Enhancing Fuel Cell Performance by Constructing a Gas Diffusion Layer with Gradient Microstructure

This study focuses on addressing the issues of water flooding and mass transfer limitations in proton exchange membrane fuel cells (PEMFCs) under high current density conditions. A multi-scale gradient pore gas diffusion layer (GDL) is designed to enhance fuel cell performance. The pore structure is precisely controlled using a self-assembled mold, resulting in the fabrication of a GDL with a gradient distribution of pore diameters ranging from 80 to 170 μm. Experimental results indicate that, with the optimized gradient pore GDL, the peak power density of the fuel cell reaches 1.18 W·cm−2, representing a 20% improvement compared to the traditional structure. A mechanism analysis reveals that this structure establishes a concentrated water transport pathway through channels while enabling gas diffusion and transport driven by concentration gradients, thereby achieving the collaborative optimization of gas–liquid transport. This approach offers a novel solution for managing water in PEMFCs operating under high current density conditions, and holds significant implications for advancing the commercialization of PEMFC technology.