A fuel cell of the type having a membrane electrode assembly (MEA)
interdisposed between a pair of bipolar plate assemblies. The MEA may
have a convoluted configuration to maximize the effective surface area of
the MEA for a given planar area. Each bipolar plate assembly includes a
gas distribution layer of open cell conductive foam material which is
divided into a plurality of generally parallel segments to define a
plurality of generally parallel porous reactant paths. The segments are
defined by selectively varying the porosity of the foam material and/or
selectively varying the thickness of the foam material. The foam material
may be a conductive graphite foam media or a conductive metallic foam
media. Each bipolar plate assembly further includes a non-porous,
conductive separator plate. The bipolar plate assembly distributes the
reactant gases delivered via a manifold structure across the face of the
MEA. A coolant layer may also be provided utilizing a segmented foam
construction similar to that utilized in the gas distribution layers.