A microporous layer (MPL) is a transition layer with a porous material structure, located between the gas diffusion layer (GDL) and catalyst layer (CL) in a proton exchange membrane fuel cell (PEMFC). It not only significantly improves electron transfer and heat conduction in membrane electrode assembly, but also effectively manages liquid water transport to enhance the fuel cell performance. The MPL is usually coated on one side of the GDL. The fragile nature of MPL makes it challenging to characterize the effective transport properties using experimental methods. In this study, a stochastic numerical method is implemented to reconstruct the three-dimensional microstructure of an MPL consisting of carbon particles and PTFE. The reliability of the MPL reconstructed model is validated using experimental data. The relationship between the effective transport properties and the compression strain is obtained using the Pore Scale Model (PSM), while the relationship between the liquid water saturation and capillary pressure is solved by Lattice Boltzmann Method (LBM). The effective transport properties in the MPL are then imported into the two-phase flow fuel cell model. It is found that the effective transport parameters in MPL obtained by PSM and LBM can improve the accuracy of the model calculation. This study provides an effective method to reconstruct the microstructure of MPL that can generate precise MPL transport parameters for utilization in various PEMFC performance prediction models.

In this study, a 3D model of a proton exchange membrane fuel cell (PEMFC) with crossed channels and an ultra-thin membrane is developed to investigate the feasibility of self-humidification; experiments utilizing a PEMFC stack with identical configurations are conducted to validate the simulation results and further investigate the effects of various operating conditions (OCs) on self-humidification. The results indicate that the crossed flow channel leads to enhanced uniformity of water distribution, resulting in improved cell performance under low/no humidification conditions. External humidifiers for the anode can be removed since the performance difference is negligible (≤3%) between RHa = 0% and 100%. Self-humidification can be achieved in the stack at 90 °C or below with an appropriate back pressure among 100–200 kPa. As the current density increases, there is a gradual convergence and crossing of the voltage at low RH with that at high RH, and the crossover points are observed at 60–80 °C with suitable pressure when successful self-humidification is achieved. Below the current density of the point, the stack’s performance is inferior at lower RH due to membrane unsaturation, and conversely, the performance is inferior at higher RH due to flooding; this current density decreases with higher pressure and lower temperature.