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

The commercial viability of fuel cells for vehicle application has been examined in the context of lightweight material options, as well as in combination with improvements in fuel cell powertrain. Investigation into ultra-lightweight bipolar plates (BPs), the main component in terms of the weight effect, is of great importance to enhance energy efficiency. This research aims to fabricate a layered carbon fiber/epoxy composite structure for BPs. Two types of carbon fillers (COOH-MWCNT and COOH-GNP) reinforced with woven carbon fiber sheets (WCFS) have been utilized. The conceptual idea is to reduce molding cycle time by improving the structural, electrical, and mechanical properties of BPs. Reducing the reactive molding cycle time is required for commercial production possibility. The desired crosslink density of 97%, observed at reactive molding time, was reduced by 83% at 140 °C processing temperature. The as-fabricated BPs demonstrate excellent electrical conductivity and mechanical strength that achieved the DOE standard. Under actual fuel cell operation, the as-fabricated BPs show superior performance to commercial furan-based composite BPs in terms of the cell potential and maximum power. This research demonstrates the practical and straightforward way to produce high-performance and reliable BPs with a rapid production rate for actual PEMFC utilization.