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Abstract

A method for catalyzing a gas diffusion electrode (GDE) with a catalytic material mixed with a solubilized electrolyte, where the electrolyte preferably comprises a perfluorocarbon sulfonic acid copolymer. The catalytic material and solubilized electrolyte are mixed to form a paste or the slurry, which is then applied layer by layer onto the catalyzable side of the GDE while the electrode is kept on a hot plate at a temperature of approximately 80.degree.-100.degree. C. The electrode and the catalyst layers are then dried in an oven at a temperature of about 100.degree. C. for about 10 minutes. The catalytic material preferably comprises a metal, such as platinum, and is further mixed with a supporting material comprising a high surface area carbon, resulting in a platinum-on-carbon mixture. A method according to the present invention avoids exposure of the high surface area catalytic material to the high temperatures of the conventional method, thereby keeping the maximum surface area of the catalyst available for the electrochemical reaction. Such gas diffusion electrodes are preferably used in operation of proton exchange membrane fuel cells without external humidification.

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First Claim