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<p>The gas diffusion layer (GDL), one of the key components of a polymer electrolyte membrane fuel cell (PEMFC) is important component that determinines mass transfer characteristics and electrical resistance. In this study, the GDL thickness under channel was controlled as a variable and its effects on PEMFC performance were analyzed under different channel type conditions. Through computational fluid dynamics (CFD) analysis of PEMFCs with various GDL thicknesses, the optimal thickness was defined as the value that maximizes the current density at a specific operating voltage. Furthermore the maximum current density results from the competing effects of ohmic resistance and concentration polarization. The optimized GDL thickness under the channel varied according to the channel type and cell voltage. In both serpentine and parallel channels, the optimal GDL thicknesses were distinctly 80&#xa0;μm at high cell voltage and 20&#xa0;μm at low cell voltage. The maximum performance improvements achieved by the patterned GDL in the serpentine channel were 9.9%, 8.1%, and 9.7% for each voltage condition. Similarly, the parallel channel showed improvements of 10.2%, 8.5%, and 11.4%. In contrast, the performance enhancement resulting from the patterned GDL thickness in the interdigitated channel was smaller than in the serpentine and parallel cases. This discrepancy in optimal thickness stems from the unique flow properties of the interdigitated channel. Specifically, the optimal thicknesses for this channel were 60&#xa0;μm and 40&#xa0;μm at high and low cell voltage conditions, respectively. The maximum improvement ratio was 7.5%, 3.7% and 3.4%. This study demonstrates that optimizing GDL thickness alone can improve PEMFC performance by 3.5–10%, depending on the channel type, without the need for improved materials or special operating conditions.</p>

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Optimizing Thickness of Selective-Patterned Gas Diffusion Layers in Polymer Electrolyte Membrane Fuel Cell Through Numerical Analysis

  • 期刊论文

  • 发表日期：

    2026年7月24日

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  • Jonghyun Son,
  • Fritz B. Prinz,
  • Young-Beom Kim

摘要

The gas diffusion layer (GDL), one of the key components of a polymer electrolyte membrane fuel cell (PEMFC) is important component that determinines mass transfer characteristics and electrical resistance. In this study, the GDL thickness under channel was controlled as a variable and its effects on PEMFC performance were analyzed under different channel type conditions. Through computational fluid dynamics (CFD) analysis of PEMFCs with various GDL thicknesses, the optimal thickness was defined as the value that maximizes the current density at a specific operating voltage. Furthermore the maximum current density results from the competing effects of ohmic resistance and concentration polarization. The optimized GDL thickness under the channel varied according to the channel type and cell voltage. In both serpentine and parallel channels, the optimal GDL thicknesses were distinctly 80 μm at high cell voltage and 20 μm at low cell voltage. The maximum performance improvements achieved by the patterned GDL in the serpentine channel were 9.9%, 8.1%, and 9.7% for each voltage condition. Similarly, the parallel channel showed improvements of 10.2%, 8.5%, and 11.4%. In contrast, the performance enhancement resulting from the patterned GDL thickness in the interdigitated channel was smaller than in the serpentine and parallel cases. This discrepancy in optimal thickness stems from the unique flow properties of the interdigitated channel. Specifically, the optimal thicknesses for this channel were 60 μm and 40 μm at high and low cell voltage conditions, respectively. The maximum improvement ratio was 7.5%, 3.7% and 3.4%. This study demonstrates that optimizing GDL thickness alone can improve PEMFC performance by 3.5–10%, depending on the channel type, without the need for improved materials or special operating conditions.