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<p>Gas diffusion layers (GDLs) are critical to the performance of proton exchange membrane fuel cells (PEMFCs) due to their roles in mass transport and interfacial mechanics. Deformation mismatch between GDLs and bipolar plates (BPPs) causes stress concentration and increases contact resistance, reducing efficiency and durability. To address this, porous GDL models were reconstructed and analyzed using finite element simulations, considering homogeneous, uniform pore, and gradient pore structures along with different material systems. Results show that gradient structures and high Young’s modulus materials redistribute stress, suppress localized deformation, and reduce contact resistance, producing more uniform pressure fields and balanced current distribution. This study provides quantitative mechanical insights for structural optimization of GDLs and supports the design of PEMFC components with improved mechanical reliability and long-term durability.</p>

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Porosity-gradient design of gas diffusion layers: Random reconstruction and finite element analysis of interfacial mechanics

  • 期刊论文

  • 发表日期：

    2026年6月18日

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  • Dongming Li,
  • Shuhong Yang,
  • Bin Liu,
  • Bona Fu,
  • Hong Zhao,
  • Yong Zhang

摘要

Gas diffusion layers (GDLs) are critical to the performance of proton exchange membrane fuel cells (PEMFCs) due to their roles in mass transport and interfacial mechanics. Deformation mismatch between GDLs and bipolar plates (BPPs) causes stress concentration and increases contact resistance, reducing efficiency and durability. To address this, porous GDL models were reconstructed and analyzed using finite element simulations, considering homogeneous, uniform pore, and gradient pore structures along with different material systems. Results show that gradient structures and high Young’s modulus materials redistribute stress, suppress localized deformation, and reduce contact resistance, producing more uniform pressure fields and balanced current distribution. This study provides quantitative mechanical insights for structural optimization of GDLs and supports the design of PEMFC components with improved mechanical reliability and long-term durability.