Abstract: A gas diffusion media for a fuel cell, such as a proton exchange membrane fuel cell, is provided. The gas diffusion media includes carbonizable acrylic pulp fibers instead of conventional phenolic resin as a binder material. The acrylic fibers are mixed with the carbon fiber dispersion during the papermaking step, thus eliminating the phenolic resin impregnation step typically associated with conventional gas diffusion media manufacturing processes. The mat is then cured and carbonized to produce gas diffusion media.

Abstract: Diffusion media for fuel cell is made by preparing an aqueous dispersion comprising a powder resin, a binder material, and a fiber material comprising carbon fibers, of these; forming a layer of the dispersion on a support; removing water from the layer to form a fiber layer; molding the fiber layer; and carbonizing or graphitizing the molded layer.

Abstract: A gas diffusion media and method of making are provided including the formation of a carbon fiber paper which is heated to a carbonization temperature without exceeding a graphitization temperature. The discovery that a final high temperature heat treatment step in the graphitization temperature zone is not necessary to make effective gas diffusion media for PEM fuel cells greatly reduces the cost associated with the high temperature final heat treatment and also allows for the processing of the diffusion media in a roll.