US 2011 02871 83A1

(19) United States

(12) Patent Application Publication (10) Pub. No.: US 2011/0287.183 A1
Sung et al. (43) Pub. Date: Nov. 24, 2011
(54) MANUFACTURING METHOD OF GAS (30) Foreign Application Priority Data
DIFFUSION LAYER
Jan. 5, 2007 (TW) ................................... 961OO460
(75) Inventors: Lung-Yu Sung, Hsinchu County Publication Classification
(TW); Kan-Lin Hsueh, Hsinchu (51) Int. Cl.
County (TW); Yi-Yie Yan, Hsinchu BOSD 5/00 (2006.01)
City (TW); Shu-Mei He, Hsinchu (52) U.S. Cl. ........................................................ 427/245
County (TW); Shi-Chern Yen,
Taipei City (TW) (57) ABSTRACT
A gas diffusion layer, a manufacturing apparatus and a manu
facturing method thereof are provided. The gas diffusion
(73) Assignee: INDUSTRIAL TECHNOLOGY layer An different Siri Siphiite and
RESEARCH INSTITUTE, channel therein can be manufactured quickly and easily by
Hsinchu (TW) using a coating mask. The gas diffusion layer is used in
various fuel cells to enhance the ability of water management
(21) Appl. No.: 13/183,478 and to solve the problem of flooding at the cathode, the
problem of water deficit at the anode, and the problem of gas
transfer. The gas diffusion layer includes a gas diffusion
(22) Filed: Jul. 15, 2011 medium having a first property and a micro porous layer
having a second property. The micro porous layer is formed
Related U.S. Application Data on one surface of the gas diffusion medium. The microporous
layer has a plurality of channel layers penetrating the gas
(62) Division of application No. 11/954.244, filed on Dec. diffusion medium. One of the first property and the second
12, 2007. property is hydrophilic, and the other is hydrophobic.

504d 504b 504

i
Patent Application Publication Nov. 24, 2011 Sheet 1 of 7 US 2011/0287.183 A1

102 100 102

FIG. 1A (PRIOR ART)
106 109-10S.

X.
102
:
Rs 100
3&

--
104
FIG. 1B (PRIOR ART)
Patent Application Publication Nov. 24, 2011 Sheet 2 of 7 US 2011/0287.183 A1

204
NN
NN
N 2O6
NNS N. g
NNS
NY
N
N

2O2 208
Patent Application Publication Nov. 24, 2011 Sheet 3 of 7 US 2011/0287.183 A1

202
206

FIG . 5A FIG 3B

206 202
-202
2222222222222222222222

206 222222222222222222222222222
Zaaaaaaaaa
M/
ZZZZ2227ZZZZZZZZZZ
22222222222222222222
Zaa222222222222
Faaaaaaaaaaaaay

FIG FIG 3D
202 206 206 202

FIG. 3E FIG. 3F
Patent Application Publication Nov. 24, 2011 Sheet 4 of 7 US 2011/0287.183 A1

406 410

N
--

- 4200

4200

FIG. 4C
Patent Application Publication Nov. 24, 2011 Sheet 5 of 7 US 2011/0287.183 A1

500
510 56 ?
504b.
FlZ."
502b
Ingooooocot
508
5040

502
——
506
520

FIG. 5A
Patent Application Publication Nov. 24, 2011 Sheet 6 of 7 US 2011/0287.183 A1

5040 504b. 504

FIG. 6C

5040 504b. 504

SS
cN
C O

FIG, 6E
Patent Application Publication Nov. 24, 2011 Sheet 7 of 7 US 2011/0287.183 A1

Providing a coating mask having a plurality 700

of through holes

Placing a gas diffusion medium having a first 702

property on the coating mask

Forming a micro porous layer slurry having 704

the first property on the gas diffusion medium
having the first property
Performing a heating and sintering step to
remove the solution in the micro porous layer - 706
slurry having the first property,so as to form
a micro porous layer having the first property

Forming a micro porous layer slurry having a 108

second property on the gas diffusion medium
having the first property

Performing the penetrating step to make the micro

porous layer slurry having the second property 710
penetrate into the gas diffusion medium having
the first property and run through the gas
diffusion medium having the first property

Performing the heating and sintering step to

remove the solution in the micro porous layer 712
slurry having the Second property, So QS to form
the micro porous layer having the Second property

