Despite their potential as a sustainable energy technology, the operation of proton exchange membrane fuel cells (PEMFCs) in sub-freezing conditions remains a critical challenge due to the risk of ice formation and performance degradation. This study introduces a new passive thermal management technique using strategically arranged multi-layer phase change materials (PCMs) to address this challenge. A numerical model was developed to evaluate the thermal behavior across various PCM configurations, incorporating one, two, and three layers arranged both in parallel and series with distinct melting points ranging from 55 to 65 ◦C. The results show that multi-layer PCM configurations provide significant improvements over the single-layer baseline. The parallel three-layer arrangement extended the thermal management duration by 48.8 % compared to the single-layer system, maintaining PEMFC temperatures above 55 ◦C for over 12 h in an ambient at − 20 ◦C. This configuration also demonstrated superior temperature stability, with a temperature differential of only 3 ◦C. The series three-layer design achieved a 39 % increase in duration but maintained the same 3 ◦C temperature differential. The novelty of this work lies in the systematic analysis of parallel and series PCM layer configurations, each designed for specific operating conditions. These passive solutions can effectively manage the energy demand of PEMFCs during cold startup, overcoming the limitations of conventional methods.
