The water transport behavior in the Gas Diffusion Layer (GDL) depends on the pore characteristics, which include the pore size distribution, the wetting properties of the fibers, and the shape of the pore. In this study we investigate the impact of pore geometry on the breakthrough pressure of the GDL. The study shows the importance of the inclusion of different types of pore shapes in the analysis of the water transport behavior. The water invasion process through a pore inlet is simulated using a surface energy minimization model. In a GDL coated with a non-wetting coating such as PTFE, water makes contact with non-wetting fibers and with defects which pin the gas-liquid interface. The mixed-non-wetting (MNW) pore inlet is defined by fiber segments of varied wetting properties, in order to capture the water percolation process in the presence of coating defects. The shape of the pore is quantified according to its aspect ratio (AR). The high aspect ratio pores present the characteristics of micro-cracks. High to moderate aspect ratio pores up to a value of one, corresponding to the unskewed pore, are considered. For wetting pores with AR close to one, the changes in breakthrough pressure are minimal. The breakthrough pressure changes significantly in the case of mixed-non-wetting pores. MNW pores with few coating defects are further investigated by varying the AR and determining the corresponding Laplace pressure for each case. The breakthrough pressure and the droplet volume at breakthrough have direct implication on water management, through their influence on liquid finger formation. The changes in breakthrough pressure with the aspect ratio point to the necessity to include the pore shape distribution in porous media models, to accurately predict the water transport behavior in the GDL.
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