FIG. 7
US 2011/02871 83 A1 Nov. 24, 2011

MANUFACTURING METHOD OF GAS 0008. The hydrogen ions (H) are produced at the anode
DIFFUSION LAYER 110. Due to the electrical field in the cell, the H" is migrated
CROSS-REFERENCE TO RELATED from the anode toward the cathode 112 continuously. During
APPLICATION the H migration, it drags water molecules (H2O) along to the
cathode 112 (i.e., osmosis drag of water, the His migrated in
0001. This application is a divisional of and claims the the form of a hydrated ion H'(H2O)). Therefore, during the
priority benefit of U.S. application Ser. No. 1 1/954.244, filed cell reaction, the HO molecules will be continuously trans
on Dec. 12, 2007, now pending, which claims the priority ferred from the anode 110 to the cathode 112. If the water
benefit of Taiwan application serial no. 96100460, filed on cannot be Supplied at adequate amount, the proton exchange
Jan. 5, 2007. The entirety of each of the above-mentioned membrane (PEM) 100 will become excessively dry, the H"
patent applications is hereby incorporated by reference herein
and made a part of this specification. conducting capability of the membrane will be reduced, and
the power output of the fuel cell will be significantly reduced.
BACKGROUND OF THE INVENTION However, a great amount of water (HO) will be produced by
0002 1. Field of the Invention the reduction reaction of O at the cathode 112. If the extra
0003. The present invention relates to a fuel cell. More water cannot be adequate discharged from the cell, the cata
precisely, the present invention relates to a gas diffusion layer lyst layer 102 and the gas diffusion layer 104 at the cathode
of a fuel cell, a manufacturing apparatus and a manufacturing 112 will be flooded and filled with water. The gas diffusion
method thereof. layer filled with water becomes a diffusion barrier of oxygen.
0004 2. Description of Related Art It retards the oxygen getting into the catalyst layer and the cell
0005 Along with the industrial development, the con output power is significantly reduced. Therefore, the require
Sumption of the conventional energy resources Such as coal, ment on the water management condition at the cathode 112
petroleum, and natural gas continuously increases. Since the and that at the anode 110 of the fuel cell are significantly
reservations of these resources are limited, new alternative different from each other. Controlling and maintaining of the
energy technology should be developed to Substitute the con water balance in the cathode 112 and the anode 110 and
ventional method of energy consumption. The fuel cell is an keeping the gas transferring freely inside the electrodes, are
important new alternative energy technology with practical critical for maintaining the performance of the PEMFC at its
value. optimal condition.
0006 Briefly speaking, the fuel cell basically is a genera
tor apparatus that uses the reverse reaction of the water elec 0009. The gas diffusion layer 104 is located between the
trolysis to convert chemical energy into electric energy. Since catalyst layer 102 and the gas flow path 108. It is one of the
the fuel cell has the advantages of low operation temperature, key components of the fuel cell in the determination of the
quick start, high energy density, low pollution, and a wide water balance in the fuel cell. A good gas diffusion layer shall
range of application, the fuel cell has a high commercial maintain the catalyst layer and membrane at adequate mois
value. It has become a Successively developed and promoted ture for high ionic conductivity and keep itself at dry condi
technology all over the world. The commonly seen fuel cell tion for good gas diffusion pathway.
includes phosphoric acid fuel cell (PAFC), direct methanol 0010 FIG. 1B is a schematic view of the internal structure
fuel Cell (DMFC), alkaline fuel cell (AFC), molten carbonate of a gas diffusion layer. As shown in FIG. 1B, the gas diffu
fuel cell (MCFC), solid oxide fuel cell (SOFC), and proton sion layer 104 has a dual-layer structure therein, one layer is
exchange membrane fuel cell (PEMFC). a gas diffusion medium (GDM) 104a. It is a macro-porous
0007 FIG. 1A is a cross-sectional view of an internal carbon fiber substrate. The other one is a micro porous layer
structure of a typical proton exchange membrane fuel cell (MPL) 104b. It is a micro-porous carbon powder substrate.
(PEMFC). As shown in FIG. 1A, the PEMFC mainly includes The MPL is coated on the GDM by a particular manufactur
a proton exchange membrane (PEM) 100, a catalyst layer ing method. This method usually uses an ultrasonic oscillator
102, a gas diffusion layer (GDL) 104, and a bipolar plate 106. to mix highly conductivity carbon powders, dispersing
During the PEMFC operation, the oxidation reaction of H is agents, a solution, and a hydrophile/hydrophobicizer, so as to
taking placed at the anode 110, and the reduction reaction of produce a liquid micro porous layer slurry. This slurry is then
O is taking placed at the cathode 112. The reactant gas H at using a coating technique to coat the microporous layer slurry
the anode 110 is decomposed into hydrogen ions (H) and on the surface of the gas diffusion medium 104a. After a high
electrons (e) in the presence of a catalyst, as shown in Equa temperature sintering, the micro porous layer 104b is
tion (1). The electrons (e) escape from the anode 110. It obtained.
flows through the cell external circuit 114 and load 115, then 0011. The gas diffusion layer 104 plays many roles in the
it reaches the cathode 112. Meanwhile, the hydrogen ions fuel cell Stack, Such as (1) providing a pathway for the reac
(H) are transferred from the anode 110 to the cathode 112 tant gas (H. O.); (2) providing a pathway for the reaction
through the proton exchange membrane (PEM) 100. The products (water, heats) to leave the catalyst layer; (3) provid
hydrogen ions (H) and the electrons (e) combine with the ing a conducting medium for the electrons current; and (4)
oxygen molecules (O) at the cathode 112 to produce water acting as a structural Support for the catalyst layer and the
(HO), as shown in Equation (2). Therefore, the overall reac PEM. Therefore, the gas diffusion layer 104 should have all
tion of the entire fuel cell is; H reacts with O. to produce the characteristics of electric conductivity, thermal conduc
H2O, as shown in Equation (3). tivity, porosity, gas permeability, hydrophilicity/hydropho
At the anode: H-->2H+2e. (1), bicity, and mechanical strength. As described above, during
the reaction of the PEMFC, many water molecules (HO) are
At the cathode: /3O+2H+2e->HO (2), required for the H to migrate from the anode 110 to the
cathode 112. So that the gas diffusion layer of a hydrophilic
Overall reaction: H2+/3O->H2O (3). material is suitable for being used at the anode 110. A great
US 2011/02871 83 A1 Nov. 24, 2011

