstructural evolution, electrical resistance, and gas permeability, with an optimized CP achieving the lowest area-specific resistance under compression while maintaining adequate gas permeability. PTFE coating imparts excellent hydrophobicity comparable to that of commercial SGL-22BB, and despite the absence of a microporous layer (MPL), X-CT image analysis and pore-scale simulations confirmed a more open pore structure, lower water breakthrough pressure, and faster water removal velocity than SGL-22BB, demonstrating that the highly porous CNT bundle network alone is sufficient to achieve superior liquid water management capability. Electrochemical evaluation revealed stable polarization performance across a wide range of relative humidity, outperforming SGL-22BB under high-humidity conditions, while EIS analysis confirmed superior mass transport characteristics at high current densities. Furthermore, the fabricated CPs exhibited excellent mechanical flexibility, withstanding sharp bending without cracking—in stark contrast to the brittle fracture behavior of commercial SGL-22BB. These results establish CNT bundle-reinforced CPs as a mechanically robust and electrochemically viable alternative to conventional carbonized gas diffusion layers, offering a scalable low-temperature fabrication route for next-generation PEMFC systems.</p>

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Low-temperature, resin-free carbon papers with carbon nanotube bundles for gas diffusion layers in PEM fuel cells

  • 期刊论文

  • 发表日期：

    2026年6月15日

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  • Jae Young Jung,
  • Dong-Ju Lee,
  • Young Je Park,
  • Chi-Young Jung,
  • Yoonjong Yoo,
  • Hyunuk Kim

摘要

Flexible and electrically conductive carbon papers (CPs) were fabricated via a low-temperature (≤ 350 °C), resin-free wet-laying process, in which carbon nanotube (CNT) bundles function as multifunctional physical binders interconnecting individual carbon fibers to form a continuous percolating network, eliminating the need for conventional resin binders and high-temperature carbonization. By systematically varying the CNT bundle content, well-defined correlations are established among microstructural evolution, electrical resistance, and gas permeability, with an optimized CP achieving the lowest area-specific resistance under compression while maintaining adequate gas permeability. PTFE coating imparts excellent hydrophobicity comparable to that of commercial SGL-22BB, and despite the absence of a microporous layer (MPL), X-CT image analysis and pore-scale simulations confirmed a more open pore structure, lower water breakthrough pressure, and faster water removal velocity than SGL-22BB, demonstrating that the highly porous CNT bundle network alone is sufficient to achieve superior liquid water management capability. Electrochemical evaluation revealed stable polarization performance across a wide range of relative humidity, outperforming SGL-22BB under high-humidity conditions, while EIS analysis confirmed superior mass transport characteristics at high current densities. Furthermore, the fabricated CPs exhibited excellent mechanical flexibility, withstanding sharp bending without cracking—in stark contrast to the brittle fracture behavior of commercial SGL-22BB. These results establish CNT bundle-reinforced CPs as a mechanically robust and electrochemically viable alternative to conventional carbonized gas diffusion layers, offering a scalable low-temperature fabrication route for next-generation PEMFC systems.