Microporous layer structures and gas diffusion layer assemblies for enhanced water management in proton exchange membrane fuel cells

Abstract

A microporous layer forming a portion of a gas diffusion layer assembly positioned adjacent to a catalyst layer within a fuel cell electrode. The microporous includes a first carbon-based material layer comprising a plurality of hydrophobic pores with a diameter of 0.05 to 0.2 μm and a plurality of bores with a diameter of 1 to 20 μm. The microporous layer structures and gas diffusion layer assemblies disclosed herein may be defined by a number of various designs and arrangements for use in proton exchange membrane fuel cell systems.

What is claimed is: 
     
         1 . A microporous layer forming a portion of a gas diffusion layer assembly positioned adjacent to a catalyst layer within a fuel cell electrode, the microporous layer comprising:
 a first carbon-based material layer comprising:
 a plurality of hydrophobic pores with a diameter of 0.05 to 0.2 μm; and 
 a plurality of bores with a diameter of 1 to 20 μm. 
   
     
     
         2 . The microporous layer of  claim 1 , wherein the first carbon-based material layer includes two or more material regions. 
     
     
         3 . The microporous layer of  claim 2 , wherein at least two of the two or more material regions are comprised of different substances. 
     
     
         4 . The microporous layer of  claim 1 , wherein the hydrophobic pores are formed of carbon particles, carbon nanofibers, or carbon nanotubes. 
     
     
         5 . The microporous layer of  claim 4 , wherein the hydrophobic pores are treated with one or more hydrophobic fluorocarbon binders. 
     
     
         6 . The microporous layer of  claim 1 , wherein the plurality of bores are laser-perforated bores. 
     
     
         7 . The microporous layer of  claim 1 , wherein the plurality of bores are characterized by a contact angle of between 50 and 150 degrees. 
     
     
         8 . A microporous layer forming a portion of a gas diffusion layer assembly positioned adjacent to a catalyst layer within a fuel cell electrode, the microporous layer comprising:
 a first carbon-based material layer comprising:
 a plurality of hydrophobic pores with a diameter of 0.05 to 0.2 μm; and 
 a plurality of bores with a diameter of 1 to 20 μm; and 
 a second carbon-based material layer disposed between the catalyst layer and the first material layer. 
   
     
     
         9 . The microporous layer of  claim 8 , wherein the second carbon-based material layer includes carbon and one or more fluorocarbon polymers. 
     
     
         10 . The microporous layer of  claim 8 , wherein the first carbon-based material layer includes two or more material regions. 
     
     
         11 . The microporous layer of  claim 10 , wherein at least two of the two or more material regions are comprised of different substances. 
     
     
         12 . The microporous layer of  claim 11 , wherein the hydrophobic pores are treated with one or more hydrophobic fluorocarbon binders. 
     
     
         13 . The microporous layer of  claim 8 , wherein the plurality of bores are laser-perforated bores. 
     
     
         14 . The microporous layer of  claim 8 , wherein the plurality of bores are characterized by a contact angle of between 50 and 150 degrees. 
     
     
         15 . A fuel cell electrode comprising:
 a catalyst layer; and   a gas diffusion layer assembly positioned adjacent to the catalyst layer and comprising a microporous carbon-based material layer comprising a plurality of hydrophobic pores with a diameter of 0.05 to 0.2 μm and a plurality of bores with a diameter of 1 to 20 μm.   
     
     
         16 . The microporous layer of  claim 15 , wherein the microporous carbon-based material layer includes two or more material regions. 
     
     
         17 . The microporous layer of  claim 16 , wherein at least two of the two or more material regions are comprised of different substances. 
     
     
         18 . The microporous layer of  claim 15 , wherein the hydrophobic pores are formed of carbon particles, carbon nanofibers, or carbon nanotubes. 
     
     
         19 . The microporous layer of  claim 18 , wherein the hydrophobic pores are treated with one or more hydrophobic fluorocarbon binders. 
     
     
         20 . The microporous layer of  claim 15 , wherein the plurality of bores are laser-perforated bores.