Work

Performance Analysis and Design of a Pulsating Heat Pipe-Based Thermal Management System for PEMFC

Year: 2026

Type: article

Abstract: Given automotive PEMFCs’ susceptibility to thermal runaway and uneven temperature distribution under high-power-density operation, this study proposes a novel embedded pulsating heat pipe cooling system. The core innovations of this work are threefold, fundamentally distinguishing it from prior PHP cooling approaches: (1) an embedded PHP cooling plate design that integrates the heat pipe within a unified copper plate, eliminating the need for external attachment or complex bipolar plate channels and enhancing structural compactness; (2) a system-level modeling methodology that derives an effective thermal conductivity (k_eff ≈ 65,000 W·m−1·K−1) from a thermal resistance network for seamless integration into a full-stack CFD model, significantly simplifying the simulation of the passive PHP component; and (3) a parametric system-level optimization of the secondary active cooling loop. Numerical results demonstrate that the system achieves an exceptional maximum temperature difference (ΔT_max) of less than 1.7 K within the PEMFC stack at an optimal coolant flow rate of 0.11 m/s, far surpassing the performance of conventional liquid cooling baselines. This three-layer framework (PHP heat transfer, cooling plate conduction, liquid coolant convection) offers robust theoretical and design support for high-efficiency, passive-dominant thermal control of automotive fuel cells.

Source: Sustainability

DOI: 10.3390/su18021047

Authors: Hongchun Zhao, Meng Zheng, Zheshu Ma, Yan Zhu, Liangyu Tao

Institution: Nanjing Forestry University

Language: English

Topic: Fuel Cells and Related Materials

Subfield: Electrical and Electronic Engineering

Field: Engineering

Domain: Physical Sciences

SDG: Affordable and clean energy

Open Access status: gold

Estimated APC paid: $2,896