The research of a hydrogen proton exchange membrane fuel cell is performed under certain designing and operational conditions. The water management technique is incorperated into the experimental work. The cell voltage vs. the current densities are studied by changing the stack reactive temperatures, the gas inlet temperatures and pressures, and the relative humidities in hydrogen stream. Eventually, we hope that these experimental results can provide the information about the optimizing conditions of fuel cells so that they can be used to design a high power multiple-cell fuel cell stack. A membrane and electrode assembly (called MEA) which contains a proton exchange membrane Nafion 112, anode catalyst Pt 0.4 mg/cm2, and cathode catalyst Pt 1.0 mg/cm2 is used in this experiment. The gas flowing area is about 58% of the total area. A proper heating and humidification equipment is applied in this experimental system. The experimental results show that the cell voltage at low current density is slightly influenced by the hydrogen inlet temperature; however, the cell voltage at high current density is strongly influenced by the humidity ratio of hydrogen stream. Raising the hydrogen pressure and the oxygen pressure at the same time can increases the cell voltage, but it is no obvious effects on the cell voltage when the gas pressure increases to more than 2 atm. When air is used as a oxidizer, increasing the inlet air temperature always reduces the cell voltage. With the hydrogen stream at saturated temperature 80¢XC, the assembly torque of the stack at 4 N-m, and the stack temperature at 80¢XC, the single fuel cell stack can always generate the best cell voltages at most of the current densities. At this time, the cell voltage at current density 1 A/cm2 already can reach a value higher than 0.6 V.

Abstract The characteristics of PEMFC stacks in different designs and operational conditions are studied and manufactured in this thesis. There are many factors that affect the PEMFC performance. They include the familiar humidity, the torque, the inlet pressure, the geometries of inlet ports and the flow channels in reaction regions, the cell numbers of the stacks, the type of the oxidizer and its flow rate. To understand the performance characteristics of stacks the voltage and current density will be measured as well as the interior temperature of stacks in this research. The membrane exchange assembly (MEA) with Nafion 112, anode Pt 0.4 mg/cm² and cathode Pt 1.0 mg/cm² is used in these experimental works. The experimental results display that increasing the applied torque will reduce the contact resistance between bipolar plate and diffusion layer but increase the difficulty of gas penetrating into the reaction region beneath the bipolar rib. So proper torque is necessary to obtain the best voltage output. The voltage vs. current density also increases as the inlet pressure increases, but its effect will reduce when the inlet pressure increases over 2atm. The geometry and size of inlet port to each cell for a multi-cell stack will influence the voltage output, especially in high current density, so that special attention is needed in designing inlet port. When the air is used as an oxidizer, the fan with a high rotation speed is helpful in an open circuit design. The high air volume flow rate can avoid that the voltage output decays greatly in high current density. Increasing the cell number may cause extra internal resistance due to assembling improperly and reduce the voltage output. So special attention is also needed in assembling. Keyword: Proton Exchange Membrane Fuel Cell Stacks

This paper presents analytical and experimental studies on optimization of the gas delivery and current collection system in a proton exchange membrane (PEM) fuel cell for the objective of reducing ohmic loss, thereby achieving higher power density. Specifically, the dimensions of current collection ribs as well as the rib distribution were optimized to get a maximized power density in a fuel cell. In the modeling process, the power output from a fixed area of membrane is calculated through analysis of an electrical circuit simulating the current from electrochemical reaction flowing to the current collectors. Current collectors of two-dimensional ribs and three-dimensional pillars were considered. Analyses found that three-dimensional pillars allow higher power density in a PEM fuel cell. Considering the mass transfer enhancement effect, three-dimensional pillars as current collectors in gas flow field may be a good choice if the fuel cell operates at low current density and there is no liquid water blocking the flow channels. The analyses did not consider the existence of liquid water, meaning the current density is not very high. The study concluded that decreasing the size of both the current collector and its control area yields a significant benefit to a higher power density. A preliminary experimental test in a PEM fuel cell has verified the conclusion of the analytical work.

