Method of compounding conductive polypropylene-graphite composite for bipolar plates of hydrogen fuel cell

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Hydrogenics Corporation, one of the Canada's market leaders in providing hydrogen electrolyzers and fuel cells world-wide as clean energy alternatives to fossil fuel. Hydrogen is one of the most efficient and cost effective energy storage for excess electricity from power grid during the off-peak hours, as well as electricity produced from wind turbines and solar panel. Hydrogenics desires to substitute the current thermoset-graphite composite material with a thermoplastic-graphite composite material, with improved electrical and mechanical properties. The conductive composite must meet the performance guidelines established by the Department of Energy (DOE), for conductivity and strength. Such a composite is expected to contain in excess of 80% of conductive filler, primarily graphite powder, carbon black powder and carbon fibre or carbon nanotubes to create synergy to achieve the desired properties. Therefore, the main objective of this work is to develop cost-effective, highly loaded polypropylene-graphite composites suitable for bipolar plates using a combination of high shear intensity mixer and single screw extruder. The composite will be produced in a two-step process: a) intensive dry blending of powder PP and powder fillers using high intensity mixer, and b) melt processing of the blended mixture in a single screw extruder. Processing and adhesion promoting aids will be used to improve and achieve the required electrical and mechanical properties. Upon successful production of proof of concept prototypes, Hydrogenics will scale up the production of such material, either through in-house compounding facility or through sub-contracting to available custom compounders in Ontario or other provinces in Canada. Successful integration of the newly developed material and process from this NSERC Engage project would translate into competitiveness and profitability of Hydrogenics. Hydrogen fuel cell market is at the crossroad of mass demand, and success will result in economy of scale and mass production.