Morphological constants of porous media to predict effective properties for electrochemical devices

A comprehensive investigation into the morphology-dependent transport behaviors of porous media is presented in this study. Three-dimensional porous structures representing granular, fibrous, and cellular (foam-like) morphologies, commonly employed in electrochemical devices, were computationally generated and characterized across a porosity range of 0.35–0.85. Structural metrics, including specific surface area, mean pore size, tortuosity, and constrictivity, were quantified and predicted via empirical equations. Transport phenomena, including electrical/thermal conduction, mass diffusion, and permeation, were simulated and quantified using finite-difference and lattice-Boltzmann methods. Results reveal that the properties are significantly governed by both porous morphology and porosity. Empirical correlations that incorporate morphological constants and porosity accurately predict effective properties (e.g., conductivity, diffusivity, and permeability). The proposed morphological constants enable simplified yet accurate predictions of key functional properties, validated against experimental and numerical literature data. This framework provides a practical basis for morphology-driven optimization of porous media across various applications, where simultaneous transport through both solid and pore phases is critical, such as in electrochemistry.