Low platinum fuel cells, catalysts, and method for preparing the same

Abstract

This invention provides novel fuel cell electrodes and catalysts comprising a series of catalytically active thin-film metal alloys with low platinum concentration supported on nanostructured materials (nanoparticles). Processing of the electrodes and catalysts can include electrodeposition methods, and high-pressure coating techniques. In certain embodiments, an integrated gas-diffusion/electrode/catalyst layer can be prepared by processing catalyst thin films and nanoparticles into gas-diffusion media such as Toray or SGL carbon fiber papers. The catalysts can be placed in contact with an electrolyte membrane for PEM fuel cell applications.