Sputter Deposition of Catalysts for Fuel-Cell Electrodes

An improved method of fabricating electrodes for fuel cells includes the use of sputtering to deposit thin layers of catalytic electrode metals. Previously, catalytic electrode metals were deposited by means of inks and decals - means that are not amenable to mass production. The sputtering process used in the improved method is better suited to mass production. Sputtering also increases the efficiency of utilization and thereby decreases the needed amounts of the catalytic electrode metals, which are expensive noble metals; whereas the catalyst loadings needed in electrodes made by older methods ranged between 4 and 12 mg/cm2, the catalyst loadings needed in electrodes made by the improved method range from 0.5 to 1.0 mg/cm2.