Performance Enhancement of Polymer Electrolyte Fuel Cells Through Gas Diffusion Layer Perforations: Insights From Single Channel Serpentine and Parallel Flow Field Configurations

ABSTRACT This study examines the impact of gas diffusion layer (GDL) perforation characteristics—perforation size, center‐to‐center spacing, and location—on the performance and transport behaviors of polymer electrolyte fuel cells (PEFCs) under varying flow field configurations. Using both single‐channel serpentine and parallel flow fields, we demonstrate that perforating the cathode GDL, particularly under the gas flow channel, significantly improves water management by facilitating liquid water removal, thus enhancing mass transport and cell performance. The findings reveal that larger perforation sizes and smaller center‐to‐center spacings are more effective in high‐velocity regions, such as those found in serpentine flow fields, due to increased convective effects. However, in low‐velocity regions like parallel flow fields, these effects are less pronounced, resulting in only marginal improvements. Importantly, perforating only the cathode under the channel was shown to sufficiently enhance cell performance while maintaining design simplicity. Strategic perforation adjustments—denser perforations in high‐velocity regions and larger perforations in low‐velocity regions—can optimize water removal and mitigate mass transport limitations.