Abstract: In at least one embodiment, a microporous layer configured to be disposed between a catalyst layer and a gas diffusion layer of a fuel cell electrode assembly is provided. The microporous layer may have defined therein a plurality of hydrophilic pores, a plurality of hydrophobic pores with a diameter of 0.02 to 0.5 ?m, and a plurality of bores with a diameter of 0.5 to 100 ?m. The microporous layer structures and gas diffusion layer assemblies disclosed herein may be defined by a number of various designs and arrangements for use in proton exchange membrane fuel cell systems.

Abstract: In at least one embodiment, a fuel cell is provided comprising a positive electrode including a first gas diffusion layer and a first catalyst layer, a negative electrode including a second gas diffusion layer and a second catalyst layer, a proton exchange membrane (PEM) disposed between the positive and negative electrodes, and a microporous layer of carbon and binder disposed between at least one of the first gas diffusion layer and the first catalyst layer and the second gas diffusion layer and the second catalyst layer. The microporous layer may have defined therein a plurality of pores with a diameter of 0.05 to 2.0 ?m and a plurality of bores having a diameter of 1 to 100 ?m. The bores may be laser perforated and comprise from 0.1 to 5 percent of a total porosity of the microporous layer.