An optimized microstructure to minimizing in-plane and through-plane pressure drops of fibrous materials: Counter-intuitive reduction of gas diffusion layer permeability with porosity

The present study experimentally investigates the realistic functionality of in-plane and through-plane pressure drops of layered fibrous media with porosity, fiber diameter, fiber spacing, fiber-fiber angles and fiber-flow angles. The study also reveals that pressure drop may increase with porosity and fiber diameter under specific circumstances. This counter-intuitive point narrows down the validity range of widely-used permeability-porosity-diameter models or correlations. It is found that, for fibrous materials, the most important parameter that impacts the in-plane pressure drop is not their porosities but the number of fibers extended in the flow direction. It is also concluded that in-plane pressure drop is highly dependent upon the flow direction (fiber-flow angles), especially at lower porosities. Contrary to in-plane pressure drop, through-plane pressure drop is a weak function of fiber-fiber angles but is strongly impacted by fiber spacing, especially at lower porosities. At a given porosity, low through-plane pressure drops occur if fiber spacing does not change practically from one layer to another. Through-plane pressure drop also, insignificantly, increases with the intersecting angles between fibers. An optimized microstructure of fibrous media resulting in minimal in-plane and through-plane pressure drops is also offered for the first time in this work.