Development of bipolar plates with different flow channel configurations for fuel cells

Bipolar plates include separate gas flow channels for anode and cathode electrodes of a fuel cell. These gases flow channels supply reactant gasses as well as remove products from the cathode side of the fuel cell. Fluid flow, heat and mass transport processes in these channels have significant effect on fuel cell performance, particularly to the mass transport losses. The design of the bipolar plates should minimize plate thickness for low volume and mass. Additionally, contact faces should provide a high degree of surface uniformity for low thermal and electrical contact resistances. Finally, the flow fields should provide for efficient heat and mass transport processes with reduced pressure drops. In this study, bipolar plates with different serpentine flow channel configurations are analyzed using computational fluid dynamics modeling. Flow characteristics including variation of pressure in the flow channel across the bipolar plate are presented. Pressure drop characteristics for different flow channel designs are compared. Results show that with increased number of parallel channels and smaller sizes, a more effective contact surface area along with decreased pressured drop can be achieved. Correlations of such entrance region coefficients will be useful for the PEM fuel cell simulation model to evaluate the affects of the bipolar plate design on mass transfer loss and hence on the total current and power density of the fuel cell.     

The effect of operating parameters on water transport in PEM fuel cells

Water content in the membrane and the presence of liquid water in the catalyst layers (CL) and the gas diffusion layers (GDL) play a very important role in the performance of a PEM fuel cell. To study water transport in a PEM fuel cell, a two‐phase flow mathematical model is developed. This model couples the continuity equation, momentum conservative equation, species conservative equation, and water transport equation in the membrane. The modeling results of fuel cell performances agree well with measured experimental results. Then this model is used to simulate water transport and current density distribution in the cathode of a PEM fuel cell. The effects of operating pressure, cell temperature, and humidification temperatures on the net water transfer through the membrane, liquid water saturation, and current density distribution are studied. © 2006 Wiley Periodicals, Inc. Heat Trans Asian Res, 35(2): 89–100, 2006; Published online in Wiley InterScience ( www.interscience. wiley.com ). DOI 10.1002/htj.20107     

Comparative analysis of two-phase flow in sinusoidal channel of different geometric configurations with application to PEMFC

The droplet dynamics inside a sinusoidal channel for PEMFC (polymer electrolyte membrane fuel cell) are investigated numerically using the VOF (volume of fluid) method. This study is done for three geometrically different channels corresponding to various non-dimensional sinusoidal distances (50, 25, 12.5, 16.7 and 8.3). The effects of key parameters like sinusoidal distance (pitch-amplitude ratio), radius of curvature and wall contact angle on the droplet removal in the flow channel are investigated. The performance of the sinusoidal as compared to the conventional channel is studied based on droplet removal rate and GDL (gas diffusion layer) surface water coverage. It is found that the droplet removal rate increases with increasing sinusoidal distance and wall contact angle. In addition, decrease in the sinusoidal distance results in a significant reduction in the average droplet speed and gas diffusion layer surface water coverage. It was also observed that broken bits of the droplet stuck on the wall corners accrued with a reduction in the wall contact angle. The curvy nature of the side walls generally induces a secondary flow effect which would be most beneficial in enhanced reactant diffusion and cell performance. It is suggested that the sinusoidal distance and wall contact angle effect on two-phase flow in a channel is highly significant. As such, needs to be considered for water management in sinusoidal channels.     

Effects of serpentine flow field with outlet channel contraction on cell performance of proton exchange membrane fuel cells

A serpentine flow field with outlet channels having modified heights or lengths was designed to improve reactant utilization and liquid water removal in proton exchange membrane (PEM) fuel cells. A three-dimensional full-cell model was developed to analyze the effects of the contraction ratios of height and length on the cell performance. Liquid water formation, that influences the transport phenomena and cell performance, was included in the model. The predictions show that the reductions of the outlet channel flow areas increase the reactant velocities in these regions, which enhance reactant transport, reactant utilization and liquid water removal; therefore, the cell performance is improved compared with the conventional serpentine flow field. The predictions also show that the cell performance is improved by increments in the length of the reduced flow area, besides greater decrements in the outlet flow area. If the power losses due to pressure drops are not considered, the cell performance with the contracted outlet channel flow areas continues to improve as the outlet flow areas are reduced and the lengths of the reduced flow areas are increased. When the pressure losses are also taken into account, the optimal performance is obtained at a height contraction ratio of 0.4 and a length contraction ratio of 0.4 in the present design.     