Two formal design methodologies, biomimetic design and the Theory of Inventive Problem Solving, TRIZ, were applied to the redesign of a Proton Exchange Membrane (PEM) fuel cell. Proof of concept prototyping was performed on two of the concepts for water management. The liquid water collection with strategically placed wicks concept demonstrated the potential benefits for a fuel cell. Conversely, the periodic flow direction reversal concepts might cause a potential reduction water removal from a fuel cell. The causes of this water removal reduction remain unclear. In additional, three of the concepts generated with biomimetic design were further studied and demonstrated to stimulate more creative ideas in the thermal and water management of fuel cells. The biomimetic design and the TRIZ methodologies were successfully applied to fuel cells and provided different perspectives to the redesign of fuel cells. The methodologies should continue to be used to improve fuel cells.

Two formal design methodologies, biomimetic design and the Theory of Inventive Problem Solving, TRIZ, were applied to the redesign of a Proton Exchange Membrane (PEM) fuel cell. Proof of concept prototyping was performed on two of the concepts for water management. The liquid water collection with strategically placed wicks concept demonstrated the potential benefits for a fuel cell. Conversely, the periodic flow direction reversal concepts might cause a potential reduction water removal from a fuel cell. The causes of this water removal reduction remain unclear. In additional, three of the concepts generated with biomimetic design were further studied and demonstrated to stimulate more creative ideas in the thermal and water management of fuel cells. The biomimetic design and the TRIZ methodologies were successfully applied to fuel cells and provided different perspectives to the redesign of fuel cells. The methodologies should continue to be used to improve fuel cells.

Proton exchange membrane fuel cell (PEMFC) has been considered as one of the most promising energy conversion devices for the future in automotive applications. One of the major technical challenges for the commercialization of PEMFC is the effective start-up from subzero temperatures, often referred to as “cold start”. The major problem of PEMFC cold start is that the product water freezes when the temperature inside the PEMFC is lower than the freezing point. If the catalyst layer (CL) is fully occupied by ice before the cell temperature rises above the freezing point, the electrochemical reaction may stop due to the blockage of the reaction sites. However, only a few of the previous PEMFC studies paid attention to cold start. Hence, understanding the ice formation mechanisms and optimizing the design and operational strategies for PEMFC cold start are critically important. In this research, an experimental setup for the cold start testing with simultaneous measurement of current and temperature distributions is designed and built; a one-dimensional (1D) analytical model for quick estimate of purging durations before the cold start processes is formulated; and a comprehensive three-dimensional (3D) PEMFC cold start model is developed. The unique feature of the cold start experiment is the inclusion of the simultaneous measurement of current and temperature distributions. Since most of the previous numerical models are limited to either 1D or two-dimensional (2D) or 3D but only considering a section of the entire cell due to computational requirement, the measured distribution data are critically important to better understand the PEMFC cold start characteristics. With a full set of conservation equations, the 3D model comprehensively accounts for the various transport phenomena during the cold start processes. The unique feature of this model is the inclusion of: (i) the water freezing in the membrane electrolyte and its effects on the membrane conductivity; (ii) the non-equilibrium mass transfer between the water in the ionomer and the water (vapour, liquid and ice) in the pore region of the CL; and (iii) both the water freezing and melting in the CL and gas diffusion layer (GDL). This model therefore provides the fundamental framework for the future top-down multi-dimensional multiphase modelling of PEMFC. The experimental and numerical results elaborate the ice formation mechanisms and other important transport phenomena during the PEMFC cold start processes. The effects of the various cell designs, operating conditions and external heating methods on the cold start performance are studied. Independent tests are carried out to identify and optimize the important design and operational parameters.

This research is to develop procedures on the fabrication of membrane electrode assembly (MEA), which is the heart of the Proton Exchange Membrane Fuel Cell. Sensitivity studies of the manipulated variable, such as pressure, temperature, and time, in the hot press process, which is adopted in the assembling on the performance of the MEA are also performed. The developed products on the cleaning of membrane as well as the hot press of MEA have been verified through many experiments. The tests of the MEA¡¦s thus produced reveal that temperature and pressure in hot press process have significant influence on MEA performance. Both have to be kept in a suitable range. Optimal operating conditions in the hot press process may be achieved by conducting more experiments and a detail understanding on the internal structure variation of membrane under high pressure and temperature condition.

