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Effect of carbon fiber orientation in gas diffusion layers on performance of Polymer electrolyte membrane fuel cell
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DOI：10.1016/j.jiec.2026.03.007.png)
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Abstract
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To accelerate PEMFC commercialization, stable water management across various humidity conditions and a lightweight balance of plant (BOP) are essential, requiring structural optimization of the gas diffusion layer (GDL). This study investigates how GDL fiber orientations, Diagonal (45°), Vertical (90°), and Parallel (0°), affect electrochemical performance at RH levels from 100% to 25%. Results reveal a fundamental shift in dominant physical mechanisms depending on RH. At 100% RH, Diagonal achieved the highest peak power density (790 mW/cm2), followed by Vertical (750) and Parallel (680), with drainage being the key factor. Conversely, at 25% RH, a performance inversion occurred between Parallel and Vertical. Parallel (220 mW/cm2) significantly outperformed Vertical (120) due to superior water retention and gas diffusion under dry conditions. Importantly, Diagonal maintained the highest performance across all levels, reaching 230 mW/cm2 at 25% RH. Furthermore, Diagonal and Parallel maintained strong performance retention of 29.1% and 32.4%, while Vertical’s performance dropped to 16.0% due to severe membrane dehydration. Overall, the diagonal orientation offers an ideal balance by combining high-humidity drainage and low-humidity retention capabilities. These findings validate the diagonal structure as an essential design parameter for next-generation, humidifier-less fuel cells, ensuring operational stability in diverse environments.
Keywords:
GDL fiber orientation
PEMFC performance
humidity effects
water management
gas diffusion layer
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