Flow channel optimization for proton exchange membrane fuel cell using zig-zag geometry

The design of flow channels in proton exchange membrane fuel cells (PEMFCs) plays a crucial role in determining overall performance. This study focuses on optimizing the conventional straight parallel flow channels of a PEMFC by incorporating various zig-zag geometries. Several zig-zag channel designs are proposed, with bending angles ranging from 5 to 45 degrees and the number of bends set between 3 and 9. A three-dimensional numerical model is developed to evaluate the performance of PEMFCs with these zig-zag channels. The trends and effectiveness of changing zig-zag bending angle, number of bends, and operating temperature are analyzed. The simulation results indicate that, PEMFCs with zig-zag channels demonstrate significantly superior performance compared to the straight parallel design, with the bending angle contributing most to the performance enhancement. A larger zig-zag bending angle significantly improves PEMFC performance. In this study, the 7-bend, 45-degree zig-zag channel design is identified as the optimal configuration, achieving a 10.10% increase in peak power density, a 15.23% improvement in O 2 uniformity, a 7.23% enhancement in O 2 effective mass transfer, a 7.63% reduction in membrane temperature deviation, and a 3.29% improvement in membrane water content. • Distribution and transport of reactants in PEMFC are enhanced by zig-zag channels. • Straight parallel channels in PEMFCs are optimized by zig-zag geometry. • PEMFC obtains 10.1% peak power improvement by the optimal zig-zag channel design.