A Novel Flow Field Design with Superimposed Vertical and Parallel Twisting for Enhanced PEMFC Performance

Proton exchange membrane fuel cells (PEMFCs) are increasingly valued for their eco-friendly feature. Nevertheless, challenges such as restricted mass transfer and suboptimal water management have hindered its high-current-density performance. This study introduces a new Three-Dimensional Sinusoidal Twisted Flow Field (3D-STFF) for PEMFCs, and its performance is evaluated using computational fluid dynamics (CFD) modeling. The 3D-STFF incorporates a helical architecture that enhances reactant delivery, optimizes water evacuation, and reduces energy losses. Compared with parallel flow fields, CFD results reveal that the 3D-STFF improves the mass transfer and water management in PEMFCs, yielding a 22.6% boost in current density (0.532 A·cm–2) and a 15.0% increase in net power density (0.504 W·cm–2) within the medium-to-high voltage range (0.5–0.8 V), while maintaining a minimal pressure drop of 174.2 Pa at 353 K, 100% relative humidity, and 1 atm. The design ensures superior oxygen distribution with a nonuniformity index of 0.259 and an oxygen molar concentration of 6.45 mol·m–3, effectively mitigating downstream oxygen depletion. The 3D-STFF design generates periodic velocity oscillations (peak at 20.5 m·s–1), fostering enhanced lateral gas diffusion and consistent reactant supply. Additionally, the 3D-STFF demonstrates superior water management compared to other flow fields, reducing liquid accumulation at both the midchannel and outlet, thereby mitigating cathode flooding. The 3D-STFF presents a robust and effective approach to improve PEMFC performance, particularly under high-load operational conditions.