Bipolar plates made of plain weave carbon/epoxy composite for proton exchange membrane fuel cell

Polymer electrolyte membrane fuel cell or proton exchange membrane fuel cell (PEMFC) is composed of bipolar plates, end plates, membrane electrode assemblies (MEAs) and gas diffusion layers (GDLs). Among the constituents of PEMFCs, the bipolar plate is a key component that collects and conducts the current from cell to cell. The electrical resistance of the bipolar plate, which consists of the bulk material resistance and interfacial contact resistance between the GDLs and the bipolar plates, should be reduced to improve the performance of the fuel cell.     

Non‐isothermal multi‐phase modeling of PEM fuel cell cathode

In this study, numerical simulation has been carried out for the heat transfer and temperature distribution in the cathode of polymer electrolyte membrane fuel cells along with the multi‐phase and multi‐species transport under the steady‐state condition. The commercial software, COMSOL Multiphysics, is used to solve the conservation equations for momentum, mass, species, charge and energy numerically. The conservation equations are applied to the solid, liquid and vapor phases in the bipolar plate and gas diffusion (GDL) and catalyst layers of a two‐dimensional cross section of the cathode. The catalyst layer is assumed to be a finite domain and the water production in the catalyst layer is considered to be in the liquid form. The temperature distribution in the cathode is simulated and then the effects of the relative humidity of the air stream, the permeability of the cathode and the flow channel shoulder to channel width ratio are investigated. It is shown that the highest temperature change, both in the in‐plane and across‐the‐plane directions, occurs in the GDL, while the highest temperature is reached in the catalyst layer. The distribution of temperature in the bipolar plate is shown to be relatively uniform due to the high thermal conductivity of the plate. A decrease in the inlet relative humidity of the air stream results in the decrease of the maximum temperature due to the absorption of heat during the evaporation of liquid water in the GDL and catalyst layer. The non‐uniformity of the temperature distribution, especially in the catalyst layer, is observed with the increase of the permeability of the cathode. Similarly, the decrease of the channel shoulder to channel width ratio leads to a non‐uniform distribution of temperature especially under the channel areas. Copyright © 2009 John Wiley & Sons, Ltd.     

Performance analysis of a proton exchange membrane fuel cell using tree-shaped designs for flow distribution

The performance of a proton exchange membrane (PEM) fuel cell is directly associated to the flow channels design embedded in the bipolar plates. The flow field within a fuel cell must provide efficient mass transport with a reduced pressure drop through the flow channels in order to obtain a uniform current distribution and a high power density. In this investigation, three-dimensional fuel cell models are analyzed using computational fluid dynamics (CFD). The proposed flow fields are radially designed tree-shaped geometries that connect the center flow inlet to the perimeter of the fuel cell plate. Three flow geometries having different levels of bifurcation were investigated as flow channels for PEM fuel cells. The performance of the fuel cells is reported in polarization and power curves, and compared with that of fuel cells using conventional flow patterns such as serpentine and parallel channels. Results from the flow analysis indicate that tree-shaped flow patterns can provide a relatively low pressure drop as well as a uniform flow distribution. It was found that as the number of bifurcation levels increases, a larger active area can be utilized in order to generate higher power and current densities from the fuel cell with a negligible increase in pumping power.     

Design and manufacturing of end plates of a 5 kW PEM fuel cell

End plate is one of the main components of the proton exchange membrane (PEM) fuel cells. The major role of the end plate is providing uniform pressure distribution between various components of the fuel cell (bipolar plates, etc.) and consequently reducing contact resistance between them. In this study a procedure for design of end plate has been developed. At first a suitable material was selected using various criteria. Then a finite element (FE) analysis was accomplished to analyze end plate deflections and get its optimized thickness. After fabricating the end plates, a single cell was assembled and electrochemical impedance spectroscopy (EIS) tests were carried out to ensure their good operation. A 5 kW fuel cell assembled with these end plates was tested at different operating conditions. The test results show an appropriate assembly pressure distribution inside the stack which indicates good performance of the designed end plates.     

