GOALI: Development and Modeling of Highly Conductive Carbon Filled Thermoplastic Resins for Fuel Cell Bipolar Plate Applications

本研究的目的是了解、模拟和探索含有几种不同碳填料的新型可回收高温热塑性材料，以满足燃料电池双极板当前和未来的所有规格。燃料电池被认为是一种清洁的替代能源，可以用来为汽车提供动力。一个典型的燃料电池包含数百个双极板，它由一种高导热和导电性的材料组成。将使用以下方法。首先，将确定不同碳基导电填料（碳纤维、炭黑、合成和天然鳞片石墨）和填料-基体粘附对高填充（高达80 wt%填料）导电树脂的电导率和导热性的协同效应（使用统计实验设计）。将不同的碳填料组合在一起，研究填料与基体的粘附作用，很有可能获得对导热性和导电性的正向协同效应。其次，双极板将在Dana公司（工业合作伙伴）为燃料电池堆制造和测试。第三，对于高填充的导电树脂，将开发出更好的电导率和导热率模型。目前的电导率模型仅针对含有40 wt%填料的树脂开发，这远低于用于双极板的70至90 wt%填料。这个项目将在几个方面造福社会。首先，高填充导电树脂的精确模型将使材料设计无需大量的实验工作和测试。这种模式将通过降低新产品开发成本而造福社会。第二，这项建议的工作将被纳入K-12（通过暑期青年项目）、本科和研究生课程。这个工业和教育合作项目将使燃料电池成为21世纪一种负担得起的、可行的、可持续的替代能源。

The objective of this research is to understand, model and explore new recyclable high temperature thermoplastic based materials containing several different carbon fillers to meet all the current and future specifications for bipolar plates in fuel cells. Fuel cells have been proposed as a clean alternative energy source, which can be used to power vehicles. A typical fuel cell contains hundreds of bipolar plates, which consist of a highly thermally and electrically conductive material. The following approach will be used. First, the synergistic effects (using statistical experimental design) of different carbon-based conductive fillers (carbon fiber, carbon black, synthetic and natural flake graphite) and filler-matrix adhesion on electrical and thermal conductivity of highly filled (up to 80 wt% filler) conductive resins will be determined. It is likely that by combining different carbon fillers and studying the effect of filler-matrix adhesion, a positive synergistic effect on thermal and electrical conductivity will be obtained. Second, bipolar plates will be fabricated and tested for a fuel cell stack at Dana Corporation (industrial partner). Third, better electrical and thermal conductivity models will be developed for highly filled conductive resins. Current conductivity models have only been developed for resins containing 40 wt% filler, which is much lower than the 70 to 90 wt% filler used for bipolar plates. This project will benefit society in several ways. First, accurate models for highly filled conductive resins will enable material design without extensive experimental work and testing. Such models will benefit society by reducing new product development costs. Second, this proposed work will be incorporated into the K-12 (through summer youth programs), undergraduate, and graduate curriculum. This collaborative industrial and educational project will allow fuel cells to become an affordable, viable, and sustainable energy alternative for the 21st century.