1. Hygro-Thermal Stresses and Deformation Distribution in Tubular-Shaped Ambient Air-Breathing PEM Micro Fuel Cell

This research investigates the displacement, deformation, and stresses inside novel micro tubular design ambient air-breathing proton exchange membrane fuel cell. An operating air-breathing PEM fuel cell has varying local conditions of temperature, humidity. As a result of in the changes in temperature and moisture, the membrane, GDL and bipolar plates will all experience expansion and contraction. Because of the different thermal expansion and swelling coefficients between these materials, hygro-thermal stresses are introduced into the unit cell during operation. In addition, the non-uniform current and reactant flow distributions in the cell result in non-uniform temperature and moisture content of the cell which could in turn, potentially causing localized increases in the stress magnitudes, and this leads to mechanical damage, which can appear as through-the-thickness flaws or pinholes in the membrane, or delaminating between the polymer membrane and gas diffusion layers. Therefore, in order to acquire a complete understanding of these damage mechanisms in the membranes and gas diffusion layers, mechanical response under steady-state hygro-thermal stresses have been studied under real cell operation conditions.

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2. Optimizes PEM Fuel Cell Durability

Damage mechanisms in a proton exchange membrane (PEM) fuel cell are accelerated by mechanical stresses arising during fuel cell assembly (bolt assembling), and the stresses arise during fuel cell running, because it consists of the materials with different thermal expansion and swelling coefficients. Therefore, in order to acquire a complete understanding of the damage mechanisms in the membrane and gas diffusion layers, mechanical response under steady-state hygro-thermal stresses should be studied under real cell operating conditions and in real cell geometry (three-dimensional). In this work, the mechanical behaviour of the membrane, catalyst layers, and gas diffusion layers during the operation of a unit cell has been studied and investigated. The results show that the non-uniform distribution of stresses, caused by the temperature gradient in the cell, induces localized bending stresses, which can contribute to delaminating between the membrane and the gas diffusion layers. These results may explain the occurrence of cracks and pinholes in the membrane during regular cell operation. Detailed analyses of the fuel cell durability under various operating conditions (operating, design, and material parameters) have been conducted and examined. The analysis helped identifying critical parameters and shed insight into the physical mechanisms leading to a fuel cell durability under various operating conditions. Optimization study of a PEM fuel cell durability has been performed. To achieve long cell life, the results show that the cell must be operate at lower cell operating temperature, higher cell operating pressure, higher stoichiometric flow ratio, and must have higher GDL porosity, higher GDL thermal conductivity, higher membrane thermal conductivity, narrower gases channels, thicker gas diffusion layers, and thinner membrane. In these optimum conditions, the maximum deformation (displacement) is reduced by about 50% than the base case operating conditions.

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3. Novel Design of a Compacted Micro-Structured Air-Breathing PEM Fuel Cell as a Power Source for Mobile Phones

The presence of microelectromechanical system (MEMS) technology makes it possible to manufacture the miniaturized fuel cell systems for application in portable electronic devices. The majority of research on micro-scale fuel cells is aimed at micro-power applications. There are many new miniaturized applications which can only be realized if a higher energy density power source is available compared to button cells and other small batteries. In small-scale applications, the fuel cell should be exceptionally small and have highest energy density. One way to achieve these requirements is to reduce the thickness of the cell (compacted-design) for increasing the volumetric power density of a fuel cell power supply.
A novel, simple to construct, air-breathing micro-structured PEM fuel cell which work in still or slowly moving air has been developed. The novel geometry enables optimum air access to the cathode without the need for pumps, fans or similar devices. In addition, the new design can achieve much higher active area to volume ratios, and hence higher volumetric power densities.

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4. Mechanical Behaviour of PEM Fuel Cell Catalyst Layers During Regular Cell Operation

Damage mechanisms in a proton exchange membrane fuel cell are accelerated by mechanical stresses arising during fuel cell assembly (bolt assembling), and the stresses arise during fuel cell running, because it consists of the materials with different thermal expansion and swelling coefficients. Therefore, in order to acquire a complete understanding of the mechanical behaviour of the catalyst layers during regular cell operation, mechanical response under steady-state hygro-thermal stresses should be studied under real cell operating conditions and in real cell geometry (three-dimensional). In this work, full three-dimensional, non-isothermal computational fluid dynamics model of a PEM fuel cell has been developed to investigate the behaviour of the cathode and anode catalyst layers during the cell operation. A unique feature of the present model is to incorporate the effect of hygro and thermal stresses into actual three-dimensional fuel cell model. In addition, the temperature and humidity dependent material properties are utilize in the simulation for the membrane. The model is shown to be able to understand the many interacting, complex electrochemical, transport phenomena, and deformation that have limited experimental data.

