Influence of binder content on gas-water two-phase flow and displacement phase diagram in the gas diffusion layer of PEMFC: A pore network view

Understanding the gas-water flow dynamics in the gas diffusion layer (GDL) is one of the keys to improving the proton exchange membrane fuel cell's (PEMFC) overall performance and avoiding water flooding. Yet, the relationship between the two-phase flow and micro-scale GDL structures (including binder, PTFE, and fiber skeleton) is not well understood. In this study, three-dimensional GDL structures with different fractions of binder contents (phi(b) = 0% similar to 50%) and a fixed porosity of 75.6 % are confidently reconstructed based on highresolution images from the confocal microscope, implying that the addition of binder will increase the number of large pores and cause a bimodal throat size distribution through morphology analysis. Thereafter, drainage simulations are performed under a wide range of capillary number (-9 < log Ca <0) and viscosity ratio (-3 < log M < 2) by the pore network model (PNM), which robustly predicts the displacement phase diagram of viscous fingering, capillary fingering, stable displacement, and transitional regime. In the viscous fingering and stable displacement regime, the nonwetting phase saturation (S-nw) is nearly the same for different phi(b), implying the fluid invading pathway does not change much with the addition of binder. However, in the capillary fingering regime (refer to the actual operating conditions), S-nw increases rapidly with phi(b) at the breakthrough time and its transient value continues to increase until the steady state, which may be attributed to the increased fractions of pores above the capillary threshold attributed by the bimodal throat size distribution. In addition, the effective water permeability increases sharply with phi(b), whereas the gas permeability remains almost constant, which means such pore structure alteration by adding the binder is beneficial to water disposal in PEMFC. This research provides insights into delineating the effect of pore and throat size distribution alteration by adding binder on two-phase dynamics in GDL.