Effect of membrane electrode assembly design on the cold start process of proton exchange membrane fuel cells

A transient multiphase model for cold start process is developed considering micro-porous layer (MPL), super-cooled water freezing mechanism and ice formation in cathode channel. The effect of MPL's hydrophobicity on the output performance and ice/water distribution is investigated under various startup temperatures, structural properties, membrane thicknesses and surrounding heat transfer coefficients. Under the maximum power startup mode, it is found that the hydrophobicity disparity of MPL has negligible influences when started from −15 °C, but it strongly affects the overall performance when started from −10 °C, especially after the cell survives the cold start. Decreasing the MPL's hydrophobicity leads to higher current density, meanwhile, it facilitates the super-cooled water's removal, which in turn reduces the ice formation in catalyst layer. However, excessive water accumulation happens if the generated water is hindered from getting into gas diffusion layer (GDL) due to the significant hydrophobicity gap. Weakening the GDL's hydrophobicity contributes to the water removal since the generated water is easier to diffuse out. A thinner membrane benefits the cold start owing to the reduction of ohmic loss and improvement of membrane hydration, and is more sensitive to the hydrophobicity of MPL. Ice formation in cathode channel is identified under various surrounding heat transfer coefficients.