Design and Modeling of Metallic Bipolar Plates for a Fuel Cell Range Extender

Fuel cells, designed for mobile applications, should feature compact and low-weight designs. This study describes a design process that fulfills the specific needs of target applications and the production process. The key challenge for this type of metallic bipolar plate is that the combination of two plates creates three flow fields, namely an anode side, a cathode side, and a coolant. This illustrates the fact that each cell constitutes an electrochemical converter with an integrated heat exchanger. The final arrangement is comprised of plates with parallel and separate serpentine channel configurations. The anode and cathode sides are optimized for operation under dry conditions. The final plate offers an almost perfect distribution of coolant flow over the active area. The high quality of this distribution is almost independent of the coolant mass flow, even if one of the six inlet channels is blocked. The software employed (OpenFOAM and SALOME) is freely available and can be used with templates.