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

Hydrogenics Corporation是加拿大的市场领导者之一，在全球范围内提供氢电解槽和燃料电池作为化石燃料的清洁能源替代品。氢是最有效和最具成本效益的能源储存之一，用于在非高峰时段从电网获得多余的电力，以及从风力涡轮机和太阳能电池板产生的电力。Hydrogenics希望用具有改进的电气和机械性能的热塑性石墨复合材料代替当前的热固性石墨复合材料。导电复合材料必须满足能源部（DOE）制定的导电性和强度的性能指南。这种复合材料预期含有超过80%的导电填料，主要是石墨粉末、炭黑粉末和碳纤维或碳纳米管，以产生协同作用来实现所需的性能。因此，这项工作的主要目标是开发具有成本效益的，高负荷聚丙烯-石墨复合材料，适用于双极板使用高剪切强度混合机和单螺杆挤出机的组合。该复合材料将在两个步骤的过程中生产：a）使用高强度混合器将粉末PP和粉末填料强烈干共混，和B）在单螺杆挤出机中将共混的混合物熔融加工。加工和粘合促进助剂将用于改善和实现所需的电气和机械性能。在成功生产概念原型验证后，Hydrogenics将通过内部复合设施或通过分包给安大略或加拿大其他省份的定制复合机来扩大此类材料的生产。成功整合NSERC Engage项目新开发的材料和工艺将转化为Hydrogenics的竞争力和盈利能力。氢燃料电池市场正处于大众需求的十字路口，成功将带来规模经济和大规模生产。

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.