amount of water (H2O) will be produced by the reduction medium. Therefore, the conductivity at the in-plane and the
reaction of O at the cathode 112, so that the gas diffusion through-plane of the gas diffusion layer can be greatly
layer of a hydrophobic material is suitable for being used at improved.
the cathode 112. If both the transference of the reactant gases 0018. The present invention provides a gas diffusion layer,
(HO) and the discharge of the water (HO) should be taken which includes a gas diffusion medium having a first property
into consideration, the gas diffusion layer made of combining and a micro porous layer having a second property. The first
different hydrophilic/hydrophobic materials can be used. micro porous layer having the second property is formed on
Based on the above, the hydrophilic/hydrophobic structure of one Surface of the gas diffusion medium, and the first micro
the gas diffusion layer 104 is the critical factor for affecting porous layer has a plurality of channel layers penetrating
the water balance in the fuel cell. through the gas diffusion medium. One of the first property
0012. The conventional manufacturing method of the gas and the second property is hydrophilic, and the other is hydro
diffusion layer only adopts a Surface coating process to form phobic.
a micro porous layer on the Surface of the gas diffusion 0019. In the gas diffusion layer of the present invention,
medium, without forming different hydrophilic/hydrophobic since the micro porous layer has the channel layers penetrat
structures and channel layers in the gas diffusion medium ing into the gas diffusion medium and having a 3-D structure,
(GDM). Moreover, the micro porous layer (MPL) has a poor the adhesion between the micro porous layer and the gas
adhesion with the gas diffusion medium, which is easily diffusion medium can be greatly enhanced, and thus, the
stripped off. Moreover, the gas diffusion layer cannot meet micro porous layer is not easily stripped off.
the requirements on both the high gas permeability/high 0020. In the gas diffusion layer of the present invention,
hydrophilicity and the high gas permeability/high electric besides one or more micro porous layers formed on the Sur
conductivity. The gas diffusion layer (GDL) usually has a low face of the gas diffusion medium, channel layers served as
electric conductivity at the through plane. conductive channels in the through-plane direction are further
SUMMARY OF THE INVENTION
formed by penetrating the micro porous layer into the gas
diffusion medium. Therefore, the conductivity at the in plane
0013 The present invention provides a gas diffusion layer, and the through plane of the gas diffusion layer can be greatly
a manufacturing apparatus and a manufacturing method improved.
thereof. A plurality channel layers are formed in a gas diffu 0021. The gas diffusion layer of the present invention
sion medium, which have a hydrophilicity/hydrophobicity forms a plurality channel layers having a hydrophilicity/hy
different from that of the gas diffusion medium, so as to solve drophobicity different from that of the gas diffusion medium
the problem of flooding at the cathode, the problem of water in the gas diffusion medium, so as to solve the problem of
deficit at the anode, and the problem of gas transfer for the flooding at the cathode, the problem of water deficit at the
fuel cell at the same time, and thus improving the power anode, and the problem of gas transfer for the fuel cell, and
generating performance and prolonging the service life of the thus enhancing the power-generating performance and pro
fuel cell. longing the service life of the fuel cell.
0014. The present invention provides a gas diffusion layer, 0022. The present invention provides a manufacturing
a manufacturing apparatus and a manufacturing method apparatus of the gas diffusion layer for forming a micro
thereof, which uses a coating mask and a vacuum system. porous layer having a plurality of channel layers on a gas
When a microporous layer slurry is coated on a gas diffusion diffusion medium. The manufacturing apparatus of the gas
medium, a plurality of channel layers are formed in the gas diffusion layer includes a vacuum system, a coating mask,
diffusion medium, which have a hydrophilicity/hydrophobic and a heating apparatus. The vacuum system includes a
ity different from that of the gas diffusion layer, and the gas vacuum chamber body and a vacuum pump. The vacuum
diffusion layer having different hydrophilicity/hydrophobic chamber body has an opening. The vacuum pump is con
ity combinations can be manufactured quickly by changing nected to the vacuum chamber body, so as to produce a
the pattern design of the coating mask. vacuum suction in the vacuum chamber body. The coating
0015 The present invention provides a gas diffusion layer mask is disposed on the opening of the vacuum chamber
of a fuel cell, a manufacturing apparatus and a manufacturing body, and has a plurality of through holes therein. The heating
method thereof. By means of disposing a heating apparatus, apparatus is disposed in the coating mask. After the gas dif
the heating and sintering process can be performed while the fusion medium is disposed on the coating mask, and the micro
microporous layer slurry is coated. Therefore, the Solution in porous layer slurry is coated on the gas diffusion medium, the
the slurry can be removed quickly, so as to from a micro gas diffusion medium is fixed and part of the micro porous
porous layer and a plurality of channel layers. layer slurry is penetrated into the gas diffusion medium under
0016. The present invention provides a gas diffusion layer the effect of the vacuum Suction, and then, the heating appa
of a fuel cell, a manufacturing apparatus and a manufacturing ratus is used to remove the solution in the micro porous layer
method thereof. Since part of the micro porous layer is pen slurry, so as to form the micro porous layer having channel
etrate into the gas diffusion medium, and has a 3-D channel layers.
structure, the adhesion between the micro porous layer and 0023. Since the manufacturing apparatus of the gas diffu
the gas diffusion medium can be greatly enhanced, and thus, sion layer has the coating mask and the vacuum system, the
the micro porous layer is not easily stripped off. gas diffusion layer having channel layers formed in the gas
0017. The present invention provides a gas diffusion layer diffusion medium (GDM) is easily manufactured, and the
of a fuel cell, a manufacturing apparatus and a manufacturing hydrophilicity/hydrophobicity of the channel layers is differ
method thereof. Besides one or more micro porous layers ent from that of the gas diffusion medium. Moreover, the gas
formed on the Surface of the gas diffusion medium, a conduc diffusion layer having different hydrophilicity/hydrophobic
tive channel is also formed in the through-plane direction by ity combinations can be produced quickly by changing the
penetrating the micro porous layer into the gas diffusion pattern design of the through holes for the coating mask.
US 2011/02871 83 A1 Nov. 24, 2011

