Expanded Graphite Fillers in Sheet-Molding Compound Process

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Fuel cell technology has become an option for the advancement of zero emission vehicle, especially for larger weight class vehicles. One of the key components in a fuel cell are bipolar plates (BPPs). Several criteria must be considered, including good electrical and thermal conductivity, good mechanical strength, resistance to corrosion and permeation, and absence of contaminants. The most common BPPs are made of metal, resin impregnated flexible expanded graphite and graphite-thermoset composite in the form of Bulk Moulding Compound (BMC). In this project, we would like to explore expanded graphite (EG) fillers in a Sheet-Molding Compound process (SMC). With EG, it is expected that it should be possible to achieve similar conductivity to existing systems at lower filler content while maintaining structural integrity. This would propel more efficient fuel cell design which would potentially reduce the cost of the energy generation units. Through this collaboration project, Hydrogenics expects to develop an economically viable process as part of multi-phase actualization project to achieve an electrically conductive, relatively inexpensive BPP. The positive outcome would be to improve a Canadian firm's competitiveness in fuel cells in the market. The success of the work will increase the status of Canada as a leader in clean energy technology. Canada would benefit from the increase employment in the high-paid STEM personnel. Canada would benefit from the Hydrogen economy, i.e., "green" economy. The new concept that is proposed in this project is related to a development of a graphite/carbon thermoset composite BPP with a metallic design concept. This concept is only possible if a thin, strong, electrically conductive, easily mouldable SMC (sheet moulding compound) can be produced with a corrugated design. Hydrogenics has conducted R&D and product development in all aspects of PEMFC, including BPP using BMC - which are suitable for the stationary fuel cell applications.