Edge Cooling of a Fuel Cell during Aerial Missions by Ambient Air

During aerial missions of fuel-cell (FC) powered drones, the option of FC edge cooling may improve FC performance and durability. Here we describe an edge cooling approach for fixed-wing FC-powered drones by removing FC heat using the ambient air during flight. A set of experiments in a wind tunnel and numerical simulations were performed to examine the efficiency of FC edge cooling at various flight altitudes and cruise speeds. The experiments were used to validate the numerical model and prove the feasibility of the proposed method. The first simulation duplicated the geometry of the experimental setup and boundary conditions. The calculated temperatures of the stack were in good agreement with those of the experiments (within ±2 °C error). After validation, numerical models of a drone’s fuselage in ambient air with different radiator locations and at different flight speeds (10–30 m/s) and altitudes (up to 5 km) were examined. It was concluded that onboard FC edge cooling by ambient air may be applicable for velocities higher than 10 m/s. Despite the low pressure, density, and Cp of air at high altitudes, heat removal is significantly increased with altitude at all power and velocity conditions due to lower air temperature.