0024. Since the manufacturing apparatus of the gas diffu 0036 FIG. 4A is a sectional view of a gas diffusion layer
sion layer has a heating apparatus, the heating and sintering according to a preferred embodiment of the present invention.
process can be performed while the microporous layer slurry 0037 FIG. 4B is an enlarged view of part B in FIG. 4A.
is coated. Therefore, the solution in the slurry can be removed 0038 FIG. 4C is a parallel-connected circuit diagram for
quickly, and the micro porous layer structure and the channel equivalent resistors of the gas diffusion layer according to the
layers can be formed quickly. present invention.
0025. The present invention provides a manufacturing 0039 FIG. 5A shows a manufacturing apparatus for a gas
method of the gas diffusion layer, which includes the follow diffusion layer according to a preferred embodiment of the
ing steps. Firstly, a coating mask is provided, which has a present invention.
plurality of through holes therein. Next, a gas diffusion 0040 FIG. 5B is a top view of a manufacturing apparatus
medium is disposed on the coating mask, and a first micro foragas diffusion layer disposed with a gas diffusion medium
porous layer slurry is formed on the gas diffusion medium. and micro porous layer slurry according to a preferred
Then, a penetrating step is performed, to make the first micro embodiment of the present invention.
porous layer slurry penetrate into the gas diffusion medium 004.1 FIGS. 6A to 6F are respectively top views of a
and run through the gas diffusion medium, and the part of the coating mask according to a preferred embodiment of the
gas diffusion medium where the first micro porous layer present invention.
slurry penetrates through is corresponding to the through 0042 FIG. 7 is a flow chart of a manufacturing method for
holes of the coating mask. Then, a first heating and sintering a gas diffusion layer according to a preferred embodiment of
step is performed to remove the solution in the first micro the present invention.
porous layer slurry, so as to form a first micro porous layer
having a plurality of channel layers. DESCRIPTION OF EMBODIMENTS
0026. Since the manufacturing method of the gas diffusion 0043. The present invention provides a gas diffusion layer
layer of the present invention adopts a coating mask, channel of a fuel cell, a manufacturing apparatus and a manufacturing
layers having hydrophilicity/hydrophobicity different from
that of the gas diffusion medium (GDM) is easily formed in method thereof. First of all, one or more layers of micro
the gas diffusion medium (GDM). Moreover, the gas diffu porous layer slurry are coated on the gas diffusion medium
sion layer having different hydrophilicity/hydrophobicity (GDM), and the micro porous layer slurry is made to pen
combinations can be produced quickly by changing the pat etrate into the gas diffusion medium. After the drying and
tern design for the coating mask. sintering process, the gas diffusion layer structure with a
0027. In the manufacturing method of the gas diffusion plurality channel layers having hydrophilicity/hydrophobic
layer of the present invention, the coating step of the micro ity different from that of a gas diffusion medium is formed in
porous layer slurry, the penetrating step of the micro porous the gas diffusion medium. The “hydrophilicity/hydrophobic
layer slurry and the heating and sintering step can be per ity' stands for hydrophilicity or hydrophobicity.
formed at the same time, so that the micro porous layer 0044 First of all, the gas diffusion layer of the present
structure and the channel layers can be formed quickly. This invention is illustrated. FIG. 2A is a sectional view of a gas
manufacturing method is not only simple, but also saves the diffusion layer according to a preferred embodiment of the
manufacturing time. present invention.
0028. In order to make the aforementioned and other 0045. As shown in FIG. 2A, the gas diffusion layer 200 is,
objectives, features and advantages of the present invention for example, formed by a gas diffusion medium 202 having a
comprehensible, preferred embodiments accompanied with first property, and a micro porous layer 204 having a second
figures are described in detail below. property. One of the first property and the second property is
0029. It is to be understood that both the foregoing general hydrophilic, and the other is hydrophobic. For example, if the
description and the following detailed description are exem gas diffusion medium 202 is hydrophilic, the micro porous
plary, and are intended to provide further explanation of the layer 204 is hydrophobic; and if the gas diffusion medium 202
invention as claimed. is hydrophobic, the micro porous layer 204 is hydrophilic.
0046. The material of the gas diffusion medium 202
BRIEF DESCRIPTION OF THE DRAWINGS includes, for example, a porous material. Such as carbon
paper, carbon cloth, carbon fiber material, metal foams, or
0030 The accompanying drawings are included to pro metal netting. A hydrophilic process or a hydrophobic pro
vide a further understanding of the invention, and are incor cess is, for example, performed on the gas diffusion medium
porated in and constitute a part of this specification. The 202, so that the gas diffusion medium 202 is hydrophilic or
drawings illustrate embodiments of the invention and, hydrophobic.
together with the description, serve to explain the principles 0047. The micro porous layer 204 is disposed on one sur
of the invention. face of the gas diffusion medium 202, and the micro porous
0031 FIG.1A is a sectional view of an internal structure of layer 204 has a plurality of channel layers 206 penetrating
a typical proton exchange membrane fuel cell (PEMFC). through the gas diffusion medium 202. That is, the channel
0032 FIG. 1B is a schematic view of an internal structure layers 206 are the part extending from the micro porous layer
of a gas diffusion layer. 204. The channel layers 206 have the hydrophilicity/hydro
0033 FIG. 2A is a sectional view of a gas diffusion layer phobicity different from that of the gas diffusion medium 202.
according to a preferred embodiment of the present invention. The micro porous layer 204 (including the channel layers
0034 FIG. 2B is a sectional view of a gas diffusion layer 206) is formed by the micro porous layer slurry with the
according to another preferred embodiment of the present Solution being removed. The micro porous layer slurry
invention. includes a carbon material having a high conductivity, a dis
0035 FIGS. 3A to 3F are respectively side views of the gas persing agent, a solution and a hydrophile/hydrophobicizer.
diffusion layer seen from the direction A in FIG. 2A or 2B. The hydrophilicity or hydrophobicity of the micro porous
US 2011/02871 83 A1 Nov. 24, 2011

