Characterization of Commercial Polymer–Carbon Composite Bipolar Plates Used in PEM Fuel Cells

Bipolar plates represent a crucial component of the PEM fuel cell stack. Polymer–carbon composites are recognized as state-of-the-art materials for bipolar plate manufacturing, but their use involves a compromise between electrical and heat conductivity, mechanical strength and costs. Thus, all key parameters must be considered when selecting a suitable plate satisfying the demands of the desired application. However, data relevant to commercial materials for such selection are scarce in the open literature. To address this issue, 13 commercially available polymer–carbon composites are characterised in terms of the following parameters: through-plane conductivity, hydrogen permeability, mechanical strength, water uptake, density, water contact angle and chemical stability. None of the materials tested reached the DOE target for electrical conductivity, while five of the materials met the target for flexural strength. The overall best-performing material showed a conductivity value of 50.4 S·cm−1 and flexural strength of 40.1 MPa. The data collected provide important supporting information in selecting the materials most suitable for the desired application. In addition, the key parameters determined for each bipolar plate supply important input parameters for the mathematical modelling of fuel cells.