Method of making carbonaceous fuel cell electrode

Claim 1

A METHOD OF FABRICATING AND USING A FUEL CELL ELECTRODE COMPOSED OF POROUS CARBONACEOUS MATERIAL, BINDER AND METAL-CONTAINING ELECTROCHEMICAL CATALYTIC MATERIAL COMPRISING INTIMATELY CONTACTING A POROUS CARBONACEOUS MATERIAL WITH A BINDER OF SUGAR SOLUTION IN AN AMOUNT SUFFICIENT TO FORM A MOLDABLE MIXTURE, MOLDING SAID MIXTURE TO FORM AN ELECTRODE BODY, AND THEREAFTER SUBJECTING THE MOLDED ELECTRODE BODY TO A CARBONIZING TREATMENT TO FORM A COHERENT, MECHANICALLY SOUND ELECTRODE AND USING SAID ELECTRODE IN A FUEL CELL.

Claim 2

A METHOD OF FABRICATING AND USING A FUEL CELL ELECTRODE COMPOSED OF POROUS CARBONACEOUS MATERIAL, BINDER AND METAL-CONTAINING ELECTROCHEMICAL CATALYTIC MATERIAL COMPRISING INTIMATELY CONTACTING A POROUS CARBONACEOUS MATERIAL WITH A BINDER OF SUGAR SOLUTION IN AN AMOUNT SUFFICIENT TO FORM A MOLDABLE MIXTURE, MOLDING SAID MIXTURE TO FORM AN ELECTRODE BODY, AND THEREAFTER SUBJECTING THE MOLDED ELECTRODE BODY TO A CARBONIZING TREATMENT TO FORM A COHERENT, MECHANICALLY SOUND ELECTRODE AND USING SAID ELECTRODE IN A FUEL CELL.

Claim 3

THE METHOD OF FABRICATING A FUEL CELL ELECTRODE CONSISTING ESSENTIALLY OF THE STEPS OF: (A) INTIMATELY MIXTURE A FINELY DIVIDED CARBONACEOUS MATERIAL AND A METAL-CONTAINING ELECTROCHEMICAL CATALYTIC MATERIAL WITH A SUFFICIENT AMOUNT OF SUGAR SOLUTION AND AT A TEMPERATURE SUITABLE TO PRODUCE A PLIABLE HOMOGENEOUS MIXTURE, THE RATIO OF SAID CARBONACEOUS MATERIAL TO SAID SUGAR SOLUTION BEING ABOUT 10:1 TO 4:1; (B) APPLYING A LAYER OF HTE MIXTURE OF STEP (A) TO A SUPPORT FROM THE GROUP CONSISTING OF (1) AN ELECTRICALLY CONDUCTIVE METAL SUBSTRATE AND (2) A PLIABLE HOMOGENEOUS MIXTURE OF A CARBONACEOUS MATERIAL AND A SUGAR SOLUTION AND APPLYING PRESSURE TO THEREBY FORM A LAMINAR STRUCTURE; AND (C) SUBJECTING SAID LAMINAR STRUCTURE TO A SUFFICIENT AMOUNT OF HEAT FOR A TIME PERIOD SUFFICIENT TO SUBSTANTIALLY CARBONIZE SAID SUGAR SOLUTION TO THEREBY FORM A COHERENT UNITARY ELECTRODE.

Claim 4

THE METHOD OF FABRICATING A FUEL CELL ELECTRODE CONSISTING ESSENTIALLY OF THE STEPS OF: (A) INTIMATELY MIXTURE A FINELY DIVIDED CARBONACEOUS MATERIAL AND A METAL-CONTAINING ELECTROCHEMICAL CATALYTIC MATERIAL WITH A SUFFICIENT AMOUNT OF SUGAR SOLUTION AND AT A TEMPERATURE SUITABLE TO PRODUCE A PLIABLE HOMOGENEOUS MIXTURE, THE RATIO OF SAID CARBONACEOUS MATERIAL TO SAID SUGAR SOLUTION BEING ABOUT 10:1 TO 4:1; (B) APPLYING A LAYER OF HTE MIXTURE OF STEP (A) TO A SUPPORT FROM THE GROUP CONSISTING OF (1) AN ELECTRICALLY CONDUCTIVE METAL SUBSTRATE AND (2) A PLIABLE HOMOGENEOUS MIXTURE OF A CARBONACEOUS MATERIAL AND A SUGAR SOLUTION AND APPLYING PRESSURE TO THEREBY FORM A LAMINAR STRUCTURE; AND (C) SUBJECTING SAID LAMINAR STRUCTURE TO A SUFFICIENT AMOUNT OF HEAT FOR A TIME PERIOD SUFFICIENT TO SUBSTANTIALLY CARBONIZE SAID SUGAR SOLUTION TO THEREBY FORM A COHERENT UNITARY ELECTRODE.