layer 204 can be controlled through the proportion of the conductivity of the gas diffusion layer. In the hydrophobic gas
hydrophile/hydrophobicizer in the micro porous layer slurry. diffusion medium, the channel layers formed by the carbon
Definitely, the micro porous layer slurry further includes a powder can provide an additional channel for current, so as to
noble metal catalyst, such as Pt, Au, Ru, Rh, Pd, Pt—Ru or reduce the resistance of the gas diffusion layer. As shown in
Pt-transient metal alloys. The Pt-transient metal alloys FIG. 4C, the additional carbon powder channel is equivalent
include Pt Ru, Pt. Sn, Pt. Ru W. Pt Co, and to a low resistance channel 420a formed in the parallel
Pt. Ru Sn. connected circuit for equivalent resistors of the gas diffusion
0048 FIG. 2B is a sectional view of a gas diffusion layer layer, so as to improve the electric conductivity of the gas
according to another preferred embodiment of the present diffusion layer. Otherwise, the low resistance channel 420a is
invention. In FIG. 2B, the same numerals are designated to used to provide the path of current, so that the hydrophobicity
the same means in FIG. 2A, and the detailed illustration is for other parts of the gas diffusion layer is enhanced, and the
omitted herein, but only the differences are illustrated. diffusion layer gains a preferred gas diffusivity.
0049. As shown in FIG. 2B, the gas diffusion layer 200a 0054. In general, depending upon various different water
further includes a micro porous layer 208 having a first prop management requirements and objectives, the gas diffusion
erty. The micro porous layer 208 is disposed on the surface of
the gas diffusion medium 202, and located between the gas layers having different hydrophilicity/hydrophobicity can be
diffusion medium 202 and the micro porous layer 204. The used correspondingly, so as to significantly improve the water
micro porous layer 208 has the hydrophilicity/hydrophobic management capability of the fuel cell, and also solve the
ity the same as that of the gas diffusion medium 202. For problem of flooding at the cathode, the problem of water
example, if the gas diffusion medium 202 and the micro deficit at the anode, and the problem of gas transfer of the fuel
porous layer 208 are hydrophilic, the micro porous layer 204 cell at the same time, and thus enhancing the power-generat
is hydrophobic; and if the gas diffusion medium 202 and the ing performance and prolonging the service life of the fuel
micro porous layer 208 are hydrophobic, the micro porous cell.
layer 204 is hydrophobic. Likewise, the micro porous layer 0055. In the gas diffusion layer of the present invention,
208 is also formed by the micro porous layer slurry with the since the micro porous layer (MPL) has the channel layers
solution being removed. The gas diffusion layers 200 and penetrating into the gas diffusion medium (GDM) and having
200a of the present invention can be used in a phosphoric acid a 3-D structure, the adhesion between the micro porous layer
fuel cell (PAFC), a direct methanol fuel cell (DMFC), or a (MPL) and the gas diffusion medium (GDM) can be greatly
proton exchange membrane fuel cell (PEMFC). increased, and thus, the micro porous layer is not easily
0050 FIGS. 3A to 3F are respectively side views of the gas stripped off.
diffusion layer seen from the direction A in FIG. 2A or 2B. As
shown in FIGS. 3A to 3F, the channel layers 206 within the 0056 Besides one or more micro porous layers (MPL)
gas diffusion medium 202 are, for example, arranged regu formed on the surface of the gas diffusion medium (GDM),
larly, which definitely also can be arranged irregularly. The the gas diffusion layer of the present invention further has the
sizes and shapes of the channel layers 206 on the same gas channel layers served as conductive channels in the through
diffusion medium 202 can be the same or different from each plane direction and formed by penetrating the micro porous
other. The cross section of the channel layers 206 is, for layer into the gas diffusion medium (GDM). Therefore, the
example, round (shown in FIGS. 3A and 3B) or rectangular conductivity at the in plane and the through plane of the gas
(shown in FIGS. 3C to 3F), and the cross section of the diffusion layer can be greatly improved through the channel
channel layer 206 can also be, for example, polygon (such as layers.
triangle, pentagon), ellipse, or an irregular shape. 0057 The gas diffusion layer of the present invention
0051 FIG. 4A is a sectional view of a gas diffusion layer forms the channel layers in the gas diffusion medium, which
according to a preferred embodiment of the present invention. has a hydrophilicity/hydrophobicity different from that of the
FIG. 4B is an enlarged view of part B in FIG. 4A. FIG. 4C is gas diffusion medium, so as to solve the problem of flooding
a parallel-connected circuit diagram of equivalent resistors of at the cathode, the problem of water deficit at the anode, and
the gas diffusion layer according to the present invention. the problem of gas transfer of the fuel cell, and thus, enhanc
0052. As shown in FIGS. 4A and 4B, a hydrophobic micro ing the power-generating performance and prolonging the
porous layer 408 and a hydrophilic microporous layer 404 are Service life of the fuel cell.
formed on the hydrophobic gas diffusion medium 402 by 0058. Then, the manufacturing apparatus of the gas diffu
means of a dual-layer coating process. The hydrophilic micro sion layer of the present invention is illustrated. FIG. 5A is a
porous layer 404 has hydrophilic channel layers 406 penetrat sectional view of a manufacturing apparatus for a gas diffu
ing through the hydrophobic micro porous layer 408 and the sion layer according to a preferred embodiment of the present
hydrophobic gas diffusion medium 402. Through the hydro invention. FIG.5B is a top view of a manufacturing apparatus
philic micro porous channel layers 406 in the hydrophobic foragas diffusion layer disposed with a gas diffusion medium
gas diffusion medium 402, the water around is absorbed into and a micro porous layer slurry according to a preferred
the hydrophilic micro porous channel layers 406 by the cap embodiment of the present invention. FIGS. 6A to 6F are
illary effect to form a liquid communication channel 412 and respectively top views of a coating mask according to a pre
a gas communication channel 410 for maintaining the nearby ferred embodiment of the present invention.
hydrophobic gas diffusion medium 402 to be fluent and 0059 Referring to FIGS. 5A and 5B, the manufacturing
Smooth. apparatus 500 for the gas diffusion layer includes, for
0053 Generally, the hydrophobic process of the gas dif example, a vacuum system 520, a coating mask 504, and a
fusion layer will reduce the electric conductivity of the dif heating apparatus 508. A gas diffusion medium 514 is dis
fusion layer. However, the gas diffusion layer structure pro posed on the coating mask 504, and the micro porous layer
vided by the present invention can enhance the electric slurry 516 is coated on the gas diffusion medium 514.
US 2011/02871 83 A1 Nov. 24, 2011

