Development of Sintered Paper Gas Diffusion Layers for Mobile Fuel Cells Optimized in Terms of Installation Space, Production and Costs

Currently, fuel cells for mobile applications still have considerable potential for improvement in terms of minimizing installation space, reducing manufacturing costs and increasing service life. An important component of the fuel cell stack for all the properties mentioned is the gas diffusion layer (GDL). The GDL is located between the bipolar plate and the electrode and must ensure optimum gas distribution and the removal of water, heat and electricity. The GDL currently consists preferably of porous graphite mats or graphite plates, which still have deficits in terms of mechanical stability, service life and costs.

The aim of the Fraunhofer IFAM Dresden sub-project is therefore to develop a metallic GDL using sintered paper technology. In addition, simulative work is being carried out to calculate the two-phase flow in the GDL in order to gain an understanding of the fluid-structure interaction and to optimize the gas and liquid distribution in the GDL. Another simulation task is the geometric design of a newly developed bipolar plate whose cooling channel structure (FlowField) is intended to ensure optimum heat dissipation with minimal pressure loss.