Patent ID: 8377149

Claim:
A process for making a catalytic electrode for an electrochemical cell, comprising the steps: (a) mixing a catalytic material for oxidizing or reducing an active material with an electrically conductive material and a binder; (b) forming the mixture from step (a) into an active layer sheet having a first surface and a second surface opposite the first surface; (c) disposing a gas diffusion layer sheet having a first surface and a second surface opposite the first surface adjacent to the active layer sheet, with the first surface of the gas diffusion layer sheet against the first surface of the active layer sheet; (d) forming a bonded sheet by applying pressure to the second surface of the gas diffusion layer sheet via a textured roller or removable interleaf sheet having a woven pattern to bond the gas diffusion layer sheet to the active layer sheet with a pattern of relatively high adhesion areas and relatively low adhesion areas corresponding to the woven pattern of the textured roller or interleaf sheet; wherein the relatively high adhesion areas have lower gas permeability than the relatively low adhesion areas; (e) forming the bonded sheet into an electrode.