3D Numerical Simulation of Metal Bipolar Plate Proton Exchange Membrane Fuel Cell Considering Wavy Interlaced Flow Field

A metal bipolar plate fuel cell (FC) composed of gas distribution zones (GDZ) with ordered distribution of “dot matrix” structures, a complex waveform staggered fluid region, and the effect of cooling flow field (FF) is proposed in this investigation. The 3D multiphase model is applied to simulate the two‐phase flow in the FC. First, the cathode catalyst layer (CCL) has a higher electrochemical reaction rate (ERR) when gas diffusion layer (GDL) is anisotropic, and the ERR under channels is much higher than ribs. Increasing the thickness of GDL is not conducive to gas mass transfer, and the maximum current density reduction rate is 2.94%. Increasing the porosity of GDL is beneficial to improve the mass transport efficiency, and the liquid discharge is promoted. Second, the increase of GDL contact angle affects the cathode microporous layer and liquid saturation in CCL, and the current density is the highest when the contact angle is 120°. Finally, the volume‐of‐fluid model is utilized to analyze the drainage process in the GDZ and cathode small‐size FF. It is indicated in the results that water tends to concentrate at the outlet corner of GDZ in liquid form.