Design and Optimization of Metal Bead Sealing Structure for Proton Exchange Membrane Fuel Cells

Proton exchange membrane fuel cells (PEMFCs) are promising clean energy devices for transportation applications; however, their long‐term reliability is often constrained by sealing system failures. To address the failure of conventional rubber gaskets in PEMFCs induced by stress relaxation, as well as the insufficient correspondence between existing studies and the mechanical behavior of practical laminated sealing structures, this study proposes a metal bead seal fabricated via integrated stamping of the metallic bipolar plate and metal bead, coupled with a screen‐printed micro‐rubber layer. Focusing on the failure‐prone inlet/outlet zone, it uses ABAQUS finite element analysis, establishing single/double BPP and single‐cell models to study effects of cross‐sectional parameters, turning radius, and channel shape/distribution. Results show: under 3 N clamping force, its compression is much lower than rubber gaskets; lower base width (W 2 ) dominates cross‐sectional effects, with pressure “steep at ends, stable in middle”; larger turning radius reduces stress concentration; Trapezoidal‐A channel (1:2 ratio) is optimal, and staggered channels ( W c = 1.5 mm, H c = 0.2 mm) cut pressure difference by 64.95% and standard deviation by 62.03%.This clarifies parameter mechanisms, confirms advantages over traditional seals, supporting PEMFC seal optimization.