Comparative Studies of Three-Dimensional Complex Flow Field Designs in a Proton Exchange Membrane Hydrogen Fuel Cell

Dilyan Gavrailov and Silviya Boycheva ()
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Dilyan Gavrailov: Department of Thermal and Nuclear Power Engineering, Technical University of Sofia, 8 Kl. Ohridsky Blvd., 1000 Sofia, Bulgaria
Silviya Boycheva: Department of Thermal and Nuclear Power Engineering, Technical University of Sofia, 8 Kl. Ohridsky Blvd., 1000 Sofia, Bulgaria

Energies, 2025, vol. 18, issue 9, 1-22

Abstract: The performance and durability of proton-exchange membrane fuel cells (PEMFCs) are dependent on fuel flow, humidifying water, and outgoing water management. Unlike conventional flow fields with linear channels, the complex 3D flow field—featuring repeating baffles along the channel, known as the baffle design—induces a micro-scale interface flux between the gas diffusion layer (GDL) and the flow fields. Thus, an intensive oxygen flow is created that removes excess water from the GDL, thereby improving the fuel cell efficiency. Another approach for channel design is the Turing flow field, which resembles the organization of fluid flows in natural objects such as leaves, lungs, and the blood system. This design enhances the distribution of inlet flow significantly compared with traditional designs. The present study aims to combine the advantages of both Turing and baffle flow field designs and to provide model investigations on the influence of the mixed flow field design on the efficiency of PEMFCs. It was established that the mixed design achieves the highest electrode current density of 1.2 A/cm 2 , outperforming the other designs. Specifically, it achieves 20% improvement over the Turing design, reaching 1.0 A/cm 2 and generating three times more current than the baffle design, which delivers 0.4 A/cm 2 . In contrast, the conventional serpentine designs exhibit the lowest current density. The mixed flow field design provides better oxygen utilization in the electrochemical reaction, offers optimal membrane hydration, and contributes to superior electrode current density performance. These data illustrate how flow field structure directly impacts fuel cell efficiency through enhancement of current density.

Keywords: flow field design; gas distribution in fuel cells; channel configuration; COMSOL Multiphysics (search for similar items in EconPapers)
JEL-codes: Q Q0 Q4 Q40 Q41 Q42 Q43 Q47 Q48 Q49 (search for similar items in EconPapers)
Date: 2025
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