The Role of Co-Rotating Twin Screw Extruder In Manufacturing of Conductive Thermoplastic Composites for the Sustainable Energy Sector

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Hydrogenics, a Canadian producer of hydrogen fuel cells, is looking to produce thinner and more definedbipolar plates which will result in the production of more efficient fuel cells used for low density energystorage produced by renewable resources such as wind and solar. The current technology and materials used tomanufacture the plates does not allow for the desired thickness or structure. As such it is necessary to develop amaterial that can be readily shaped while also allowing for fine definition of the plate structure and not add asignificant increase in cost, or loss of conductivity. Thus, the development of such a material presents manymajor technical challenges related to energy density, contact resistance, strength and formability to be solved; aportion of these challenges will be examined through this project. The main challenge handled in this study isthe high level yet not completely uniform dispersion of carbon filler for conductivity in a highly viscouspolymer matrix required to develop the required material. Conductivity requires pathways produced byaggregated 'chains' of fillers through the thickness of the part that are uniformly spread out in-plane. Thisrequires an atypical level of mixing control, complicated by the very high viscosity of the system. Anunderstanding of polymer chemistry, interfacial science, and polymer processing is required to systematicallyovercome these challenges.The goal of this six-month project is to develop examples of the desired material for Hydrogenics, for theproduction of highly conductive, lightweight bipolar plates. The goal will be met through a systematic study offiller to polymer ratio, looking at different fillers and compatibilizing additives. The resulting blend willincrease the economics of fuel cell production typically used for low density energy storage increasing theefficiency of renewable energy sources such as wind and solar.