Flat panel direct methanol fuel cell and method of making the same

A method for fabricating an integrated cathode electrode sheet of a flat-panel direct methanol fuel cell, the method comprising:

• (1) providing a CCL (copper clad laminate) substrate comprising a base layer, a first copper layer laminated on an upper surface of the base layer, and a second copper layer laminated on a lower surface of the base layer;
• (2) drilling the CCL substrate within pre-selected electrode areas to form a plurality of apertures through the first copper layer, the base layer and the second copper layer;
• (3) chemically depositing a third copper layer on the CCL substrate and interior sidewalls of inside the apertures;
• (4) forming a patterned resist layer on the CCL substrate to expose the pre-selected electrode areas;
• (5) using the patterned resist layer as a plating mask, performing an electroplating process to electroplate a fourth copper layer within the expose the pre-selected electrode areas and area not covered by the patterned resist layer, and then electroplating a Sn/Pb layer on the fourth copper layer;
• (6) stripping the patterned resist layer;
• (7) performing a copper etching process to etch away the third copper layer and the first and second copper layer that are not covered by the Sn/Pb layer;
• and
• (8) removing the Sn/Pb layer to expose the fourth copper layer.