THIN-FILM CATALYST LAYERS FOR POLYMER ELECTROLYTE FUEL-CELL ELECTRODES

New structures for the Pt/C catalyst layer of polymer electrolyte fuel cell electrodes have been developed that substantially increase the utilization efficiency of the catalyst. Fabricating the catalyst layers and gas diffusion backings separately makes it possible to formulate each structure with the properties that are most suitable for its function. In the case of catalyst layer, the optimal properties are hydrophilicity, thinness, uniformity, and the proper ratio of ionomer and supported catalyst. The catalyst layers are cast from solution as thin films that utilize the ionomer itself as a binder. The thin films are hot pressed directly onto the ionomer membranes, and the hydrophobic gas diffusion backings are inserted when the cells are assembled. The performances of fuel cells based on the thin film catalyst layers are comparable with those of gas diffusion electrode designs that utilize several times as much platinum, thus the specific activities of the Pt catalysts in the new structures are significantly higher.