Novel Low Cost Conductive Coatings for PEM Fuel Cell Bipolar Plates

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State-of-the-art PEM fuel cells utilise metallic separator plates which require a coating to reduce their contact resistance to acceptable levels. Such coatings are usually applied by PVD which has high capital costs in order to achieve high volume. This feasibility project aims to reduce PEM bipolar plate coating costs by developing high conductivity carbon-based coatings suitable for application by traditional high volume wet coating processes. Methods for depositing thin film coatings onto preformed, roll material for subsequent forming into fuel cell plates will be developed, these will then undergo ex-situ characterisation for adhesion of the coating through the forming operation and contact resistance before in-situ fuel cell testing. In parallel, coating options for formed parts will be devised such that a comparative costing of pre- vs post-forming coating options can be carried out. The project will aim to develop a process which represents a 30% reduction over the volume cost of existing PVD processed materials whilst achieving equivalent to, or better than, incumbent contact resistance, and demonstrating a route to volume realisation.