A gas diffusion electrode and method of making the same. According to one
embodiment, the electrode comprises a support layer, a first cushioning
layer positioned on top of the support layer, a second cushioning layer
positioned on top of the first cushioning layer, and a catalyst layer
positioned on top of the second cushioning layer. The support layer is a
mechanically stable, electrically-conductive, gas porous substrate, such
as carbon fiber paper. The first cushioning layer, which is also gas
porous, comprises a non-woven mat of electrically-conductive,
chemically-inert fibers, preferably carbon nanofibers, bound together
with a polymeric binder, such as polytetrafluoroethylene. The second
cushioning layer is similar to the first cushioning layer, except that
carbon black or a similar electrically-conductive, chemically-inert
particulate material is included in addition to or instead of the fibrous
material for the purpose of fine-tuning pore size.