Fuel cell bipolar plates are commonly fabricated from graphite and stainless steel, however machining intricate channels into these materials can be a costly and time-consuming process. For this reason, we are exploring injection molding of polymer composite bipolar plates. Polymer composites offer the potential for lightweight, low-cost plates [1]. Several factors impact the ability of a polymer composite to conduct electricity. The geometry, filler weight percentage, dispersion, and the physical properties of the fillers are important in forming an electrical pathway through the composite. In this study, polymer composites based on nylon were injection molded with different weight percentages of conductive filler. Initially, carbon fiber was added to nylon at weight percentages ranging from 10 to 50%. Results show that the percolation threshold for carbon fiber in nylon occurs around 25 wt%. While carbon fiber loadings beyond 50 wt% would further increase conductivity, the increased viscosity of the polymer blends can inhibit proper injection molding.

Multiwalled carbon nanotubes were then added to the direct injection-molded nylon/carbon fiber composites to investigate the synergistic effects of multiple conductive fillers [2]. By introducing carbon nanotubes into the polymer matrix, the nanotubes act as a bridge between the carbon fibers. SEM images show that the MWCNTs fill the void between each fiber due to their smaller size and their ease of dispersion. This bridging creates more conductive pathways within the composite, thereby increasing the electrical conductivity. Samples with MWCNTs reached conductivities nearing the United States Department of Energy technical target for bipolar plate conductivity (> 100 S/cm).

1. Mighri, F.; Huneault, M. A.; Champagne, M. F., Electrically conductive thermoplastic blends for injection and compression molding of bipolar plates in the fuel cell application. Polymer Engineering and Science 2004, 44 (9), 1755-1765.
2. Zameroski, R.; Kypta, C. J.; Young, B. A.; Sanei, S. H. R.; Hollinger, A. S., Mechanical and Electrical Properties of Injection-Molded MWCNT-Reinforced Polyamide 66 Hybrid Composites. Journal of Composites Science 2020, 4 (4), 14.