Deposition of gold–titanium and gold–nickel coatings on electropolished 316L stainless steel bipolar plates for proton exchange membrane fuel cells

The effects of electropolishing and coating deposition on electrical resistance and chemical stability were studied for the stainless steel bipolar plates in proton exchange membrane fuel cell (PEMFC). A series of 316L stainless steel plates, selected as the substrate for a proton exchange membrane fuel cell (PEMFC) bipolar plate, were electropolished with a solution of H₂SO₄ and H₃PO₄ at temperatures ranging from 70 to 110 °C. The surface regions of the two electropolished stainless steel plates were coated with gold and either a titanium or nickel layer using electron beam evaporation. The electropolished stainless steel plates coated in 2-μm thick gold with a 0.1-μm titanium or nickel interlayer showed remarkably smooth and uniform surface morphologies in AFM and FE-SEM images compared to the surfaces of the plates that were coated after mechanical polishing only. The electrical resistance and water contact angle of the deposited stainless steel bipolar plates are strongly dependent on the surface modification treatments (i.e., mechanical polishing versus electropolishing). ICP-MS and XPS results indicate that after electropolishing, the coating layers show excellent chemical stability after exposure to an H₂SO₄ solution of pH 3. Finally, it was concluded that before coating deposition, the surface modification using electropolishing was very suitable for enhancing the electrical property and chemical stability of the stainless steel bipolar plate.     

Performance prediction of proton exchange membrane fuel cells using a three-dimensional model

In this study a steady-state three-dimensional computational fluid dynamics (CFD) model of a proton exchange membrane fuel cell is developed and presented for a single cell. A complete set of conservation equations of mass, momentum, species, energy transport, and charge is considered with proper account of electrochemical kinetics based on Butler–Volmer equation. The catalyst layer structure is considered to be agglomerate. This model enables us to investigate the flow field, current distribution, and cell voltage over the fuel cell which includes the anode and cathode collector plates, gas channels, catalyst layers, gas diffusion layers, and the membrane. The numerical solution is based on a finite-volume method in a single solution domain. In this investigation a CFD code was used as the core solver for the transport equations, while mathematical models for the main physical and electrochemical phenomena were devised into the solver using user-developed subroutines. Three-dimensional results of the flow structure, species concentrations and current distribution are presented for bipolar plates with square cross section of straight flow channels. A polarization curve is obtained for the fuel cell under consideration. A comparison between the polarization curves obtained from the current study and the corresponding available experimental data is presented and a reasonable agreement is obtained. Such CFD model can be used as a tool in the development and optimization of PEM fuel cells.     

A novel intersectant flow field of metal bipolar plate for proton exchange membrane fuel cell

A novel intersectant flow field of metal bipolar plate for proton exchange membrane fuel cell (PEMFC) was proposed. The bionics, fractal theory, and Murray's law were employed to design the novel flow field to decrease the drag force for the reaction medium and product. Computational fluid dynamics method was employed to investigate the performance of the novel flow field. The performance of traditional serpentine flow field was compared with the said one to calibrate the efficiency of the novel design of flow field. A test system of PEMFC was assembled to validate the reliability of the numerical simulation. The metal bipolar plates with the intersectant flow field were fabricated by electro discharge machining for the test. The surface treatment of the bipolar plate was conducted. Results showed that the novel flow field exhibited some advantages than the serpentine flow field in terms of the uniform distribution of reaction medium and exhausting of reaction product. The polarization curve also released that the novel flow field owned the higher power and current density. The experimental results certified the accuracy of numerical simulation and validated the advantage of the novel flow field in promoting the efficiency of PEMFC. Copyright © 2017 John Wiley & Sons, Ltd.     

