Effect of composition and structure of gas diffusion layer and microporous layer on the through-plane gas permeability of PEFC porous media

The through-plane permeability of the gas diffusion media (GDM) is investigated experimentally with regard to the microporous layer (MPL) composition and the gas diffusion layer (GDL) composition and structure. The MPL composition is held constant at 80% carbon powder and 20% polytetrafluorethylene (PTFE) (by weight) for various carbon loadings. The decrease or increase in GDM permeability was found to be dependent on the structure of the GDL used in conjunction with the type of carbon powder. It was found that low-surface-area carbon powder (Vulcan XC-72R) forms thin, dense MPLs with small cracks when compared to high-surface-area powder (Ketjenblack EC-300J), which creates thick, rough MPLs with large cracks with increased carbon loadings. For most cases, the permeability decreases with increasing carbon loading; however, the non-woven, straight fibre carbon papers using Ketjenblack EC-300J show the lowest permeability at the lowest carbon loading. Furthermore, the percentage reduction from the GDL substrate permeability appears to be predictable for similar structures with increasing carbon loading. The increase in PTFE loading from 10% to 30% in the GDL was shown to have a significant impact on the percentage reduction from the original GDL permeability of ~9% to 15% for the GDM composed of Vulcan XC-72R as carbon powder; however, such effects are insignificant when using Ketjenblack EC-300J carbon powder.