Integrated Gas Diffusion Layer for Fuel Cell Thickness Reduction

The patent merges the base and fine pore layer into a single integrated structure formed from one continuous carbon fiber mat. The carbon fibers themselves provide the base structure while simultaneously creating the fine pore network through their arrangement and interstices, eliminating the need for separate layer formation and reducing overall thickness while maintaining structural integrity.

The patent uses a composite structure where carbon fibers form both the base matrix and the fine pore framework. By utilizing the carbon fiber network to serve dual functions as structural base and pore-forming element, the design achieves thickness reduction without compromising strength, as the carbon fiber composite provides both mechanical support and transport pathways.

The carbon fiber base serves multiple functions simultaneously: it provides structural support, defines the layer geometry, and creates the fine pore network for gas and water transport. This multi-functional design eliminates the need for separate base and fine pore layers, as the carbon fiber mat inherently performs all required functions while maintaining layer stability.

The patent segments the carbon fiber mat into regions with different fiber arrangements and densities to create distinct functional zones. By controlling the local distribution and orientation of carbon fibers, the design defines stable layer structures with integrated fine pore regions, achieving both thickness reduction and layer stability through spatial segmentation of fiber properties.