Patent ID: 7572533

Claim:
A method for fabricating an integrated cathode electrode sheet of a flat-panel direct methanol fuel cell, the method comprising: (1) providing a CCL (copper clad laminate) substrate comprising a base layer, a first copper layer laminated on an upper surface of the base layer, and a second copper layer laminated on a lower surface of the base layer; (2) drilling the CCL substrate within pre-selected electrode areas to form a plurality of apertures through the first copper layer, the base layer and the second copper layer; (3) chemically depositing a third copper layer on both surfaces of the CCL substrate and interior sidewalls of inside the apertures; (4) forming a patterned resist layer on the CCL substrate to expose the pre-selected electrode areas; (5) using the patterned resist layer as a plating mask, performing an electroplating process to electroplate a fourth copper layer within the expose the pre-selected electrode areas and area not covered by the patterned resist layer, and then electroplating a Sn/Pb layer on the fourth copper layer; (6) stripping the patterned resist layer; (7) performing a copper etching process to etch away the third copper layer and the first and second copper layer that are not covered by the Sn/Pb layer; and (8) removing the Sn/Pb layer to expose the fourth copper layer.