Structural optimization of the cathode flow field is a viable approach to homogenize multi-physical field distributions and boost the output of air-cooled proton exchange membrane fuel cells (PEMFCs). This work develops a three-dimensional non-isothermal model to systematically evaluate the performance of graded flow channel designs. The results indicate that the graded structure promotes fluid transport in the central zone, thereby improving oxygen distribution uniformity at the gas diffusion layer/catalyst layer (GDL/CL) interface. Compared to the traditional parallel flow channel (with an average oxygen mass fraction of 0.051% and a uniformity index of 0.779), this configuration yields a 6.4% increase in the average oxygen mass fraction and a 0.96% enhancement in distribution uniformity. However, increased gradient flow reduces the flow velocity within the channels and raises the operating temperature, posing challenges for water and thermal management. The curved channel design, featuring longer channels at the ends and shorter channels in the center, compensates for the uneven air supply caused by the fan, thus balancing the flow distribution. Among the tested configurations, the 10° curved structure exhibits optimal performance, achieving the best compromise between gas distribution and liquid water removal. It effectively promotes oxygen diffusion and uniform water distribution, significantly alleviating mass transfer polarization and yielding a more uniform interface temperature distribution due to evaporative cooling. Both excessively small and large curvature angles lead to performance degradation, primarily due to inadequate water removal and flow separation, accompanied by excessive pressure drop, respectively. In contrast, the 10° curved channel strikes an optimal balance, offering significant advantages in overall cell performance and water–thermal management, which provides critical guidance for optimizing PEMFC flow field designs.
Li et al. (Thu,) studied this question.