As part of the development of a portable fuel cell for air independent applications using Direct Sodium Borohydride/Hydrogen Peroxide fuels, we have been studying methods for deposition of the catalysis on the diffusion layer. Optimal conditions (minimum activation, ohmic and transport losses) are obtained in this all liquid fuel cell design when the catalysis is coated throughout the diffusion layer. Catalysis deposition by various electrochemical and sputtering techniques onto a porous carbon cloth diffusion layer is briefly reviewed. We also present preliminary studies of a deposition method designed for use with larger pore diffusion layer materials such as nickel micro felt.
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