A model reduction framework of flow maldistribution and mitigation strategy for parallel flow field based polymer exchange membrane fuel cell

Mitigating flow maldistribution plays a crucial role in next-generation industry-used parallel-based flow field design for polymer exchange membrane fuel cells (PEMFCs), especially for larger-size cells and higher current density. In this study, a model reduction framework is proposed to alleviate flow maldistribution among parallel gas flow channels and associated computational burden. The gas flow features and electrochemical kinetics of four mitigation strategies including expanded manifold, partially porous media, dot matrix, and partially narrow structures are investigated in detail. The results indicate that the fuel cell model and a fluid flow model without the reactions show similar maldistribution features among parallel channels. The observed flow maldistribution can be effectively reduced by mitigating designs. Expanding the manifold space significantly alleviates the vortex impeding the gas entry to individual channel inlet, and the inlet exhibits better flow uniformity and pressure drop in the direction perpendicular to the channel than in the parallel to. The fully-inserted and manifold-inserted porous media methods present symmetrical quadratic-shaped flow patterns among channels, while that of the partially-inserted porous media inside channels is unsymmetrical. Additionally, the concentration loss with a partially narrowed design decreases by 44.7%, 12.9%, and 24.2% compared with the expanded manifold, partial porous media, and dot matrix designs at 1.8 A cm⁻² owing to better flow uniformity and mass transport. These model framework and mitigation strategies are valuable for designing future high-performance industrial PEMFCs.