Catalyst ink preparation for fuel cell electrode fabrication

Abstract

Methods of fabricating gas diffusion electrodes and gas diffusion electrodes made from such methods are disclosed herein. One method of fabricating a gas diffusion electrode for a fuel cell comprises preparing a catalyst ink of a predetermined viscosity. Preparing the catalyst ink comprises mixing a catalyst solution comprising catalyst particles, an ionomer and a solvent at a first speed for a first period of time and homogenizing the catalyst solution at a second speed in a temperature controlled environment for a second period of time, wherein the second period of time is longer than the first period of time, the second period of time and the second speed selected to preserve a structure of the catalyst particles during homogenization. An active electrode layer is formed by spraying the catalyst ink directly on a gas diffusion layer in a single application and a uniform loading.

Dependencies are inferred from the claim text.