Multi-Objective Optimization of Passive-Type Air-Cooled Fuel Cell Designs to Mitigate Electrolyte Dehydration and Fan Power Consumption

Passive air-cooled polymer electrolyte membrane (PEM) fuel cell systems, recognized for their lightweight and simple design, are particularly suitable for drone and aircraft applications. Unlike their water-cooled counterparts, these systems utilize ambient air, facilitated by a fan, for both fuel and cooling purposes, which makes water and heat management crucial. This study aims to optimize such systems, focusing on cathode design variables, including gas diffusion layer thickness and gas channel dimensions. Employing a three-dimensional, multiscale, two-phase model, we analyze the impact of these variables on system performance and pressure drop to identify optimal configurations. Additionally, a neural network model helps in understanding design factor trends and pinpointing the best design setup. Our results indicate that specific optimal configurations for each design variable can significantly enhance system efficiency and stability, facilitating an effective design tailored for lightweight aviation applications.