Enhanced Scalability and Durability of Bipolar Plates for Heavy-Duty Vehicle Applications

Statement of the problem or situation that is being addressed in your application. Zero-emission heavy-duty fuel cell vehicles require a lifetime of over a million miles and 57,000 operation hours, which imposes significant strain on component materials. Currently, bipolar plates are projected to represent 20 to 40% of the stack cost and up to 80% of the total stack weight. However, to meet DOE cost targets for heavy-duty vehicles ($80/kW) bipolar plate costs still need to be dramatically reduced. General statement of how this problem is being addressed. To address this need, Giner, Inc, in collaboration with University of California Irvine (UCI), University of Tennessee, Knoxville (UTK) and Hyzon Motors, Inc. (Hyzon), propose an innovative approach to producing ultra-thin, light-weight bipolar plates by producing a composite polymer using a graphite loaded thermoplastic with a liquid crystal polymer (LCP), to obtain high mechanical strength, excellent thermal and electronic conductivity and ease of processing, at a low price. What is to be done in Phase I? In Phase I Giner will develop and synthesize the polymer composite material in house using VectranTM and graphite loaded polyphenylene sulfide. UCI will design a 3-D fuel cell model with a bipolar plate sub-model utilizing the composite material properties as an input to predict electron and heat transport properties. UTK will 3D print small scale samples and supply them to Giner for extensive ex-situ characterization. Finally, Hyzon will help validate the bipolar plate performance under heavy duty operating conditions. Commercial Applications and Other Benefits: In Phase II the composite BPs will be scaled up using injection molding, and delivered directly to a major industry partner, Hyzon, from where they will reach the domestic heavy duty FC market. This will lead to a reduction of CO2 emissions by replacing diesel motors in trucks with zero emission electric powertrains, dramatically improving overall air quality, in line with DOE mission. Our novel material can also be used in PEM electrolyzers, alkaline fuel cells/electrolyzers, or aircraft and space applications.