Polymer-based Bipolar Plates for Fuel Cells

This paper presents the optimization of bipolar plates for polymer-based fuel cells designed for small-scale applications like drones and portable devices. The fuel cell uses an open-cathode system, where air from the environment is the oxidant, reducing weight and complexity. Three initial design concepts were created, and the counter-flow design was selected for further development due to its higher performance potential. The plate geometry was optimized with semi-circular channels on the anode side to improve hydrogen flow and U-shaped channels on the cathode side for better water removal. Flow and pressure distributions were analyzed using Computational Fluid Dynamics (CFD). Although early results showed uneven distribution, further adjustments led to a new design, which improved manufacturability and reduced deformation. After testing different gas inlet configurations, a final design was developed, showing more uniform flow and better performance for lightweight applications.