Innovative flow field design strategies for performance optimization in polymer electrolyte membrane fuel cells

This study introduces an innovative flow field design methodology that departs from traditional approaches, aiming to simplify design variables and ensure an efficient, automated design process. This methodology integrates topology optimization, the Gray-Scott reaction/diffusion system, and Murray's law to design the flow field layout. We applied this methodology to the flow field design of Polymer Electrolyte Membrane Fuel Cells (PEMFC) bipolar plates. Specifically, the optimal two-dimensional pattern of the PEMFC cathode flow field was achieved by merging topology optimization with the Gray-Scott reaction/diffusion system. Applying Murray's law, an optimal three-dimensional flow field with an unpredictable new pattern was established. The design emphasizes efficient fuel diffusion and reduced flow resistance, validated through experiments. Quantitative comparisons with serpentine and parallel flow fields showed performance differences of approximately 60 mV and 120 mV at a current density of 1.43 A/cm², respectively. These metrics reflect the impact on mass transfer efficiency under high-power PEMFC operations, serving as critical indicators of flow field effectiveness. Additionally, simulations confirmed an 18-fold reduction in pressure drop compared to the serpentine design. This innovative design process offers advantages that could be incorporated into diverse research areas in the future.