Proton exchange membrane fuel cell (PEMFC) has been considered as one of the most promising energy conversion devices for the future in automotive applications. One of the major technical challenges for the commercialization of PEMFC is the effective start-up from subzero temperatures, often referred to as “cold start”. The major problem of PEMFC cold start is that the product water freezes when the temperature inside the PEMFC is lower than the freezing point. If the catalyst layer (CL) is fully occupied by ice before the cell temperature rises above the freezing point, the electrochemical reaction may stop due to the blockage of the reaction sites. However, only a few of the previous PEMFC studies paid attention to cold start. Hence, understanding the ice formation mechanisms and optimizing the design and operational strategies for PEMFC cold start are critically important. In this research, an experimental setup for the cold start testing with simultaneous measurement of current and temperature distributions is designed and built; a one-dimensional (1D) analytical model for quick estimate of purging durations before the cold start processes is formulated; and a comprehensive three-dimensional (3D) PEMFC cold start model is developed. The unique feature of the cold start experiment is the inclusion of the simultaneous measurement of current and temperature distributions. Since most of the previous numerical models are limited to either 1D or two-dimensional (2D) or 3D but only considering a section of the entire cell due to computational requirement, the measured distribution data are critically important to better understand the PEMFC cold start characteristics. With a full set of conservation equations, the 3D model comprehensively accounts for the various transport phenomena during the cold start processes. The unique feature of this model is the inclusion of: (i) the water freezing in the membrane electrolyte and its effects on the membrane conductivity; (ii) the non-equilibrium mass transfer between the water in the ionomer and the water (vapour, liquid and ice) in the pore region of the CL; and (iii) both the water freezing and melting in the CL and gas diffusion layer (GDL). This model therefore provides the fundamental framework for the future top-down multi-dimensional multiphase modelling of PEMFC. The experimental and numerical results elaborate the ice formation mechanisms and other important transport phenomena during the PEMFC cold start processes. The effects of the various cell designs, operating conditions and external heating methods on the cold start performance are studied. Independent tests are carried out to identify and optimize the important design and operational parameters.

No description available.

Water management is a serious issue that affects the performance and durability of PEM fuel cells. It is known, from previous experimental investigations, that surface wettability has influence on water behaviour and fuel cell performance. This finding has lead researchers to develop numerical tools for further investigation of the liquid water behaviour in gas channels. The Volume-of-Fluid (VOF) method has been used in a wide range of studies for its advantage of showing the multi-phase interface in a Computational Fluid Dynamics (CFD) simulation to understand liquid water behaviour in gas channels. In this thesis, numerical study has been carried out to examine the behaviour of liquid water in gas channels. The dynamic movement of the liquid water in the channel and the associated pressure drop, water saturation and water coverage of the GDL have been investigated. Firstly, flow diffusion into the GDL was examined to determine its effect on liquid droplet behaviour in a small section of a gas channel. Furthermore, the effects of the percentage of flow diffusion, GDL wettability, pore size, and water inlet velocity were investigated. Fluid diffusion into GDL found to have insignificant impact on liquid water behaviour so further investigations has been carried with a solid GDL surface. Secondly, gas channel geometry effect on liquid water behaviour was studied. Square, semicircle, triangle, trapezoid with a long base and trapezoid with a short base were compared to find suitable cross section geometry to carry wall wettability investigations. Among the examined geometries, the square cross section showed reasonable results for both scenarios of geometry design, fixed Reynolds number and fixed GDL interface. The effect of wall wettability was assessed by comparing nine different wall/GDL wettability combinations for straight and bend channels. Wall wettability found to have an impact on liquid water behaviour but not as much as GDL wettability. It affects liquid water saturation in the channel by a great deal by accumulating water in the channel edges affecting water behaviour. This was also proven in the last test case of a long channel where water accumulation was investigated by running the calculation until the percentage of water saturation is stabilized. It is also concluded that changing wall wettability from hydrophobic to hydrophilic doubles the percentage of channel occupied by liquid water and increases the time to reach steady state.