Proceedings of the ASME 2014 12th International Conference on Fuel Cell Science, Engineering and Technology

FUELCELL2014
June 30-July 2, 2014, Boston, Massachusetts, USA

FuelCell2014-6547

INNOVATIVE DESIGN OF A PIEZOELECTRIC PEMFC HONEY COMB STACK

Hsiao-Kang Ma *, Wei-Yang Cheng, Yuan-Lung Hsu, Hou-Yi Lin, Chiung-Ting Hsieh

Department of Mechanical Engineering
National Taiwan University, Taipei 10617, Taiwan

ABSTRACT
Previous studies have shown that the pseudo-bipolar
design of the bi-cell is composed of two outside anodes and two
inside cathodes that share a common PZT vibrating device used
to pump the airflow. The bi-cell is operated by three modes of
PZT-actuating process as pump mode (Pc > Pout > Pin), supply
mode (Pout > Pin > Pc), and transition mode (Pout > Pc > Pin).
In this study, a single module of piezoelectric PEMFC honey
comb composed of 6 bi-cells on each inside wall of the honey
comb has been developed to deliver the net power output 7.5W.
The hydrogen storage tank is located in the middle duct of one
honey comb with hydrogen supply valves and pipelines.
Furthermore, for the required power output, the honey comb
stack can be designed as erect-stack or planar-stack by
assembling different number modules. Comparing with other
polygons, the stronger honey comb stack can be designed to fit
in the limited space and coupled with the fuel supply system or
other power output system, for example, LED lights.
Introduction
Air-breathing proton exchange membrane fuel cells
(AB-PEMFCs) have attracted attention as substitutes for
currently used batteries. In general, AB-PEMFCs do not need
an additional oxygen supply device; their performance is
proportional to the oxygen transfer coefficient [1]. Santa Rosa
et al. [2] developed an open-air cathode PEMFC stack with an
air fan. This design combined oxidant supply and stack cooling.
In these cases, the air supply device should be small, provide
sufficient air flow with piezoelectric devices, and require low
power consumption. Among the various actuating methods, the
piezoelectric actuator demonstrates good reliability, energy
efficiency, and moderate volume displacement [3]. Ma et al.
[4-5] have proposed a novel cathode channel design that utilizes
the piezoelectric (PZT) effect in AB-PEMFC systems, known as
the PZT-PEMFC. The PZT-PEMFC can feed air into the
cathode channel through a gas pump with a piezoelectric
actuation structure. Previous studies [6-8] of a piezoelectric
proton exchange membrane fuel cell with a nozzle and a
diffuser (PZT-PEMFC-ND) have shown that a PZT device was
able to solve these water-flooding problems in cathode and
improve the cell performance. The study [9] also showed that
improved PZT-PEMFC-ND cell performance could be obtained
using an aspect ratio (AR) of 5.63 and a θ of 10°. Furthermore,
a bi-cell piezoelectric proton exchange membrane fuel cell with
a nozzle and a diffuser (PZT-PEMFC-ND bi-cell) has been
developed, its performance has been shown to be 1.6 times
better than that of a single cell [10].
The common methods of stacking consist of three types:
bipolar, pseudo-bipolar, and mono-polar, for the pseudo-bipolar
cell stack design it is easy to achieve high power by simple
addition of more bi-cell units, but each bi-cell has to be filled
with fuel and air separately. In the mono-polar cell stack design
a common gas flow field is shared by a whole strip, when a
single cell fails the stack performance will not be affected
seriously. Mono-polar cell stack design is suitable for
applications in low power and high voltage devices because of
its high internal resistance [12]. Previous studies [13] also have
noted that series fuel intake module can achieve higher total
reactant utilizations.
There are two regular shapes for PEMFC stack, planar and
tubular. For planar fuel cell stack, Ismail et al. [14] investigate
the thermal situation over the cathode surface. They found heat
is dissipated far more effectively if the AB-PEMFC is oriented
vertically or horizontally facing upwards than if it is oriented
horizontally facing downwards. Rajani et al. [15] developed a
two-dimensional complete model for a vertical, fully planar,
AB-PEMFC with hydrogen fuel supplied by forced convection
at the anode. The maximum power density and the optimum
current density are found to increase with decreasing height of
the fuel cell, decreasing ambient temperature and increasing
ambient relative humidity. Hsieh [16] proposed and tested a
novel planar array module consisting of 4,8, 12 and 16 single
polymer electrotype membrane fuel cells connected in series on
a plane with two different pin electrode flow field
configurations, the influences of different operating parameters,
such as stack temperature and gas flow rate, on the
performance of individual PEM fuel cells and fuel cell stacks,
have been studied. For tubular fuel cell stack, Green [17]
developed a tubular PEMFC which enables optimum air access
to the cathode without the need for pumps, fans or similar