0060. The vacuum system 520 is formed by, for example, printing). The micro porous layer slurry 516 not only forms a
a vacuum chamber body 502 and a vacuum pump 506. An coating layer on the Surface of the gas diffusion medium 514,
opening 502a is, for example, disposed on one end of the but also penetrates into the gas diffusion medium 514 accord
vacuum chamber body 502. ing to the pattern constituted by the through holes 504a of the
0061 The vacuum pump 506 is connected to the vacuum coating mask 504, and run through the gas diffusion medium
chamber body 502, so as to produce a vacuum suction in the 514 due to the vacuum suction. Therefore, the part of the gas
inner part 502b of the vacuum chamber body 502, and under diffusion medium 514 where the micro porous layer slurry
the vacuum suction, the gas diffusion medium 514 is fixed 516 penetrates through is corresponding to the through holes
and the micro porous layer slurry 516 can penetrate into the 504a of the coating mask 504. Since the heating apparatus
gas diffusion medium quickly. That is, through the vacuum 508 is disposed on the coating mask 504, the heating and
suction, the micro porous layer slurry 516 located above the sintering process can be performed while coating the micro
through hole 504a of the coating mask 504 penetrates down porous layer slurry 514, so as to remove the solution in the
wards to form a plurality of channel layers. Therefore, a microporous layer slurry, and thus forming the microporous
pattern constituted by the channel layers depends upon a layer and the channel layers quickly. In this embodiment, the
pattern constituted by the through holes 504a of the coating step of forming the micro porous layer slurry 516 on the gas
mask 504. The vacuum pump 506 is, for example, connected diffusion medium 514, the step of penetrating the micro
to the vacuum chamber body 502 through a vacuum pipe
fitting 512. porous layer slurry 516 into the gas diffusion medium 514,
0062. The coating mask 504 is, for example, disposed on and the heating and sintering steps are performed at the same
the opening 502a of the vacuum chamber body 502. The time. Definitely, the step of forming the micro porous layer
coating mask 504 has a plurality of through holes 504a slurry 516 on the gas diffusion medium 514, the step of
therein. A plurality of screw holes 504b are, for example, penetrating the micro porous layer slurry 516 into the gas
disposed around the coating mask 504, and thus, the coating diffusion medium 514, and the heating and sintering step can
mask 504 is fixed on the opening 502a of the vacuum chamber also be performed separately. For example, after the micro
body 502 through the plurality of screws 510. Moreover, as porous layer slurry 516 has been formed on the gas diffusion
shown in FIGS. 6A to 6F, the through holes 504a of the medium 514, the vacuum pump 506 and the heating apparatus
coating mask 504 are, for example, arranged regularly. Of 508 are started, and then, the step of penetrating the micro
course, the through holes 504a may also be arranged irregu porous layer slurry 516 into the gas diffusion medium 514,
larly. The sizes and shapes of the through holes 504a on the and the heating and sintering step are performed.
same coating mask 504 can be the same or different from each 0065. The manufacturing apparatus for the gas diffusion
other. The cross section of the through hole 504a of the layer of the present invention has the coating mask and the
coating mask 504 is, for example, round (shown in FIGS. 6A vacuum system, so that it is easy to manufacture a gas diffu
and 6B) or rectangular (shown in FIGS. 3C to 3F). Of course, sion layer with channel layers formed in the gas diffusion
the cross section of the through hole 504a may also be, for medium (GDM). The channel layers have a hydrophilicity/
example, polygon (such as triangle, pentagon), ellipse or an hydrophobicity different from that of the gas diffusion
irregular shape. The material of the coating mask 504 is, for medium. Moreover, by changing the pattern design for the
example, metal, rubber, plastic or ceramic. The coating mask through hole of the coating mask, the gas diffusion layer
504 has through holes 504a with different sizes and shapes on having different hydrophilicity/hydrophobicity combina
the Surface, which are not only used for fixing the gas diffu tions can be produced quickly.
sion medium.514, but also used for forming the channel layers 0.066 Since the manufacturing apparatus for the gas dif
in the gas diffusion medium 514, in which the channel layers fusion layer of the present invention has a heating apparatus,
have a hydrophilicity/hydrophobicity different from that of the heating and sintering process can be performed while the
the gas diffusion medium 514. microporous layer slurry is coated. Therefore, the solution in
0063. The heating apparatus 508 is, for example, disposed the micro porous layer slurry can be removed quickly, and
in the coating mask 504. Such that the heating and sintering thus, the micro porous layer structure and the channel layers
process can be performed while coating the micro porous can be formed quickly.
layer slurry 516, and thus, the solution in the micro porous 0067. Then, the manufacturing method for the gas diffu
layer slurry 516 can be removed quickly to form the micro sion layer of the fuel cell in the present invention is illustrated.
porous layer structure and the channel layers. FIG. 7 is a flow chart of a manufacturing method for a gas
0064. Then, the operations of the manufacturing apparatus diffusion layer according to a preferred embodiment of the
for the gas diffusion layer of the present invention are illus present invention. In this embodiment, the manufacturing of
trated below. Referring to FIG. 5A, the coating mask 504 is the gas diffusion layer in FIG. 2B is taken as an example for
fixed on the opening 502a of the vacuum chamber body 502 illustration. Moreover, in the following illustration, one of the
through the screws 510. Then, the gas diffusion medium 514 first property and the second property is hydrophilic, and the
is placed on the coating mask 504, and meanwhile, the other is hydrophobic. For example, if the first property is
vacuum pump 506 and the heating apparatus 508 on the hydrophilic, the second property is hydrophobic; and if the
coating mask 504 are started. At this time, the gas diffusion first property is hydrophilic, the second property is hydro
medium 514 is fixed on the coating mask 504 under the philic.
vacuum suction produced by the vacuum pump 506, and the 0068 Referring to FIGS. 7 and 2B, a coating mask is
gas diffusion medium 514 is also heated by the heating appa provided, which has a plurality of through holes therein (Step
ratus 508. When the gas diffusion medium 514 reaches the 700). In Step 700, the used coating mask is, for example, the
required temperature, the micro porous layer slurry 516 is coating mask shown in the FIGS. 6A to 6F. The material of the
coated on the gas diffusion medium 514 by means of a coating coating mask is, for example, metal, rubber, plastic or
technique (Such as spraying coating, blade coating, Screen ceramic.
US 2011/02871 83 A1 Nov. 24, 2011

