A coupled three-dimensional (3D) mathematical model including real physical domain of an air-breathing proton exchange membrane fuel cell (PEMFC) was developed in this work. The free convection in the channel and porous media was included in the model, and the concentration over-potential was considered as a result of limited supply of oxygen in the catalyst layer. The model was based on finite-volume methods. Governing equations coupling flow, mass transfer, heat transfer, and the electrochemical reactions are solved simultaneously. From this calculation, field details of velocity, mass fraction, temperature and the polarization curves are illustrated and discussed. The model is validated by experimental data. Results from this model can provide insight into design issues of air-breathing PEMFCs.
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