Simulation-driven optimization and experimental validation of a triple-serpentine flow field for enhanced proton exchange membrane fuel cells power density

Proton Exchange Membrane Fuel Cells (PEMFCs) are promising zero-emission power sources for the transportation sector, playing a vital role in establishing a clean and safe energy infrastructure while promoting the transformation and upgrading of the automotive industry. However, the commercialization of PEMFCs is currently constrained by power density, durability, and costs, which collectively impede their technological maturation and commercial development. Among these challenges, the design of bipolar plates (BPs) is critical to the performance and cost-effectiveness of PEMFC systems. Consequently, this study provides an in-depth analysis of strategies to enhance PEMFC power density by focusing on the simulation-driven optimization of the BP flow field. The optimized triple-serpentine configuration with a channel depth of 0.5 mm achieves a peak power density of 0.946 W cm⁻² at 0.4 V, outperforming the conventional single-serpentine design (0.93 W cm⁻² at 0.5 V). Notably, this work establishes direct correlation between advanced flow field geometry and power density, demonstrating that a triple-serpentine flow field with an optimized, reduced channel depth is a crucial factor in boosting PEMFC performance. Furthermore, the underlying mechanism for this enhancement is analyzed, showing that the optimized geometry promotes higher reactant gas velocity for more uniform oxygen distribution and efficient water removal. Additionally, a systematic validation of the design is presented through experimental testing on a physically fabricated BP, confirming the simulation’s accuracy and the design’s practical feasibility. In summary, this work provides a validated design pathway for developing high-performance PEMFC stacks, directly addressing critical challenges in power density and operational stability.