Proton Exchange Membrane Fuel Cell (PEMFC) is majorly used for power generation without producing any emission. In PEMFC, the water generated in the cathode heavily affects the performance of fuel cell which needs better water management. The flow channel designs, dimensions, shape and size of the rib/channel, effective area of the flow channel and material properties are considered for better water management and performance enhancement of the PEMFC in addition to the inlet reactant's mass flow rate, flow directions, relative humidity, pressure and temperature. With the purpose of increasing the output energy of the fuel cell, many flow field designs are being developed continuously. In this paper, the performance of various conventional, modified, hybrid and new flow field designs of the PEMFC is studied in detail. Further the effects of channel tapering, channel bending, landing to channels width ratios, channel cross‐sections and insertion of baffles/blockages/pin‐fins/inserts are reviewed. The power density of the flow field designs, the physical parameters like active area, dimensions of channel/rib, number of channels; and the operating parameters like temperature and pressure are also tabulated.

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Flooding of the cathode flow channel is a major hindrance in achieving maximum performance from Proton Exchange Membrane Fuel Cells (PEMFC) during the scaling up process. Water accumulated between the interface region of Gas Diffusion Layer (GDL) and rib of the cathode flow field can be removed by the use of Porous Sponge Inserts (PSI) on the ribs. In the present work, the experimental investigations are carried out on PEMFC for the various reaction areas, namely 25, 50 and 100 cm2. Stoichiometry value of 2 is maintained for all experiments to avoid variations in power density obtained due to differences in fuel utilization. The experiments include two flow fields, namely Serpentine Flow Field (SFF) and Modified Serpentine with Staggered provisions of 4 mm PSI (4 mm × 2 mm × 2 mm) Flow Field (MSSFF). The peak power densities obtained on MSSFF are 0.420 W/cm2, 0.298 W/cm2 and 0.232 W/cm2 compared to SFF which yields 0.242 W/cm2, 0.213 W/cm2 and 0.171 W/cm2 for reaction areas of 25, 50 and 100 cm2 respectively. Further, the reliability of experimental results is verified for SFF and MSSFF on 25 cm2 PEMFC by using Electrochemical Impedance Spectroscopy (EIS). The use of 4 mm PSI is found to improve the performance of PEMFC through the better water management.

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