Improved analytical modeling and mechanical characterization of gas diffusion layers under compression load

Gas diffusion layers (GDLs) are the most rigid layers in a 5‐layer or 7‐layer membrane electrode assembly (MEA) of a proton exchange membrane fuel cell. Therefore, in the fuel cell analysis, the mechanical properties of GDLs have a great impact on the stress distribution of the membrane as well as the performance of the whole cell. However, the mechanical properties of GDLs are not sufficiently studied. Nonlinear behavior of GDLs under cyclic compression is discussed rarely in literature. The existing model takes both constraints into consideration, but due to a geometrical oversimplification of the carbon paper microstructure, it shows some deviation, which cannot be overcome by selecting appropriate parameters. In this paper, the geometry of carbon paper microstructure has been reanalyzed. Based on the improved geometry formula, a modified model of carbon paper GDL is presented and verified by experimental data. Furthermore, both the experimental mechanical characteristics are achieved as support data for the improved model. A mechanical model of GDL under compression is established. Microstructure deformation was linked to the macroscopic model. The model showed a good agreement when porosity was as low as 75%. Mechanical characteristics were achieved as support data.