Optimizing Parasitic Pumping Power in Proton Exchange Membrane Fuel Cells via Bio-Inspired Cooling Channels Guided by Constructal Theory and Murray’s Law

Efficient thermal management is critical for proton exchange membrane fuel cells (PEMFCs). This study develops a bio-inspired active liquid cooling architecture to overcome the limitations of conventional flow channels, where convective heat transfer augmentation significantly increases pressure drop. The proposed configuration adheres to constructal theory and Murray’s law. A three-dimensional conjugate heat transfer model was formulated to evaluate the thermo-hydrodynamic performance against parallel and serpentine flow channels. Under identical conditions, the proposed configuration exhibits superior thermal uniformity and hydrodynamic behavior, alongside minimized parasitic pumping power. At an inlet Reynolds number (Re) of 400, this configuration stabilizes the average bipolar plate temperature at 349.63 K. It reduces the index of uniform temperature (IUT) to 1.49 K, representing a 52.8% thermal uniformity improvement over the parallel flow channel. Furthermore, at an inlet Re of 600, the overall pressure drop is restricted to 68.44 Pa, reducing the single-plate parasitic pumping power to 1.27 × 10−4 W, which represents reductions of 93.5% and 12.5% relative to the serpentine and parallel flow channels, respectively. This study provides an alternative architectural scheme for the design of active liquid cooling flow channels in PEMFCs.