The most critical aspect of fuel cell water management is the delicate balance of membrane hydration and avoiding cathode flooding. Liquid water accumulation in the interfacial contact area between the flow channel landing and gas diffusion layer (GDL) can dramatically impact steady and transient performance of proton exchange membrane fuel cells (PEMFCs). In this concern, a porous landing could facilitate water removal in the cathode flow channel and significantly improve PEMFCs performance. In this work, an attempt has been made to fabricate the porous interdigitated cathode flow channels from a porous carbon sheet. Performance measurements have been made with nominally identical PEMFCs using non-porous (serpentine and interdigitated) and porous (interdigitated) cathode flow channels. PEMFCs with porous interdigitated flow channels had 48% greater power output than PEMFCs with non-porous interdigitated flow channels at high current densities. For the non-porous interdigitated flow channel, significant performance loss appears to arise from greatly reduced oxygen transport rates when the water generation rate exceeds the water removal rate, however for the porous interdigitated flow channel, the design removes the accumulated liquid water from the landing area through the capillarity of its porous structure and eliminates the stagnant regions under the landing, thereby reducing liquid flooding in the interface between landing and GDL area.
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