Design and simulation of a novel bipolar plate based on lung‐shaped bio‐inspired flow pattern for PEM fuel cell

Finding the optimal flow pattern in bipolar plates of a proton exchange membrane is a crucial step for enhancing the performance of the device. This design plays a critical role in fluid mass transport through microporous layers, charge transfer through conductive media, management of the liquid water produced in microchannels, and microporous layers and heat management in fuel cells. This article investigates different types of common flow patterns in bipolar plates while considering a uniform pressure and velocity distribution as well as a uniform distribution of reactants through all the surfaces of the catalyst layer as the design criteria so that there would be a consistent electron production by the catalyst layer. Then, by identifying the important parameters in achieving the best performance of a fuel cell, a microfluidic flow pattern is inspired from the lungs in the human body, and an innovative bipolar plate is suggested, which was not proposed before. Afterwards, numerical simulations were carried out using computational fluid dynamics methods, and the mentioned bipolar plate called lung‐shaped bipolar plate was modeled. Simulations in this research showed that the lung‐shaped microfluidic flow pattern is an appropriate flow pattern to gain maximum power and energy density. In other words, the best polarization curve and power density curve are obtained by using the lung‐shaped bipolar plate in a proton exchange membrane fuel cell compared with previously suggested patterns. Copyright © 2017 John Wiley & Sons, Ltd.     

A novel material fabrication method for the PEM fuel cell bipolar plate

Gelcasting, a near net-shape forming process, is suitable for manufacturing of structural ceramics with various shapes. In this study, the gelcasting process was adopted to obtain the material for PEM fuel cell bipolar plates. The mesocarbon microbead (MCMB) that has the unique self-sintering property was chosen as the starting material. In order to optimize the MCMB suspensions for gelcasting, the zeta potentials of the MCMB particles dispersing in water were investigated. A stable MCMB suspension with solid loading up to 66.7 wt.% was prepared from which the uniform green parts with complex structures were successfully molded. Finally, the physical properties of green parts and sintered samples were evaluated.     

质子交换膜燃料电池建模及水热传输特性分析

针对质子交换膜燃料电池(PEMFC)水管理开展了研究,建立了一维非等温两相流解析模型,研究了不同电流密度、微孔层接触角和不同加湿方案对电池内部水分布和温度分布的影响,提出了更好的进气加湿方案。结果表明:电流密度增大会导致阳极拖干、阴极水淹加剧,导致电池各部分温度上升。因各层材料亲水性不同,在交界面处能观察到液态水阶跃现象。增大微孔层接触角促进阴极液态水反扩散到阳极,一定程度上缓解阳极变干,但过大的接触角可能导致阴极水淹加剧。通过采取"阳极充分加湿、阴极低加湿"的进气加湿方案可以有效提高电池性能,并且能在一定程度改善电池内部受热,提高电池使用寿命。     

A linear quadratic regulator control of a stand-alone PEM fuel cell power plant

This paper introduces a technique based on linear quadratic regulator (LQR) to control the output voltage at the load point versus load variation from a standalone proton exchange membrane (PEM) fuel cell power plant (FCPP) for a group housing use. The controller modifies the optimal gains k _i by minimizing a cost function, and the phase angle of the AC output voltage to control the active and reactive power output from an FCPP to match the terminal load. The control actions are based on feedback signals from the terminal load, output voltage and fuel cell feedback current. The topology chosen for the simulation consists of a 45 kW proton exchange membrane fuel cell (PEMFC), boost type DC/DC converter, a three-phase DC/AC inverter followed by an LC filter. Simulation results show that the proposed control strategy operated at low commutation frequency (2 kHz) offers good performances versus load variations with low total harmonic distortions (THD), which is very useful for high power applications.     

Development of shut-down process for a proton exchange membrane fuel cell

Several different shut-down procedures were carried out to reduce the degradation of membrane electrode assembly (MEA) in a proton exchange membrane fuel cell (PEMFC). The effects of close/open state of outlets of a single cell and application of a dummy load during the shut-down on the degradation of the MEA were investigated. Also, we elucidated the relationship between the thickness of the electrolyte membrane and the degradation of the MEA for different shut-down procedures. When a thin electrolyte membrane was used, the closer of outlets mitigated the degradation during on/off operation. For the thicker electrolyte membrane, the dummy load which eliminates residual hydrogen and oxygen in the electrodes should be applied to lower the degradation.     