1 Copyright © 2014 by ASME

devices. The cells are composed of composite materials, such
as Tufnol. Maher [18] developed a full three-dimensional
computational fluid dynamics model of a tubular-shaped
PEMFC, the module can understand the many interacting,
complex electrochemical, and transport phenomena that cannot
be studied experimentally. Coursange [19] compared the
performance between planar and tubular-shaped PEMFC by
three dimensional numerical simulations, the results show
higher power densities are achieved with the tubular design
mainly because of lower activation potentials. Bullecks et al.
[20] presented some experimental studies on a novel tubular
PEMFC design that addresses the cost, gravimetric and
volumetric power density issues. The performances of the
cylindrical and planar cells were compared using the same
MEA. The tubular cell performs better than the planar cell in
the higher overpotential regions.
On the other side, there is another shape of fuel cell stack,
honey comb. For the honey comb modules, Wetzko et al. [21]
developed the solid oxide fuel cell stacks using extruded
honeycomb type elements, a module consisting of 100
honeycomb sections of each 6×6 cells with overall dimensions
of 6×6×12 cm3 of the active part should be able to provide a
power of 1 kW. Rauch et al. [22] produced monolithic and
hybrid honeycomb fuel cells. Hybrid structures consisting of
three interconnects and two electrolytes. To produce a
functional cell; the extrusion would typically go through a
manifolding process to create gas pathways.
Candusso [23] indicated that there are four examples of
topologies for a four-stack association that could be used as a
power source for further applications. The FC modules can be
autonomously or serially coupled to the load with the power
converter or they can also be twin-coupled (a power module
with two stacks in electrical cascade arrangement) to increase
the voltage per module. Additionally, four FC stacks can be
coupled together before connecting to the power converter; this
arrangement allows an increase in the total output voltage, but
exhibits a severe weakness when one or more FCs fails,
because of the pseudo-bipolar design, the PZT-Stack does not
become an open circuit even if one of the component cells fails
in the electrical cascade. In addition, Bernardinis [24] indicated
that a diode can preclude a reverse current from flowing back to
the stacks, and MOSFETs switches allow the coupling of an
additional FC stack to maintain and control the total output
voltage.
For the heat transfer of honey comb, Luo et al. [25]
developed a honeycomb porous micro channel cooling system;
the experimental results show that the cooling system is able to
remove 18.2W cm-2 of heat flux under 2.4W pumping power,
while the junction wall temperature is 48.3 ℃at the room
temperature of 26℃. Liu et al. [26] developed a novel heat sink
based on a multilayer stack of thin metal plates with staggered
honeycomb cell micro channels, the heat power density of
17.7W cm-2 could effectively be removed with the substrate
temperature of 61.4℃ and 61.2℃ under 0.72W pump powers.
Lu [27] studied the heat transfer efficiency of metal
honeycombs, at low Reynolds numbers (<2000), the flow is
essentially laminar in honeycombs, in contrast to the large
turbulent flow; this deficiency in fluid dynamics is compensated
for by the superior surface area density offered by honey combs
over foams. Zhao et al. [28] focused on the experimental and
numerical methods to determine the macroscopic effective
thermal conductivities of honeycomb cores. As the cavity
surface emissivity increases with the other parameters
unchanged, the total thermal conductivity of honey comb core
increases not obviously when the temperature is below 200
℃;when the temperature is above 200℃, the emissivity makes
2 Copyright © 2014 by ASME
a more important contribution to the growth of honeycomb core
conductivities as the temperature grows up. On the other side,
the smaller honeycomb size is, the more important heat
dissipation will be, such as stack effect.
Our previous study [29] had shown the three sets bi-cell
stack has maximum net power as 3.8627W at 60Hz of the
piezoelectric device. Under different PZT-Stack circuit modules,
the maximum power density is 0.1874W cm-2 in the electrical
parallel and 0.1765W cm-2 in the electrical cascade
configuration. In addition, the PZT-Stack does not exhibit open
circuit behavior, even if one of the component cells fails in the
electrical cascade configuration. In this study, a single module
of piezoelectric PEMFC honey comb composed of 6 L-PZT-D
type bi-cells on each inside wall of the honey comb has been
developed to deliver the net power output 7.5W. The testing
conditions include different PZT vibration frequencies,
operating temperatures, and electrical circuit arrangements
(parallel or cascade). In addition, a piezoelectric PEMFC honey
comb stack can be designed in an erect-stack form or a
planar-stack form based on the required power output and the
limited space.
Nomenclature
APZT piezoelectric area (m2)
AR aspect ratio
C conductivity coefficient
D channel opening width
f frequency of PZT (Hz)
L channel path
P pressure (N m−2)
Pc channel pressure
Pin inlet pressure
Pout outlet pressure
R gas constant (J mol−1 K−1)
t time (s)
T temperature (K)
TH2 anode humidifier temperature (°C)
Tcell cell temperature (°C)
VPZT motion equation of the piezoelectric device
(m s−1)
Q flow rate
Qan anode flow rate (ml min-1)
Λ amplitude
ζ loss coefficient
θ diffuser angle
ρ density (kg m−3)
 volume displacement (m3)
The PZT-PEMFC-ND bi-cell
The bi-cell is composed of two outside anodes and two
inside cathodes that share a common PZT vibrating device used
to pump the airflow, as shown in Figure 1. Figure 2 shows the
mechanism of the novel pseudo bipolar design of the
PZT-PEMFC-ND bi-cell module operated in supply mode and
pump mode. When one cell is operated in supply mode, sucking
air into the cathode, the other cell is in pump mode, delivering
reacted gas and produced water out of the cathode chamber.
This arrangement allows one PZT device to supply air to the
two component cells and pump the produced water out of the
cells, thus reducing the total power consumption.