Influence of geometric parameters of the flow fields on the performance of a PEM fuel cell. A review

The proton Exchange membrane fuel cell (PEMFC) performance depends not only on many factors including the operation conditions, transport phenomena inside the cell and kinetics of the electrochemical reactions, but also in its physical components; membrane electrode assembling (MEA) and bipolar plates (BPs). Among the PEM stack components, bipolar plates are considered one of the crucial ones, as they provide one of the most important issues regarding the performance of a stack, the homogeneous distribution of the reactive gases all over the catalyst surface and bipolar plate areas through, the so call, flow channels; physical flow patterns or paths fabricated on the BPs surfaces to guide the gases all along the BPs for its correct distribution. The failure in flow distribution among different unit cells may severely influence the fuel cell stack performance. Thus, to overcome such possible failures, the design of more efficient flow channels has received considerable attention in the research community for the last decade.     

Performance of the gold-plated titanium bipolar plates for the light weight PEM fuel cells

In this present work, we are attempting to develop a light weight and corrosion resistant bipolar plate for the proton exchange membrane fuel cell. A titanium bipolar plate substrate has been chosen as the base metal due to its low cost, ease of manufacture into stampable bipolar plates, and its light weight. Our approach to obtain a smaller and lighter weight single fuel cell is to coat titanium with a corrosion resistant coating. Gold (Au) was investigated. The cell performance of the gold-plated bipolar plates is close to and even better than the PEM fuel cells with graphite and pure titanium bipolar plates. Gold-plated titanium bipolar plates can be employed to produce fuel cells with light weight, low coating cost and low contact resistance, ideal for portable applications.     

Optimization design of slotted-interdigitated channel for stamped thin metal bipolar plate in proton exchange membrane fuel cell

The stamped metal bipolar plate is a promising candidate of the traditional graphite plate for proton exchange membrane fuel cells (PEMFCs) due to its advantages, such as low cost, compactness, robustness and high production efficiency. This study proposes a new type of flow configuration, which is called slotted-interdigitated channel, for stamped metal bipolar plates. Numerical simulation of the flow distribution of slotted-interdigitated channels is studied by using three-dimensional computational fluid dynamics (CFD) and the results show the flow distribution is uneven. Consequently, an optimization model, based on a linear analytical model, is proposed to eliminate flow maldistribution. Finally, even flow distribution is obtained according to the optimum results and high fuel cell performance can be achieved.     

A graphite-coated carbon fiber epoxy composite bipolar plate for polymer electrolyte membrane fuel cell

A PEMFC (polymer electrolyte membrane fuel cell or proton exchange membrane fuel cell) stack is composed of GDLs (gas diffusion layers), MEAs (membrane electrode assemblies), and bipolar plates. One of the important functions of bipolar plates is to collect and conduct the current from cell to cell, which requires low electrical bulk and interfacial resistances. For a carbon fiber epoxy composite bipolar plate, the interfacial resistance is usually much larger than the bulk resistance due to the resin-rich layer on the composite surface.In this study, a thin graphite layer is coated on the carbon/epoxy composite bipolar plate to decrease the interfacial contact resistance between the bipolar plate and the GDL. The total electrical resistance in the through-thickness direction of the bipolar plate is measured with respect to the thickness of the graphite coating layer, and the ratio of the bulk resistance to the interfacial contact resistance is estimated using the measured data. From the experiment, it is found that the graphite coating on the carbon/epoxy composite bipolar plate has 10% and 4% of the total electrical and interfacial contact resistances of the conventional carbon/epoxy composite bipolar plate, respectively, when the graphite coating thickness is 50 μm.     

Development and performance evaluation of a high temperature proton exchange membrane fuel cell with stamped 304 stainless steel bipolar plates

In this work, a high temperature proton exchange membrane fuel cell (HT-PEMFC) with stamped SS304 bipolar plates is successfully developed. Its performance was evaluated under two types of gaskets at different assembly torques and air stoichiometric ratios. The rates of pressure loss at a torque of 7 N-m with 50 Shore A hardness gaskets was 2.0 × 10^?3 MPa min^?1, which is acceptable. The best performance of the developed HT-PEMFC with stamped SS304 bipolar plates was 228.33 mW cm^?2, which approaches the performance of HT-PEMFCs with graphite bipolar plates. The optimal air stoichiometric ratio for the HT-PEMFC with stamped SS304 bipolar plates was 4.0, which is higher than that for proton exchange membrane fuel cells with CNC milled graphite bipolar plates. This is probably because of the deformation of the flow channels under the assembly compression force, which causes an elevated gas-diffusion drag in the flow channels. After the test, it was observed that some products of corrosion reaction formed on the surface of the SS304 bipolar plate. This phenomenon may lead to a decrease in the operating life of the HT-PEMFC.     

