Process for making layer-structured catalysts at the electrode/electrolyte interface of a fuel cell

Abstract

A method of fabricating a layer-structured catalysts at the electrode/electrolyte interface of a fuel cell is provided. The method includes providing a substrate, depositing an electrolyte layer on the substrate, depositing a catalyst bonding layer to the electrolyte layer, depositing a catalyst layer to the catalyst bonding layer, and depositing a microstructure stabilizing layer to the catalyst layer, where the bonding layer improves adhesion of the catalyst onto the electrolyte. The catalyst and a current collector is a porous catalyst and a fully dense current collector, or a fully dense catalyst and a fully dense current collector structure layer. A nano-island catalyst and current collector structure layer is deposited over the catalyst and current collector or over the bonding layer, which is deposited over the electrolyte layer. The fuel cell can be hydrogen-fueled solid oxide, solid oxide with hydrocarbons, solid sensor, solid acid, polymer electrolyte or direct methanol.