Figure 1. An exploded drawing of the PZT-PEMFC-ND
bi-cell.
Figure 2. Operation modes of the novel pseudo bipolar
design of PZT-PEMFC-ND bi-cell.
Actuation Mechanism
In this study, there are three modes of PZT-actuating
process shown in Figure 3 as pump mode (Pc > Pout > Pin),
supply mode (Pout > Pin > Pc), and transition mode (Pout > Pc
> Pin). In supply mode, the diaphragm moved outward and the
cathode chamber volume increased, which let the chamber
pressure (Pc) become lower than the atmospheric pressure (Pin
and Pout), the air was sucked into the chamber. In pump mode,
the diaphragm moved inward and the cathode chamber volume
decreased. Because the pressure inside the cell (Pc) was higher
than the atmospheric pressure, the air was pushed into the
catalyst layer and the water produced was pumped out of the
cell. A transition mode occurred between the pump mode and
the supply mode, when the outlet pressure was higher than the
chamber and inlet pressures, Pout > Pc > Pin. In Figure 4, the
simulated pressure contour of supply mode shows Pout
=873.9N/m2> Pc= 270.5N/m2> Pin= -13.2N/m2.
To analyze the airflow rate of the PZT-Stack system, the
control volume of the system was located inside the cathode
chamber. The equation of motion of the PZT device was
modeled as a sine function given by Eq. (1):

VPZT  d dt   sin2ft  . (1)
3 Copyright © 2014 by ASME
Thus, using the Reynolds Transport Theorem and the
continuity equation, the airflow rate can be written as Eq. (2):
 
