Optimization of a serpentine flow field with variable channel heights and widths for PEM fuel cells

The present study proposes a modified serpentine flow field design in which the channel heights vary along each straight flow path to enhance reactant transport and liquid water removal. An optimization approach, combining a simplified conjugate-gradient method (inverse solver) and a three-dimensional, two-phase, non-isothermal fuel cell model (direct solver), has been developed to optimize the key geometric parameters. The optimal design has tapered channels for channels 1, 3 and 4 and increasing heights for channels 2 and 5 with the flow widths first increasing and then decreasing. The optimal channel heights and widths enhance the efficiency by 22.51% compared with the basic design having all heights and widths of 1 mm. The diverging channels have a greater impact on cell performance than fine adjustments of the channel widths for the present simulation conditions. The channel heights have more effect on the sub-rib convection, while the channel widths affect the uniformity of the fuel delivery more. The reduced channel heights of channels 2–4 significantly enhance the sub-rib convection to effectively transport oxygen to and liquid water out of the diffusion layer. The final diverging channel prevents significant leakage of fuel to the outlet via sub-rib convection.