Recent advancements in composite bipolar plates (BPPs) for proton exchange membrane fuel cells (PEMFCs) have focused on optimizing material composition to enhance conductivity and durability. Studies reveal that carbon-polymer composites, incorporating 60-70% graphite and 20-30% polymer binders, achieve electrical conductivities exceeding 200 S/cm while maintaining mechanical strength above 50 MPa. For instance, a composite with 65% graphite and 25% polypropylene demonstrated a conductivity of 220 S/cm and a flexural strength of 55 MPa, outperforming traditional metallic BPPs in corrosion resistance. These materials also exhibit a corrosion current density below 0.1 µA/cm² in simulated PEMFC environments, ensuring long-term stability.
Innovative manufacturing techniques such as injection molding and compression molding have enabled the production of lightweight BPPs with complex flow field designs. Research shows that compression-molded BPPs with a thickness of 1.5 mm achieve a weight reduction of up to 40% compared to stainless steel counterparts, while maintaining a thermal conductivity of 20 W/m·K. A recent study demonstrated that injection-molded BPPs with micro-channel flow fields improved fuel cell performance by 15%, achieving a power density of 1.2 W/cm² at 0.6 V. These advancements highlight the potential for scalable production of cost-effective BPPs with enhanced mass transport properties.
The integration of advanced fillers such as graphene and carbon nanotubes (CNTs) into composite BPPs has significantly improved their electrochemical performance. Experimental results indicate that adding 2-3 wt% graphene to graphite-polymer composites increases electrical conductivity by up to 30%, reaching values of 280 S/cm, while reducing interfacial contact resistance to below 10 mΩ·cm². Similarly, composites with 1 wt% CNTs exhibit a tensile strength improvement of 25%, reaching 70 MPa, and a corrosion rate reduction of over 50%. These enhancements are critical for achieving high-efficiency fuel cells with extended operational lifetimes.
Surface modification techniques, including plasma treatment and coating deposition, have been employed to further enhance the performance of composite BPPs. Plasma-treated surfaces exhibit a contact angle reduction from >90° to <30°, improving hydrophilicity and water management within the fuel cell. Coatings such as titanium nitride (TiN) have been shown to reduce interfacial contact resistance by up to 40%, achieving values as low as 5 mΩ·cm², while maintaining excellent corrosion resistance under harsh operating conditions. These modifications contribute to a more uniform current distribution and improved overall cell efficiency.
Lifecycle analysis (LCA) studies reveal that composite BPPs offer significant environmental benefits compared to metallic alternatives. A comprehensive LCA demonstrated that carbon-polymer composites reduce greenhouse gas emissions by up to 50% during production, primarily due to lower energy requirements and reduced material usage. Additionally, the recyclability of these materials has been shown to reduce end-of-life environmental impact by over 30%. These findings underscore the potential of composite BPPs to support sustainable energy systems while meeting the demanding performance criteria of modern fuel cells.
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