R t C T
Qc  1 P d  V A . (2)
PZT PZT
The inlet flow from the nozzle and the diffuser can be
found using the diffuser element theory as follows Eq.(3) and
Eq.(4):
For the air inflow from top to bottom:
Q  C P  P 
in ,l n out C
(3)
For the air inflow from bottom to top:
Qin,r  Cd Pin  PC  (4)
Figure 3. The three flow modes of the PZT-actuating
process.
Figure 4. The simulated pressure contours of supply
mode.
Experimental setup
Figure 5 shows the test platform for analyzing the
performance of a PZT-PEMFC-ND module. On the anode side,
the hydrogen from the hydrogen storage bottle flows through
the mass flow controller and enters the bubble humidifier. The
humidifier is a water tank with a heater that allows the reactant
gas to pass through at a specific temperature. Next, the
hydrogen with water vapor is delivered to the
PZT-PEMFC-ND module for an electrochemical reaction. To
activate the PZT vibrating device, a function generator is
utilized, first, to deliver the sine wave signals, then the signals
from the function generator are sent to an amplifier to magnify
the signals so that the piezoelectric device vibrates when it
receives the signal. To measure the power consumption of the
PZT device, a power meter is connected to the output terminal
of the amplifier.
In this study, the two cells were electrically parallel and,
thus, the reaction area of the bi-cell is 8 cm2. As a result, two
hydrogen supply lines and two thermocouples were prepared. In
contrast, the signal from the amplifier was transmitted through
the signal wires in the middle of the module. The total reaction
area is 48 cm2 with a diffuser angle (θ) of 10°, a channel path (L)
of 5.63mm, and a channel opening width (D) of 1 mm, as
shown in Figure 6.
The PZT device controls the airflow on the cathode side.
A function generator is used to deliver sine wave signals to
activate the PZT vibration. The signals from the function
generator are sent to an amplifier for magnification and are
Figure 5. Schematic of the PZT-PEMFC testing system.
A DC electronic load was used to simulate the electronic
loading of voltage and current. In the electrical cascade
configuration, a constant current mode was chosen, and the
polarization curve was obtained by increasing the current from
0 A to 4 A by 0.4 A every 10 minutes. In the electrical parallel
arrangement, a constant voltage mode was chosen, and the
polarization curve was obtained by decreasing the open-circuit
voltage to 0.1 V from 0.2 V every 10 minutes, with control via
LabVIEW software.
Figure 6. The design of L-PZT-D-type bi-cell in cathode
channel.
4 Copyright © 2014 by ASME
subsequently transmitted through the signal wires to the middle
of the module. A power meter is connected to the output
terminal of the amplifier to measure the power consumption of
the PZT device.
In this study, the constant voltage mode is chosen when
the bi-cell is arranged in an electrical parallel configuration.
The pseudo-bipolar design is used as the common cathode
collector, and the collector support is constructed from
gold-plated copper plate to allow conduction between the two
component cells. The constant current mode of the electronic
load is chosen when the bi-cell is arranged in the electrical
cascade configuration.
Result and discussion
The different directions of nozzle and direction
and different PZT fix locations
The orientation of the nozzle/diffuser and the position of
the PZT device are important parameters for the PZT-PEMFC
due to its pumping efficiency and pressure distribution in the
cathode channel. For this study, a one-sided actuator was
chosen; therefore, the position of maximum PZT deformation
was decided by the fixed side of PZT. The L-PZT-D-type has
been used in this study because the performance of this type is
the best.
Figure 7 shows that there are three directions of the nozzle
and diffuser: up, down, and horizontal.