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5. Effect of Ambient Conditions on the Hygro-Thermal Stresses Distribution in a Planar Ambient Air-Breathing PEM Fuel Cell

The need for improved lifetime of air-breathing proton exchange membrane (PEM) fuel cells for portable applications necessitates that the failure mechanisms be clearly understood and life prediction models be developed, so that new designs can be introduced to improve long-term performance. An operating air-breathing PEM fuel cell has varying local conditions of temperature and humidity. As a result of in the changes in temperature and moisture, the membrane, GDL and bipolar plates will all experience expansion and contraction. Because of the different thermal expansion and swelling coefficients between these materials, hygro-thermal stresses are introduced into the unit cell during operation. In addition, the non-uniform current and reactant flow distributions in the cell result in non-uniform temperature and moisture content of the cell which could in turn, potentially causing localized increases in the stress magnitudes, and this leads to mechanical damage, which can appear as through-the-thickness flaws or pinholes in the membrane, or delaminating between the polymer membrane and gas diffusion layers. In this work, the effects of ambient conditions (ambient temperature and relative humidity) on the temperature distribution, displacement, deformation, and stresses inside a planar PEM fuel cell has been studied and investigated. The results showed that the ambient conditions (ambient temperature and relative humidity) have a strong impact on the temperature distribution and hygro-thermal stresses inside the cell.

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6. Optimal Design of PEM Fuel Cells to Generate Maximum Power

Optimization study of a PEM fuel cell performance has been performed. The study quantifies and analyses the impact of operating, design, and material parameters on fuel cell performance and get an optimal design for PEM fuel cells to generate maximum power. To generate maximum power, the results show that the cell must be operate at higher cell operating temperature, higher cell operating pressure, higher stoichiometric flow ratio, and must have higher GDL porosity, higher GDL thermal conductivity, narrower gases channels, and thinner membrane. At these optimum conditions, the result shows that the total displacement and the degree of the deformation inside the MEA were decreased. However, the Miss stress in the membrane was increased due to higher cell operating temperature.

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7. Novel Design of a Disk-Shaped Compacted Micro-Structured Air-Breathing PEM Fuel Cell

The presence of microelectromechanical system (MEMS) technology makes it possible to manufacture the miniaturized fuel cell systems for application in portable electronic devices. The majority of research on micro-scale fuel cells is aimed at micro-power applications. There are many new miniaturized applications which can only be realized if a higher energy density power source is available compared to button cells and other small batteries. In small-scale applications, the fuel cell should be exceptionally small and have highest energy density. One way to achieve these requirements is to reduce the thickness of the cell (compacted-design) for increasing the volumetric power density of a fuel cell power supply. A novel disk-shaped air-breathing micro-structured PEM fuel cell which work in still or slowly moving air has been developed. The novel geometry enables optimum air access to the cathode without the need for pumps, fans or similar devices. In addition, the new design can achieve much higher active area to volume ratios, and hence higher volumetric power densities.

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8. Prediction of Deformation and Hygro-Thermal Stresses Distribution in PEM Fuel Cell Vehicle

Durability is one of the most critical remaining issues impeding successful commercialization of broad PEM fuel cell transportation energy applications. Automotive fuel cells are likely to operate with neat hydrogen under load-following or load-levelled modes and be expected to withstand variations in environmental conditions, particularly in the context of temperature and atmospheric composition. In addition, they are also required to survive over the course of their expected operational lifetimes i.e., around 5,500 hrs, while undergoing as many as 30,000 startup/shutdown cycles. The damage mechanisms in a PEM fuel cell are accelerated by mechanical stresses arising during fuel cell assembly (bolt assembling), and the stresses arise during fuel cell running, because it consists of the materials with different thermal expansion and swelling coefficients. Therefore, in order to acquire a complete understanding of the damage mechanisms in the membrane, mechanical response under steady-state hygro-thermal stresses should be studied under real cell operating conditions and in real cell geometry (three-dimensional). In this work, full three-dimensional, non-isothermal computational fluid dynamics model of a PEM fuel cell has been developed to simulate the stresses inside the PEM fuel cell, which are occurring during fuel cell assembly (bolt assembling), and the stresses arise during fuel cell running due to the changes of temperature and relative humidity.

[Full Text (PDF)]