Liquid water is pushed through flow channels of fuel cells, where one surface is a porous carbon electrode made up of carbon fibers. Water drops grow on the fibrous carbon surface in the gas flow channel. The drops adhere to the superficial fiber surfaces but exhibit little penetration into the voids between the fibers. The fibrous surfaces are hydrophobic, but there is a substantial threshold force necessary to initiate water drop motion. Once the water drops begin to move, however, the adhesive force decreases and drops move with minimal friction, similar to motion on superhydrophobic materials. We report here studies of water wetting and water drop motion on typical porous carbon materials (carbon paper and carbon cloth) employed in fuel cells. The static coefficient of friction on these textured surfaces is comparable to that for smooth Teflon. But the dynamic coefficient of friction is several orders of magnitude smaller on the textured surfaces than on smooth Teflon. Carbon cloth displays a much smaller static contact angle hysteresis than carbon paper due to its two-scale roughness. The dynamic contact angle hysteresis for carbon paper is greatly reduced compared to the static contact angle hysteresis. Enhanced dynamic hydrophobicity is suggested to result from the extent to which a dynamic contact line can track topological heterogeneities of the liquid/solid interface. KEYWORDS: contact angle, hydrophobic, carbon, wetting, carbon fibers, contact angle hysteresis, Teflon
■ INTRODUCTIONWater transport is an essential element of polymer electrolyte membrane (PEM) fuel cell operation. 1−5 Liquid water that is formed at a catalyst/membrane interface is pushed through porous electrodes into gas flow channels. The water drops emerge from the largest pores in the electrode, and grow in the channel. Initially, the drops are held in place by adhesion to the water column in the electrode pore, but as the drops grow surface contact with the porous electrode and surface contact with the walls of the flow channel are the dominate adhesive forces. The drop must be detached and pushed through the gas flow channel in contact with the electrode surface to be removed from the fuel cell. Efficient fuel cell operation requires removal of liquid water drops from the fuel cell with minimal work. The surface properties of the porous electrode play a key role in the energy required to remove water drops from the gas flow channels of the fuel cell. We have been devising experiments to isolate the flow resistances for water transport through the porous electrode and gas flow channel. 6−8 The porous electrode is required to carry the electron current from the electrocatalyst to the external circuit. 9 It must also permit transport of gas reactants and liquid product between the gas flow channels and the catalyst/PEM interface. 4,10,11 The porous electrode, or gas diffusion layer (GDL), of the fuel cell is typically made from carbon fibers, either as a random sheet of fibers in the form of carbon paper or as a woven arr...