Improving Water Management and Reactant Distribution in PEM Fuel Cells Via Flow Fields with Biomimetic Auxiliary Channels

The bipolar plate, a component of the polymer electrolyte membrane (PEM) fuel cell is responsible for reactant delivery, product removal, and mechanical stability of PEM fuel cell stacks. Bipolar plates also account for 70-90% of the weight and volume, and 18-28% of the production cost of stacks (1). Improving the function of the flow fields embedded in the bipolar plates can significantly impact the energy density of PEM fuel cells by improving liquid water management and reactant distribution. Previous works show that water preferentially accumulates under the lands of flow fields in the gas diffusion layer (GDL) for various GDL materials, creating a heterogeneous distribution of water and reactants, thereby increasing cathode mass transport overpotential(2–4). Biomimetic channel architectures have been shown to enhance preferential water flow; however, these designs have not been tailored to control water accumulation for improved reactant distribution (5,6). Targeting areas of known water accumulation such as the under-land regions of GDLs, could have a profound impact on reducing mass transport losses and improving reactant homogeneity, thereby improving the power density and efficiency of the PEM fuel cell. In this work, biomimetic auxiliary channels were laser-cut into the lands of a parallel PEM fuel cell flow field to enhance the liquid water removal and reactant distribution in the under-land region of the GDL. Constant-current electrochemical testing and electrochemical impedance spectroscopy revealed a 29% increase in peak power density resulting from a 54% decrease in oxygen mass transport overpotential using the biomimetic flow field (BFF) compared to a baseline trapezoidal flow field (TFF). Operando synchrotron X-ray radiography revealed reduced GDL water accumulation when using the BFF compared to the TFF. Water accumulation under the BFF flow fields was more homogenous especially near the catalyst layer (CL) – GDL interface, indicating enhanced reactant distribution near the CL reaction sites. Therefore, the reduced mass transport overpotential and corresponding power density increase were attributed to enhanced liquid water removal and reactant distribution due to the biomimetic auxiliary channels. These results demonstrate that significant performance enhancements can be realized by embedding alternate pathways for air and water in the lands of flow field components. Ultimately, this work can be used to further optimize the design of bipolar plates for more efficient stacks and accelerate the commercialization of PEM fuel cells. Y. Wang, D. F. Ruiz Diaz, K. S. Chen, Z. Wang, and X. C. Adroher, Materials Today, 32, 178–203 (2020). N. Ge et al., Electrochim Acta, 328, 135001 (2019). D. Muirhead et al., Int J Hydrogen Energy, 42, 29472–29483 (2017). S. Chevalier et al., J Electrochem Soc, 164, F107–F114 (2017) N. Guo, M. C. Leu, and U. O. Koylu, Int J Hydrogen Energy, 39, 21185–21195 (2014). S. Feng et al., Science, 373, 1344–1348 (2021).