Optimization of mass transport in PEM electrolysis cell via Triply Periodic Minimal Surfaces (TPMS) based integrated transport layer

Abstract

The decarbonization of heavy-duty transport depends critically on affordable green hydrogen, with proton exchange membrane electrolysis cell (PEMEC) serving as a key green-hydrogen production technology due to its high efficiency and dynamic response to renewable power. However, severe mass transfer limitations at the anode—primarily caused by oxygen bubble accumulation—restrict PEMEC performance at high current densities (>2 A cm⁻²), thereby elevating hydrogen production cost and hindering its competitiveness for mobility applications. In the study, an innovative integrated transport layer (ITL) is proposed by inspiring from the triply periodic minimal surface (TPMS) structure. The TPMS structure is optimized for mass transfer through gas-liquid two-phase flow simulations. Guided by the results, the TPMS-based flow field is fabricated via 3D printing and evaluated in an electrolyzer. The simulations reveal that the TPMS structure significantly enhances gas-liquid distribution uniformity. Specifically, it increases water saturation at the catalytic layer interface by 110 %, and improves the oxygen distribution uniformity index by 78 % over conventional flow fields. The TPMS flow field reduces the cell voltage by 50 mV at 2 A cm⁻² and decreases mass transfer loss by 44.6 %, compared to conventional serpentine flow fields. This work provides a critical theoretical foundation for designing high-performance mass transport structures in PEMEC.