Synergy effects of hybrid carbon system on properties of composite bipolar plates for fuel cells

A hybrid carbon system of graphite powder (GP) and continuous carbon fibre fabric (CFF) is used for an epoxy composite to improve the electrical conductivity, mechanical properties and mouldability of a composite bipolar plate. These improvements are achieved simultaneously by inserting several layers of CFF into the GP/epoxy composite to enhance the mechanical properties and in-plane conductivity. The electrical properties, flexural strength and mouldability of the composite plates are measured as a function of conducting filler content and number of CFF layers. The composites show improved electrical conductivity, flexural properties and mouldability. Composites with 70–75 vol.% carbon fillers have the highest electrical conductivity with reasonable flexural properties. These results suggest that the poor mouldability and low through-plane electrical conductivity of the continuous fibre composite bipolar plate, as well as the weak flexural properties of GP composites, can be overcome by incorporating a GP/CFF hybrid system.