Numerical investigation on the performance of proton exchange membrane fuel cells with channel position variation

Such factors as mole fractions of species, water generation, and conductivity influence the performance of proton exchange membrane fuel cells (PEMFCs). The geometrical shape of the fuel cells also should be considered a factor in predicting the performance because this affects the species' reaction speed and distribution. Specifically, the position between the channel and rib is an important factor influencing PEMFC performance because the current density distribution is affected by the channel and rib position. Three main variables that decide the current density distribution are selected in the paper: species concentration, overpotentials, and membrane conductivity. These variables should be considered simultaneously in deciding the current density distribution with the given PEMFC cell voltage. In addition, the inlet relative humidity is another factor affecting current density distribution and membrane conductivity. In this paper, two channel‐to‐rib models, namely, channel‐to‐channel and the channel‐to‐rib, are considered for comparing the PEMFC performance. Thorough performance comparisons between these two models are presented to explain which is better under certain parameters. A three‐dimensional numerical PEMFC model is developed for obtaining the current density distribution. Water transfer mechanism because of electro osmotic drag and concentration diffusion also is presented to explain the PEMFC performance comparison between the two models. Copyright © 2012 John Wiley & Sons, Ltd.     

Manufacturing and performance assessment of stamped,laser welded,and nitrided FeCrV stainless steel bipolar plates for proton exchange membrane fuel cells

A manufacturing and single-cell fuel cell performance study of stamped, laser welded, and gas nitrided ferritic stainless steel foils in an advanced automotive bipolar plate assembly design was performed. Two developmental foil compositions were studied: Fe–20Cr–4V and Fe–23Cr–4V wt.%. Foils 0.1 mm thick were stamped and then laser welded together to create single bipolar plate assemblies with cooling channels. The plates were then surface treated by pre-oxidation and nitridation in N₂–4H₂ based gas mixtures using either a conventional furnace or a short-cycle quartz lamp infrared heating system. Single-cell fuel cell testing was performed at 80 °C for 500 h at 0.3 A/cm² using 100% humidification and a 100%/40% humidification cycle that stresses the membrane and enhances release of the fluoride ion and promotes a more corrosive environment for the bipolar plates. Periodic high frequency resistance potential-current scans during the 500 h fuel cell test and post-test analysis of the membrane indicated no resistance increase of the plates and only trace levels of metal ion contamination.     

Development of composite-metal hybrid bipolar plates for PEM fuel cells

In this study, in order to increase the electrical conductivity, a carbon composite-metal hybrid bipolar plate has been developed using pre-forming method followed by a plasma surface treatment. A pre-formed metal foil between the carbon fiber/polymer composite plates promotes the metal foil to follow the shape of the channels of the bipolar plates without tearing and permits a continuous flow of electrons. The pre-formed metal foil also reduces the residual stress between the composite and metal foils, which helps prevent delamination between the composite and metal foils. The composite surface has been treated with plasma to increase the contact area between the carbon fiber and the gas diffusion layer (GDL). The composite-metal hybrid bipolar plates have only 1.4% of the total electrical resistance of that of the conventional composite bipolar plates. Unit cell test results have proved that the developed composite-metal hybrid bipolar plates with reduced total electrical resistance increase the cell performance.     

Baffle shape effects on mass transfer and power loss of proton exchange membrane fuel cells with different baffled flow channels

In proton exchange membrane fuel cells, baffled flow channels can enhance the reactant transfer and improve the cell performance. Many different baffled flow channels have been numerically studied in previous published papers. However, what kind of baffled flow channels can improve the cell performance most is still unknown. In this simulation work, a two‐dimensional, two‐phase, nonisothermal, and steady‐state model of proton exchange membrane fuel cells is developed. The mass transfer and cell performance of PEMFCs with different baffled flow channels have been numerically compared. Simulation results show that the rectangular baffle can enhance the reactant transfer most and improve the cell performance most; however, the power loss in rectangular baffled flow channel is also the highest. To inherit the advantages and overcome the shortages of the rectangular baffled flow channel, an optimized baffled flow channel is developed. In this newly developed baffled flow channel, the windward side is designed as the streamline shape and the leeward side is designed as the sloped shape. Results of the simulation also show that the optimized baffled flow channel can reduce the power loss accounted by the pumping power in reactant delivering process and the cell performance can be further improved.     

