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Summary:The polymer electrolyte membrane fuel cell (PEMFC) holds tremendous promise for a variety of mobile and stationary power generation applications and is the cornerstone of the anticipated hydrogen economy. One of the major factors limiting fuel cell commercialization is the development of bipolar plates since bipolar plates account for approximately 70% of the PEMFC weight, and 60% of the stack manufacturing and materials cost. The objective of this research is to investigate a feasibility of a conductive composite family to be used as bipolar plates in a PEMFC, in order to get the highly conductive, light weight, and low cost bipolar plates. This work utilized a combination of a polypropylene and low cost conductive filler materials: graphite, conductive carbon black, and carbon fibers. The components were combined in a batch mixer and injection molded into samples for testing with loadings up to 65%wt of fillers. The novel blends were tested for electrical conductivity, hydrophobicity, rheology, and actual plates (16 cm 2 ) were tested in fuel cell testing trials. The impact of different types of fillers on the composite properties was evaluated, as well as the synergetic effect of mixtures of fill types within a polypropylene matrix. From the results, the highest conductivity, 1900 S/m (in-plane) and 156 S/m (through plane), was obtained with the 65% composite. Moreover, the effects of additives such as coupling agents, and intrinsically conductive polymer (polypyrrole) were observed in this work. The electrical conductivity was influenced by polypyrrole added to the polypropylene composite.

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The in-house fuel cell test station.