Microporous carbon catalyst support material

A fuel cell gas diffusion layer, comprising:

• a carbon fiber substrate layer;
• a microporous carbon skeleton layer adjacent the carbon fiber substrate layer, the microporous carbon skeleton layer having an average pore size from 0.1 to 10 nanometers and being substantially free of pores greater than 100 nanometers;
• and
• a plurality of catalyst particles on or within the microporous carbon skeleton layer.

A fuel cell, comprising:

• an electrolyte membrane having a first surface;
• and
• a fuel cell gas diffusion layer disposed on the first surface, the fuel cell gas diffusion layer comprising:
• a carbon fiber substrate layer;
• a microporous carbon skeleton layer adjacent the carbon fiber substrate layer, the microporous carbon skeleton layer having an average pore size from 0.1 to 10 nanometers and being substantially free of pores greater than 100 nanometers;
• and
• a plurality of catalyst particles on or within the microporous carbon skeleton layer,
• wherein at least selected catalyst particles are in contact with the first surface.

A method of forming a fuel cell gas diffusion layer, comprising;

• forming a hydrocarbon plasma from a hydrocarbon gas;
• depositing the hydrocarbon plasma adjacent a carbon fiber substrate layer to form a hydrocarbon layer;
• and
• heating the hydrocarbon layer and removing at least a portion of the hydrogen to form a microporous carbon skeleton layer having an average pore size from 1 to 10 nanometers and being substantially free of pores greater than 100 nanometers, wherein a plurality of catalyst particles are on or within the microporous carbon skeleton layer.