Performance enhancement of proton exchange membrane fuel cell through assembly optimization by designing component structure and surface morphology

In proton exchange membrane fuel cell (PEMFC) assembly, the gas diffusion layer (GDL) experiences non-uniform deformation, impacting its transport properties and overall PEMFC performance. This study introduces an innovative optimization method that integrates mechanical behavior and electrical performance to enhance PEMFC output. By incorporating non-uniform transport properties, the analysis captures the effects of non-uniform GDL compression on species distribution and output performance, focusing on the roles of mass transfer resistance and electrical contact resistance, and the ideal GDL compression state is determined through this approach. Targeting this optimal state, PEMFC assembly is refined using a combined strategy of component structure and surface morphology adjustments. The non-uniform compression effects within the assembly are then included in performance analyses, validating the optimization method's efficacy in improving mechanical behavior and electrical performance. Key findings include that as oxygen supply decreases, the negative impact of mass transfer resistance intensifies, while electrical contact resistance effects diminish. The optimal GDL compression ratio of 21 % achieves a balance between the effects of mass transfer resistance and electrical contact resistance. Through the dual-component assembly optimization, GDL compression unevenness decreases by 98.6 % and uniformly reaches the ideal compression state, which boosts PEMFC power density by over 14.7 %.