Figure 7. The different directions of nozzle and direction
and different PZT fix locations.
The electrical cascade/parallel configuration
Figure 8 shows current shunt with data acquisition
modules can get the voltage of two component cells in electrical
cascade and get the current density of two component cells in
electrical parallel.
Figure 8. Electrical cascade/parallel configuration of the
bi-cell.
Influence of PZT vibration frequencies
The PZT vibration frequency is an important parameter for
actuation of the airflow in the cathode chamber. When the PZT
device attached to a PDMS film is operated in its harmonic
frequency, the bi-cell performance can be improved by intake
of additional air into the chamber and ejection of additional
produced water out of the chamber. Figure 9 shows the
performance of an L-PZT-D-type bi-cell operated under various
PZT vibration frequencies. The result shows that the
performance of the bi-cell increases as the frequency increases
from f=0 Hz to f=90 Hz because additional air is sucked into the
chamber and additional produced water is pumped out of the
cathode side. However, the performance of the bi-cell decreases
5 Copyright © 2014 by ASME
between f=90 Hz and f=150 Hz because these frequencies lie
outside of the harmonic frequency range of the PZT device.
When the frequencies lie outside of the harmonic frequency
range, the vibrating amplitude of PZT is decreasing to supply
less air flow and drops the cell performance. Although the
performance of the bi-cell at f=90 Hz is better than that at f=60
Hz, the net power is higher at f=60 Hz if the power
consumption of the PZT device is considered, as shown in
Figure 10.
Figure 9. The performance of an L-PZT-D-type bi-cell
operated under various PZT vibration frequencies.
Figure 10. The net power of the bi-cell under different PZT
vibration frequencies.
Development of a single module of piezoelectric
PEMFC honey comb
Our previous study [29] had shown the three sets bi-cell
stack has maximum net power as 3.8627W at 60Hz of the
piezoelectric device. In this study, a single module of
piezoelectric PEMFC honey comb composed of 6 bi-cells on
each inside wall of the honey comb has been developed to
deliver the net power output 7.5W. As shown in Figure 11, the
middle of a sun-like framework is a circle for setting the
hydrogen storage tank, the major geometrical parameters of the
honeycomb, including the comb height H, the edge length L,
the rim length R, the center circle diameter D, and t is the
thickness of the wall. Because the module is a regular hexagon,
a = √3𝐿. The design of a bi-cell and the dimension of demo
module is shown in Table 1. The remaining space is used for
other hydrogen supply valves, pipelines and electrical wires.
Furthermore, the honey comb modules can be connected
together to form a charging platform. Figure 12 shows the
benzene-type arrangement. This arrangement locates three sets
of bi-cell on the inner side of the wall and three sets of bi-cell
on the outer side of the wall. A honey comb with fuel tank is
surrounded by six honey combs without fuel tank. The red
arrows represent main fuel supply lines, and the blue arrows
represent the sharing fuel supply lines. The six main fuel
supply lines are connected to the honey comb module with fuel
tank, and the other six sharing fuel supply lines are connected to
the outer honey comb module without fuel tank. Figure 13
shows the co-wall arrangement of bi-cells with the similar fuel
supply system. Both arrangements of supplied lines are
asymmetric.

Table 1. The design of a bi-cell and the dimension of demo

honey comb module
A bi-cell Honey comb module
Total reaction area=8.00cm2 H=105.00 mm
Height=34.60mm L=110.00 mm
Length=82.30mm R=80.47 mm
Depth=30.64mm D=44.00 mm
H2 inlet flow rate t=10.00mm Figure 13. The co-wall arrangement.
= 60.00 mlmin-1 a≒190.53mm
The maximum net power
Innovative design of a piezoelectric PEMFC
≒1.24W
honey comb stacks

For the required power output, a piezoelectric PEMFC

honey comb stack can be designed in an erect-stack form or a
planar-stack form and can be coupled with the fuel supply
system or other power output system, for example, LED lights.
Figure 14 shows the piezoelectric PEMFC planar-stack with
honey comb modules. The the top surface will be colder when
the heat source (i.e. LED lights) is located at the bottom of
honey comb stack. The heat flow will go up to the top along the
walls and the colder flow will be sucked from the outside and
passed into the bottom based on the natural convection, as
shown in Figure 15.

Figure 11. A 7.5W single module of piezoelectric PEMFC

honey comb with fuel tank in the center.

Figure 14. The piezoelectric PEMFC planar-stack with

honey comb modules.

Figure 12. The benzene-type arrangement.

6 Copyright © 2014 by ASME


Figure 15. The schema of hexagonal pipes’ heat transfer.
CONCLUSION
An innovative single module of piezoelectric PEMFC honey
comb composed of 6 bi-cells on each inside wall of the honey
comb has been developed to deliver the net power output 7.5W.
The major findings are as follows:
(1) The L-PZT-D-type bi-cell is chosen to study the
performance of a single module of piezoelectric PEMFC
honey comb.
(2) Comparing with other polygons, the stronger honey comb
stack can be designed with many modules to fit in the
limited space.
(3) Two types of benzene-type and co-wall arrangements are
proposed to form the honeycomb platforms in the
application of natural convection.
(4) For the required power output, a piezoelectric PEMFC
honey comb stack can be designed in an erect-stack form
or a planar-stack form and coupled with the fuel supply
system or other power output system, for example, LED
lights.
ACKNOWLEDGEMENT
This research was funded by the National Science Council of
the Republic of China (NSC 102-2221-E-002-147).
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