The effect of pH and halides on the corrosion process of stainless steel bipolar plates for proton exchange membrane fuel cells

Stainless steel is attractive as material for bipolar plates in proton exchange membrane fuel cells, due to its high electrical conductivity, high mechanical strength and relatively low material and processing cost. Potentiostatic and potentiodynamic tests were performed in H₂SO₄ solutions on AISI 316L stainless steel bipolar plates with etched flow fields. The effect of pH and presence of small amounts of fluoride and chloride on the corrosion rate and interfacial contact resistance of the stainless steel bipolar plate were investigated. The tests performed in electrolytes with various pH values revealed that the oxide layer was thinner and more prone to corrosion at pH values significantly lower than the pH one expects the bipolar plate to experience in an operating proton exchange membrane fuel cells. The use of solutions with very low pH in such measurements is thus probably not the best way of accelerating the corrosion rate of stainless steel bipolar plates. By use of strongly acidic solutions the composition and thickness of the oxide layer on the stainless steel is probably altered in a way that might never have happened in an operating proton exchange membrane fuel cell. Additions of fluoride and chloride in the amounts expected in an operating fuel cell (2 ppm F⁻ and 10 ppm Cl⁻) did not cause significant changes for neither the polarization- nor the contact resistance measurements. However, by increasing the amount of Cl⁻ to 100 ppm, pitting was initiated on the stainless steel surface.     

Fabrication of metallic bipolar plate for proton exchange membrane fuel cells by rubber pad forming

In this paper, the rubber pad forming process is used to fabricate the metallic bipolar plate for a proton exchange membrane (PEM) fuel cell, which has multi-array micro-scale flow channels on its surface. The rubber pad forming process has the following advantages: high surface quality and dimensional accuracy of the formed parts, low cost of the die because only one rigid die is required, and high efficiency. The process control parameters (rubber hardness, internal and outer radii, draft angle) of the rubber pad forming are analyzed by the finite element method using the commercial software Abaqus. After that, the rubber pad forming process is used to manufacture a metallic bipolar plate of SS304 stainless steel with perfect flow micro-channels. The results of this effort indicated that the rubber pad forming process is a feasible technique for fabricating the bipolar plates of PEM fuel cells.     

Performance improvement of proton exchange membrane fuel cell by using annular shaped geometry

A complete three-dimensional and single phase CFD model for a different geometry of proton exchange membrane (PEM) fuel cell is used to investigate the effect of using different connections between bipolar plate and gas diffusion layer on the performances, current density and gas concentration. The proposed model is a full cell model, which includes all the parts of the PEM fuel cell, flow channels, gas diffusion electrodes, catalyst layers and the membrane. Coupled transport and electrochemical kinetics equations are solved in a single domain; therefore no interfacial boundary condition is required at the internal boundaries between cell components.This computational fluid dynamics code is used as the direct problem solver, which is used to simulate the three-dimensional mass, momentum and species transport phenomena as well as the electron- and proton-transfer process taking place in a PEMFC that cannot be investigated experimentally. The results show that the predicted polarization curves by using this model are in good agreement with the experimental results. Also the results show that by increasing the number of connection between GDL and bipolar plate the performance of the fuel cell enhances.     

