Porous carbon body for a fuel cell having an electronically conductive hydrophilic agent

A porous carbon body having an electronically conductive hydrophilic agent for use in an electrochemical cell comprising:

• a. an electronically conductive graphite powder in an amount of between 60%-80% by weight of the body;
• b. a carbon fiber in an amount of between 5%-15% of the body;
• c. a thermoset binder in an amount of between 6%-18% by weight of the body;
• d. a modified carbon black electronically conductive hydrophilic agent in an amount of between 2%-20% by weight of the body, the modified carbon black being carbon having attached at least one organic group, the organic group comprising i.) at least one aromatic group or a C1-C12 alkyl group, and ii.) at least one ionic group, one ionizable group, or a mixture of an ionic group and an ionizable group wherein the ionic or the ionizable group is a sulfonic acid or a salt thereof, wherein the at least one aromatic group or C1-C12 alkyl of the organic group is directly attached to the carbon, and the organic group is present at a level of from about 0.10 to about 4.0 micromoles/m2 of the carbon used based on the nitrogen surface area of the carbon.

A method of forming a porous carbon body having an electronically conductive hydrophilic agent for use in an electrochemical cell, the method comprising the steps of:

• a. mixing together an electronically conductive graphite powder in an amount of between 67%-87% by weight of the mixture, a thermoset binder in an amount of between 6%-18% by weight of the mixture, and a modified carbon black electronically conductive hydrophilic agent in a amount of between 2% and 20% by weight of the mixture, the modified carbon black being carbon having attached at least one organic group, the organic group comprising i.) at least one aromatic group or a C1-C12 alkyl group, and ii.) at least one ionic group, one ionizable group, or a mixture of an ionic group and an ionizable group wherein the ionic or the ionizable group is a sulfonic acid or a salt thereof, wherein the at least one aromatic group or C1-C12 alkyl of the organic group is directly attached to the carbon, and the organic group is present at a level of from about 0.10 to about 4.0 micromoles/m2 of the carbon used based on the nitrogen surface area of the carbon;
• and,
• b. then simultaneously compressing and heating the mixture in a mold at a pressure of between 250-1,000 pounds per square inch and at a temperature of between 300-450 degrees Fahrenheit to form a body having a mean pore size of greater than 2.0 microns and an open porosity of greater than 25%.