Pre-oxidized and nitrided stainless steel alloy foil for proton exchange membrane fuel cell bipolar plates. Part 2: Single-cell fuel cell evaluation of stamped plates

Thermal (gas) nitridation of stainless steel alloys can yield low interfacial contact resistance (ICR), electrically conductive and corrosion-resistant nitride containing surface layers (Cr₂N, CrN, TiN, V₂N, VN, etc.) of interest for fuel cells, batteries, and sensors. This paper presents results of proton exchange membrane (PEM) single-cell fuel cell studies of stamped and pre-oxidized/nitrided developmental Fe-20Cr-4V weight percent (wt.%) and commercial type 2205 stainless steel alloy foils. The single-cell fuel cell behavior of the stamped and pre-oxidized/nitrided material was compared to as-stamped (no surface treatment) 904L, 2205, and Fe-20Cr-4V stainless steel alloy foils and machined graphite of similar flow field design. The best fuel cell behavior among the alloys was exhibited by the pre-oxidized/nitrided Fe-20Cr-4V, which exhibited ∼5-20% better peak power output than untreated Fe-20Cr-4V, 2205, and 904L metal stampings. Durability was assessed for pre-oxidized/nitrided Fe-20Cr-4V, 904L metal, and graphite plates by 1000+ h of cyclic single-cell fuel cell testing. All three materials showed good durability with no significant degradation in cell power output. Post-test analysis indicated no metal ion contamination of the membrane electrode assemblies (MEAs) occurred with the pre-oxidized and nitrided Fe-20Cr-4V or graphite plates, and only a minor amount of contamination with the 904L plates.     

质子交换膜燃料电池自增湿研究进展

概述了质子交换膜燃料电池自增湿研究状况，指出自增湿的出发点是有效利用电池阴极过程生成水。综述了薄电解质膜、新型自增湿膜、自增湿流场结构三种方法的研究进展及适用空间。对自增湿技术发展前景进行了探讨。     

Parallel serpentine-baffle flow field design for water management in a proton exchange membrane fuel cell

In a proton exchange membrane fuel cell (PEMFC) water management is one of the critical issues to be addressed. Although the membrane requires humidification for high proton conductivity, water in excess decreases the cell performance by flooding. In this paper an improved strategy for water management in a fuel cell operating with low water content is proposed using a parallel serpentine-baffle flow field plate (PSBFFP) design compared to the parallel serpentine flow field plate (PSFFP). The water management in a fuel cell is closely connected to the temperature control in the fuel cell and gases humidifier. The PSBFFP and the PSFFP were evaluated comparatively under three different humidity conditions and their influence on the PEMFC prototype performance was monitored by determining the current density–voltage and current density–power curves. Under low humidification conditions the PEMFC prototype presented better performance when fitted with the PSBFFP since it retains water in the flow field channels.     

基于Python的质子交换膜燃料电池引射器自动仿真设计

质子交换膜燃料电池（PEMFC）引射器设计通常需经过结构参数计算、计算域建模、网格划分和数值模拟等步骤,并经过多轮迭代得到一个性能较优的设计方案,所需时间成本较高。针对PEMFC引射器,通过Python编程语言将以上功能进行集成,自动计算引射器结构参数,并调用OpenFOAM软件中的blockMesh工具进行计算域建模、网格划分,以及rhoSimpleFoam求解器进行数值仿真验证,形成一套参数化的自动仿真设计工具。研究表明,该工具可显著提高PEMFC引射器设计开发的速度,从而促进汽车工业的发展。     

Development and performance evaluation of a high temperature proton exchange membrane fuel cell with stamped 304 stainless steel bipolar plates

In this work, a high temperature proton exchange membrane fuel cell (HT-PEMFC) with stamped SS304 bipolar plates is successfully developed. Its performance was evaluated under two types of gaskets at different assembly torques and air stoichiometric ratios. The rates of pressure loss at a torque of 7 N-m with 50 Shore A hardness gaskets was 2.0 × 10^?3 MPa min^?1, which is acceptable. The best performance of the developed HT-PEMFC with stamped SS304 bipolar plates was 228.33 mW cm^?2, which approaches the performance of HT-PEMFCs with graphite bipolar plates. The optimal air stoichiometric ratio for the HT-PEMFC with stamped SS304 bipolar plates was 4.0, which is higher than that for proton exchange membrane fuel cells with CNC milled graphite bipolar plates. This is probably because of the deformation of the flow channels under the assembly compression force, which causes an elevated gas-diffusion drag in the flow channels. After the test, it was observed that some products of corrosion reaction formed on the surface of the SS304 bipolar plate. This phenomenon may lead to a decrease in the operating life of the HT-PEMFC.     

质子交换膜燃料电池故障检测研究

针对质子交换膜燃料电池(PEMFC)发电系统的故障检测和系统稳定性问题,结合其多传感器特性,采用基于实时PCA的质子交换膜燃料电池故障检测方法,根据燃料电池反应信号数据建立PCA模型,通过窗口过滤方式和遗忘因子算法实时更新模型,并将降维后获得的数据用统计方法进行处理,从而检测出故障。有效地简化了燃料电池系统故障检测的过程,改善了故障检测的实时性,提高了燃料电池系统工作的稳定性和可靠性。