Mass transfer in proton exchange membrane fuel cells with baffled flow channels and a porous‐blocked baffled flow channel design

In proton exchange membrane fuel cells, baffled flow channels enhance the reactant transfer from flow channels to gas diffusion layers. However, the reactant transfer depends on both the diffusive transfer and convective transfer, and how the baffles in flow channels affect them is still unknown. Therefore, in this work, a two‐dimensional, two‐phase, nonisothermal, and steady‐state model of proton exchange membrane fuel cells is developed, and these two transfer processes from flow channels to gas diffusion layers are comparatively studied. Simulation results show that first of all, the reactant transfer from flow channels to gas diffusion layers mainly depends on the diffusive transfer. Therefore, if the desire is to enhance the mass transfer from flow channels to gas diffusion layers, the diffusive mass transfer should be enhanced firstly. Being guided by this goal, a porous‐blocked baffled flow channel is developed. This flow channel design can further enhance the reactant transfer from flow channels to gas diffusion layers, and the cell performance can be improved. Moreover, when the porosities of porous blocks at the front place of flow channels are lower, the cell power is also increased but the pumping power can be reduced a lot.     

Innovative gasketless carbon composite bipolar plates for PEM fuel cells

Conventional bipolar plates for proton exchange membrane (PEM) fuel cells use extra rubber gaskets to seal the stack, which require an additional curing process at high temperature and increase the manufacturing and assembling time. To reduce the assembling time of fuel cell stacks and achieve gas sealability without using extra gaskets or curing cycles, innovative gasketless carbon composite bipolar plates were developed. To ease the assembling of the cell stacks, special grooves on the edge of the composite bipolar plate are provided for mechanical joining and the behavior of the bipolar plates under the stack compaction pressure conditions was investigated by FE analysis. The mechanical properties of the grooves were measured by the compressive strength test and compared with the FE analysis results. The sealability of the gasketless bipolar plate with grooves was tested to verify the integrity of the design.     

管理与技术并重的企业清洁生产工作研究

质子交换膜燃料电池（PEMFC）以其能量转化率高、低排放、能量和功率密度高等优点被认为是适应未来能源和环境要求的理想动力源之一。双极板是质子交换膜燃料电池组中的关键功能部件之一,而且时电池组的成本、体积和质量有直接影响。开发同时具有优良的综合性能和低成本的双极板是质子交换膜燃料电池实现产业化的必然要求。综述了目前各种双极板材料的研发现状,并对各种材料进行了比较,提出了双极板材料的发展趋势。     

Performance of PEMFC stack using expanded graphite bipolar plates

The bipolar plates are in weight and volume the major part of PEM fuel cell stack, and also a significant effect to the stack cost. To develop the low-cost and low-weight bipolar plate for PEM fuel cell, we have developed a kind of cheap expanded graphite plate material and a production process for fuel cell bipolar plates. The plates have a high electric conductivity and low density, and can be stamped directly forming fuel cell bipolar plates. Then, 1 and 10 kW stacks using expanded graphite bipolar plates are successfully assembled. The contact resistance of the bipolar plate is investigated and the electrochemical performances of the fuel cell stacks are tested. Good fuel cell performance is obtained and the voltage distribution among every single cell in the stacks is very uniform.     

The preparation technique optimization of epoxy/compressed expanded graphite composite bipolar plates for proton exchange membrane fuel cells

Vacuum resin impregnation method has been used to prepare polymer/compressed expanded graphite (CEG) composite bipolar plates for proton exchange membrane fuel cells (PEMFCs). In this research, three different preparation techniques of the epoxy/CEG composite bipolar plate (Compression-Impregnation method, Impregnation-Compression method and Compression-Impregnation-Compression method) are optimized by the physical properties of the composite bipolar plates. The optimum conditions and the advantages/disadvantages of the different techniques are discussed respectively. Although having different characteristics, bipolar plates obtained by these three techniques can all meet the demands of PEMFC bipolar plates as long as the optimum conditions are selected. The Compression-Impregnation-Compression method is shown to be the optimum method because of the outstanding properties of the bipolar plates. Besides, the cell assembled with these optimum composite bipolar plates shows excellent stability after 200 h durability testing. Therefore the composite prepared by vacuum resin impregnation method is a promising candidate for bipolar plate materials in PEMFCs.