Fuel cell with convoluted Membrane Electrode Assembly

The present invention is related to a proton exchange membrane fuel cell including a membrane electrode assembly (MEA) comprising a proton transmissive membrane, a catalytic anode layer on one face of the membrane, and a catalytic cathode layer on the other face of the membrane. An electrically conductive distribution layer on each of the cathode and anode layers defines a gas flow field extending over each of the catalytic layers, and the MEA has a convoluted configuration defining alternating peaks and valleys. The MEA and the gas distribution layers form a sandwich construction having first and second opposite edges; each gas distribution layer being formed of conductive foam media and being divided by the convolutions of the MEA into a plurality of generally parallel segments each extending from the first edge to the second edge of the sandwich construction whereby to define a plurality of generally parallel separate porous reactant paths extending across each catalytic layer; first and second gas separators outboard of the respective distribution layers; the foam media filling the space defined by the MEA and respectively the first and second separators. The peaks of the MEA are positioned proximate the first gas separator, and the valleys of the MEA are positioned proximate the second gas separator whereby to accentuate the separation of the porous reactant paths extending across each catalytic layer, wherein the separation between the paths is further accentuated by decreasing the porosity of each gas distribution layer proximate the peaks and valleys of the MEA.