Abstract: A method for catalyzing a gas diffusion electrode (GDE) with a catalytic material mixed with a solubilized electrolyte, where the electrolyte preferably comprises a perfluorocarbon sulfonic acid copolymer. The catalytic material and solubilized electrolyte are mixed to form a paste or the slurry, which is then applied layer by layer onto the catalyzable side of the GDE while the electrode is kept on a hot plate at a temperature of approximately 80.degree.-100.degree. C. The electrode and the catalyst layers are then dried in an oven at a temperature of about 100.degree. C. for about 10 minutes. The catalytic material preferably comprises a metal, such as platinum, and is further mixed with a supporting material comprising a high surface area carbon, resulting in a platinum-on-carbon mixture.

Abstract: Simplified and improved solid polymer fuel cells for operation at near ambient conditions of temperature and pressure and without humidification are disclosed. In a first embodiment, a fuel cell is disclosed having two electrodes with opposing surfaces and an electrolyte comprising a solution of a proton conducting material deposited at the central portion of the surface of each electrode leaving the outer periphery of each electrode surface exposed. A slightly oversized non-conducting plastic type film having a central hole is located between and in contact with the electrodes, where its central hole surrounds and contacts the electrolyte deposits. The film is bonded with the electrodes and acts as a barrier for reactant cross-overs. In a second embodiment, the electrolyte deposit is thinner and located along the entire surface of the electrodes. A slightly oversized solid polymer electrolyte membrane is located between and is in contact with the electrolyte deposits.

Abstract: The solid polymer fuel cell (SPFC), also known as the solid polymer electrolyte (SPE.RTM.) fuel cell, sold by Hamilton Standard, a Division of United Technologies Corporation, of Hartford, Conn., needs simplification for the fuel to become commercially viable. A simplified design is thus sought that would avoid prior humidification of reactants and the membrane, i.e., the electrolyte. A proton conducting material, such as perfluorocarbon copolymer, is deposited as the electrolyte on top of the catalytic side of the porous gas diffusion electrodes acting as anode and cathode. With sufficient deposits on both electrodes, it is then possible to avoid the use of electrolyte membrane which is used in the state-of-the-art solid polymer fuel cell design. The system operates at near ambient temperatures, pressures and at near stoichiometric reactant flows without requiring extra humidification of the reactant gases and the electrolyte.