Performance Evaluation for Ultra-Lightweight Epoxy-Based Bipolar Plate Production with Cycle Time Reduction of...

Area of Science:

• Materials Science
• Electrochemistry
• Mechanical Engineering

Background:

• Fuel cell vehicles require lightweight components to enhance energy efficiency.
• Bipolar plates (BPs) are critical, heavy components in fuel cells, impacting overall weight.
• Reducing manufacturing time for BPs is essential for commercial viability.

Purpose of the Study:

• To fabricate advanced, ultra-lightweight bipolar plates (BPs) using a layered carbon fiber/epoxy composite structure.
• To improve structural, electrical, and mechanical properties of BPs to reduce molding cycle time.
• To assess the performance of novel BPs under actual fuel cell operation.

Main Methods:

• Utilizing COOH-functionalized multi-walled carbon nanotubes (COOH-MWCNT) and graphene nanoplatelets (COOH-GNP) as carbon fillers.
• Reinforcing the composite structure with woven carbon fiber sheets (WCFS).
• Optimizing processing temperature and reactive molding time to achieve desired crosslink density.

Main Results:

• Achieved excellent electrical conductivity and mechanical strength in fabricated BPs, meeting Department of Energy (DOE) standards.
• Reduced reactive molding cycle time by 83% at a 140 °C processing temperature.
• Demonstrated superior performance compared to commercial furan-based composite BPs in cell potential and maximum power.

Conclusions:

• The developed carbon fiber composite BPs offer a practical and straightforward method for high-performance fuel cell applications.
• Rapid production rates and enhanced properties make these BPs suitable for proton exchange membrane fuel cell (PEMFC) utilization.
• This advancement contributes to the commercial viability of fuel cells in vehicle applications through lightweight material innovation.