Metal and metal oxide catalyzed electrodes for...

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319/81, 319/92

H01M 4/48 (2006.01) H01M 4/86 (2006.01) H01M 4/90 (2006.01) H01M 4/96 (2006.01)

Patent

CA 1306284

METAL AND METAL OXIDE CATALYZED ELECTRODES FOR ELECTROCHEMICAL CELLS, AND METHODS OF MAKING SAME ABSTRACT OF THE DISCLOSURE Porous electrodes for use in fuel cells and other electrochemical cells are disclosed. Principally, the electrode is intended for use as a cathode of a fuel cell, having a catalytically active layer on a porous conductive substrate, which catalytically active layer is derived from non-noble metals. The loading of the catalytically active layer is lower in terms of weight of catalyst per unit area of geometrical electrode surface than heretofore, and the operating characteristics of the electrode compare favourably with prior art electrodes having noble metal catalysts, at considerably lower cost. Several alternative methods of forming the electrode are taught, including impregnating a porous conductive substrate with a metal salt solution, followed by chemical or thermal formation of the porous catalytically active layer; or mixing the catalytically active material with the material of the porous conductive substrate, followed by fabrication of the electrode; or depositing pyrolitic carbon from the gas phase onto a porous conductive substrate, at elevated temperatures in a gas atmosphere. The electrode may comprise a porous metallic current collector, and also a further gas diffusion layer. The current collector may be situated or embedded in the porous conductive substrate or the gas diffusion layer. If used as a fueld cell anode, a further small amount of noble metal is included in the porous catalytically active layer. Porous electrodes of this invention may also be used in alkaline primary or secondary cells.

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