Polymer electrolyte fuel cells, methods of manufacturing electrodes therefor , and apparatuses for making the same

A polymer electrolyte fuel cell comprising a hydrogen ion conductive polymer electrolyte membrane, a pair of electrodes sandwiching said polymer electrolyte membrane therebetween, an electrically conductive separator plate having a gas flow channel for supplying a fuel gas to one of said electrodes, and an electrically conductive separator plate having a gas flow channel for supplying an oxidant gas to the other of said electrodes, wherein each of said electrodes comprises a catalyst layer and a gas diffusion layer, wherein said catalyst layer comprises electrically conductive multinary granules having an average granule diameter of about 3 μm to 15 μm, said multinary granules comprising electrically conductive primary particles having an average particle diameter not exceeding about 150 nm, a catalyst and a hydrogen ion conductive polymer electrolyte, and wherein the polymer electrolyte fuel cell further comprises, between said catalyst layer and said gas diffusion layer, a layer of multinary granules having an average granule diameter of about 3 μm to 15 μm and comprising electrically conductive primary particles which do not carry a catalyst and have an average particle diameter not exceeding about 150 nm.