Proton exchange membrane fuel cell with variable porosity gas distribution layers

摘要

A proton exchange membrane fuel cell comprising a proton transmissive membrane, a catalytic anode layer on one face of the membrane, a catalytic cathode layer on the other face of the membrane, and a gas distribution layer on each of the cathode and anode layers defining a gas flow field extending over each of the catalytic layers. Each of the gas distribution layers comprises a layer of open cell conductive foam material (78) which is divided into a plurality of generally parallel segments extending from one edge of the fuel cell to an opposite edge of the fuel cell whereby to define a plurality of generally parallel porous reactant paths extending across each catalytic layer. The segments may be defined by selectively varying the porosity of the foam material or selectively varying the thickness of the foam material. Reactant gases are delivered to the foam gas distribution layers via a manifold structure (80,82) in which the reactant gases are moved upwardly along an edge of the fuel cell stack in parallel paths and selectively distributed within the stack at the desired cathode or anode levels by selective baffling and partitioning structures. A coolant layer (88) may also be provided utilizing the same segmented foam construction utilized in the anode and cathode layers. The resultant fuel cell is lighter, smaller, and less expensive than prior art cells having comparable per surface area unit electrical energy output.