SBIR Phase II: Investigation of Novel, Low-Cost Materials and Manufacturing Methods for Polymer Electrolyte Membrane (PEM) Fuel Cell Bipolar Plates

Directed Technologies Inc, Arlington VA

Investigators

Abstract

This Small Business Innovation Research Phase II project will continue the development of inherently low cost, mass-producable conductive composite materials and novel manufacturing processes for Polymer Electrolyte Membrane (PEM, also called Proton Exchange Membrane) fuel cells. Current PEM fuel cell bipolar plates often achieve good overall technical performance, but have some combination of high materials, manufacturing and assembly cost. This high cost is a barrier to market penetration of fuel cells. In order to develop a fuel cellbipolar plate which has acceptable technical performance, as well as, low cost, novel composite materials amenable to low cost manufacture will be developed. Three novel manufacturing processes identified during Phase I will be used to fabricate small and large format bipolar plates from composite materials identified in Phase I. These bipolar plates will be tested for electrical conductivity and will be operated in both short-term, performance-oriented testing and longer-term, lifetime testing. Additionally, the materials development work of Phase I will be continued in order to further optimize the novel composite materials for performance and cost. Successful completion of the project will lead to low cost, mass-manufacturable fuel cell stacks, thereby enhancing U.S. competitiveness in the emerging markets for fuel cells. This will further lead to a greatly accelerated market penetration of fuel cells especially in low cost applications such as light duty vehicles.