0069. Then, the gas diffusion medium 202 having the first 0074 Then, a heating and sintering step is performed
property is placed on the coating mask (Step 702). The mate (Step 712) to remove the solution in the micro porous layer
rial of the gas diffusion medium 202 includes a porous mate slurry having the second property, so as to form the micro
rial, for example, carbon paper, carbon cloth, carbon fiber porous layer 204 having a plurality of channel layers 206 and
material, metal foams, or metal netting. A hydrophilic process having the second property. A pattern constituted by the chan
or a hydrophobic process is, for example, performed on the nel layers 206 depends upon the pattern constituted by the
gas diffusion medium, Such that the gas diffusion medium is through holes. In this embodiment, Steps 708, 710, and 712
hydrophilic or hydrophobic. can also be performed at the same time, or Step 708 is per
0070 The micro porous layer slurry having the first prop formed before Steps 710 and 712.
erty is formed on the gas diffusion medium 202 having the 0075 Moreover, if it is intended to form the gas diffusion
layer shown in FIG. 2A, it is only necessary to omit Step 704
first property (Step 704). The process for forming the micro and Step 706.
porous layer slurry having the first property on the gas diffu 0076. In the manufacturing method for the gas diffusion
sion medium 202 having the first property includes, for layer of the present invention, through using the coating
example, spraying coating, blade coating, or screen printing. mask, it is easy to form the channel layers in the gas diffusion
The micro porous layer slurry having the first property medium (GDM), in which the channel layers have a hydro
includes a carbon material having a high conductivity, a dis philicity/hydrophobicity different from that of the gas diffu
persing agent, a solution and a hydrophile/hydrophobicizer. sion medium (GDM). Moreover, by changing the pattern
The hydrophilicity/hydrophobicity of the micro porous layer design of the coating mask, the gas diffusion layer having
204 can be controlled through the proportion of the hydro different hydrophilicity/hydrophobicity combinations can be
phile/hydrophobicizer in the micro porous layer slurry. Defi produced quickly.
nitely, the micro porous layer slurry further includes a noble 0077. In the manufacturing method for the gas diffusion
metal catalyst, such as Pt, Au, Ru, Rh, Pd, Pt. Ru or Pt layer of the present invention, the step of coating the micro
transient metal alloys. The Pt-transient metal alloys include porous layer slurry, the step of penetrating the micro porous
Pt Ru, Pt. Sn, Pt. Ru W. Pt Co, and Pt Ru–Sn. layer slurry, and the heating and sintering step can be per
0071. Aheating and sintering step is performed (Step 706) formed at the same time, so that the micro porous layer
to remove the solution in the microporous layer slurry having structure and the channel layers can be formed quickly. This
the first property, so as to form the micro porous layer 208 manufacturing method is simple and saves the manufacturing
having the first property. In this embodiment, Step 704 and time.
Step 706 can be performed at the same time, or Step 706 is 0078 Based on the above, in the gas diffusion layer of the
performed after Step 704. present invention, since the microporous layerpenetrates into
0072 The micro porous layer slurry having the second the gas diffusion medium (GDM) to form the channel layers
property is formed on the gas diffusion medium 202 having having a 3-D structure, the adhesion between the micro
the first property (Step 708). The process for forming the porous layer and the gas diffusion medium can be greatly
micro porous layer slurry having the second property on the enhanced, Such that the micro porous layer is not easily
gas diffusion medium 202 having the first property includes, stripped off.
for example, spraying coating, blade coating, or screen print 0079. In the gas diffusion layer of the present invention,
ing. The microporous layer slurry having the second property besides one or more micro porous layers (MPL) formed on
includes a carbon material having a high conductivity, a dis the surface of the gas diffusion medium (GDM), a conductive
persing agent, a solution and a hydrophile/hydrophobicizer. channel layers are also formed in the through-plane direction
The hydrophilicity/hydrophobicity of the micro porous layer by penetrating the micro porous layer into the gas diffusion
can be controlled through the proportion of the hydrophile/ medium (GDM). Therefore, the conductivity at the in plane
hydrophobicizer in the micro porous layer slurry. Definitely, and the through plane of the gas diffusion layer (GDL) can be
the micro porous layer slurry further includes a noble metal greatly improved.
catalyst such as Pt, Au, Ru, Rh, Pd, Pt—Ru or Pt-transient 0080 Since the gas diffusion layer of the present invention
metal alloys. The Pt-transient metal alloys include Pt Ru, has different hydrophilic/hydrophobic structures and chan
Pt. Sn, Pt. Ru W. Pt Co, and Pt Ru–Sn. nels, the problem of flooding at the cathode, the problem of
0073. Then, a penetrating step is performed (Step 710) to water deficitat the anode, and the problems of gastransfer can
make the micro porous layer slurry having the second prop be solved at the same time.
erty penetrate into the gas diffusion medium 202 having the I0081. Since the manufacturing method for the gas diffu
first property, and run through the gas diffusion medium 202 sion layer of the present invention has the coating mask and
having the first property, in which the part of the gas diffusion the vacuum system, it is easy to form the channel layers in the
medium 202 where the first micro porous layer slurry pen gas diffusion medium (GDM), which have a hydrophilicity/
etrates through is corresponding to the through holes of the hydrophobicity different from that of the gas diffusion
coating mask. The penetrating step includes using the Suction medium (GDM). Moreover, the gas diffusion layer (GDL)
to fix the gas diffusion medium 202 and making the micro having different hydrophilicity/hydrophobicity combina
porous layer slurry having the second property penetrate into tions can be produced quickly by changing the pattern design
the gas diffusion medium having the first property. For of the coating mask.
example, the coating mask is disposed on the opening of the I0082 Since the manufacturing apparatus for the gas dif
vacuum chamber body, and then, the vacuum pump is used to fusion layer has a heating apparatus, the heating and sintering
produce a Suction in the vacuum chamber body, so as to make process can be performed while the microporous layer slurry
the micro porous layer slurry having the second property is coated, so as to remove the Solution in the slurry quickly,
penetrate into the gas diffusion medium having the first prop and thus, forming the micro porous layer structure and the
erty. channel layer quickly.
US 2011/02871 83 A1 Nov. 24, 2011

