Novel Low Cost Conductive Coatings for PEM Fuel Cell Bipolar Plates

最先进的PEM燃料电池使用金属分离板，需要涂层将其接触电阻降低到可接受的水平。这类涂层通常由PVD应用，为了实现高产量，PVD具有较高的资本成本。本可行性项目旨在通过开发适合传统大批量湿涂工艺的高导电性碳基涂层，降低PEM双极板涂层成本。将开发将薄膜涂层沉积到预成型材料上的方法，用于随后成型成燃料电池板，然后在原位燃料电池测试之前，通过成型操作和接触电阻对涂层的附着力进行非原位表征。与此同时，将设计成型零件的涂层选择，以便对成型前和成型后的涂层选择进行比较成本计算。该项目旨在开发一种比现有PVD加工材料的体积成本降低30%的工艺，同时达到或优于现有的接触电阻，并展示了批量实现的途径。

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.