Self-adaptive optimization design of flow channel structure for proton exchange membrane fuel cells with ultra-low catalyst loadings

Developing next-generation high-performance, low-cost, long-life proton exchange membrane fuel cells (PEMFCs) depends on material enhancements in membrane electrode assemblies (MEAs) and flow channel design that maximize MEA benefits. This study proposes a novel self-adaptive optimization evaluation factor (SAEF) for flow channel structure to assess the adaptation effect between flow channel structures and MEAs. SAEF acts as an objective function to guide the geometric parameter design of flow channel to achieve the optimal structure. A full-scale 3D PEMFC model was constructed and subjected to visualization experiments to elucidate the influence of proposed flow channel design on multi-phase mass transfer, heat, water management, and electrochemical performance of PEMFCs. In comparison with conventional parallel flow channels (PFCHs), the self-adaptive optimization flow channels (SFCHs) alleviate oxygen concentration deficiencies and maldistribution, enhance water removal capability, and improve temperature homogeneity and overall cell performance. Results show that the newly-designed SFCH achieves a peak power density enhancement of ∼38% compared with PFCH with sufficient oxygen supply. Concurrently, under extreme conditions of insufficient oxygen supply and ultra-low catalyst loadings (Cathode: 0.1 mg cm−2, Anode: 0.05 mg cm−2), SFCH significantly enhances catalyst utilization rate and mitigates Pt particle degradation and flooding, endowing PEMFC with a remarkable peak power density enhancement of ∼57.1%. This study sheds light on offering new perspectives for the optimal design of flow channels and achievement of ultra-low catalyst loadings for practical PEMFCs.