0083. Since the manufacturing method for the gas diffu micro porous layer on the gas diffusion medium, before the
sion layer of the present invention adopts the coating mask, it step of forming the first micro porous layer slurry on the gas
is easy to form the channel layers in the gas diffusion medium diffusion medium.
(GDM), which have a hydrophilicity/hydrophobicity differ 3. The manufacturing method of the gas diffusion layer as
ent from that of the gas diffusion medium (GDM). Moreover, claimed in claim 1, wherein the step of forming the second
the gas diffusion layer having different hydrophilicity/hydro
phobicity combinations can be produced quickly by changing micro porous layer on the gas diffusion medium comprises:
the pattern design of the coating mask. forming a second micro porous layer slurry on the gas
0084. In the manufacturing method for the gas diffusion diffusion medium; and
layer of the present invention, the step of coating the micro performing a second heating and sintering step, to remove
porous layer slurry, the step of penetrating the micro porous the solution in the second micro porous layer slurry, so
layer slurry and the heating and sintering step can be per
formed at the same time, so that the micro porous layer as to form the second micro porous layer.
structure and the channel layers can be formed quickly. This 4. The manufacturing method of the gas diffusion layer as
manufacturing method is simple and can save the manufac claimed in claim 1, wherein the first micro porous layer slurry
turing time. and the second micro porous layer slurry comprise a carbon
0085 Though the present invention has been disclosed material having a high conductivity, a dispersing agent, a
above by the preferred embodiments, they are not intended to solution and hydrophile/hydrophobicizer.
limit the present invention. Anybody skilled in the art can 5. The manufacturing method of the gas diffusion layer as
make some modifications and variations without departing
from the spirit and scope of the present invention. Therefore, claimed in claim 1, wherein the through holes of the coating
the protecting range of the present invention falls in the mask are arranged regularly or irregularly.
appended claims and their equivalents. 6. The manufacturing method of the gas diffusion layer as
What is claimed is: claimed in claim 1, wherein the material of the gas diffusion
1. A manufacturing method of a gas diffusion layer, com medium comprises a porous material.
prising:
providing a coating mask having a plurality of through 7. The manufacturing method of the gas diffusion layer as
holes therein; claimed in claim 1, wherein a pattern constituted by the
disposing a gas diffusion medium on the coating mask, channel layers depends upon a pattern constituted by the
forming a first micro porous layer slurry on the gas diffu through holes.
sion medium; 8. The manufacturing method of the gas diffusion layer as
performing a penetrating step to penetrate the first micro claimed in claim 1, wherein the penetrating step comprises
porous layer slurry into the gas diffusion medium, and to fixing the gas diffusion medium and making the microporous
run through the gas diffusion medium, wherein the part layer slurry be penetrated into the gas diffusion medium
of the gas diffusion medium where the first microporous under the effect of a suction.
layer slurry penetrates through is corresponding to the
through holes of the coating mask; and 9. The manufacturing method of the gas diffusion layer as
performing a first heating and sintering step to remove a claimed in claim 8, wherein the coating mask is disposed on
Solution in the first micro porous layer slurry, so as to an opening of a vacuum chamber body; and
form a first micro porous layer having a plurality of in the penetrating step, a vacuum pump is used to produce
channel layers. the Suction in the vacuum chamber body.
2. The manufacturing method of the gas diffusion layer as
claimed in claim 1, further comprising forming a second c c c c c