Doctor of Philosophy, University of Akron, 2008, Polymer Engineering
In this work, highly conductive carbon-filled epoxy composites were developed for manufacturing bipolar plates in proton exchange membrane (PEM) fuel cells. These composites were prepared by solution intercalation mixing, followed by compression molding and curing. The in-plane and through-plane electrical conductivity, thermal and mechanical properties, gas barrier properties, and hygrothermal characteristics were determined as a function of carbon-filler type and content. For this purpose, expanded graphite and carbon black were used as a synergistic combination. Mixtures of aromatic and aliphatic epoxy resin were used as the polymer matrix to capitalize on the ductility of the aliphatic epoxy and chemical stability of the aromatic epoxy. The composites showed high glass transition temperatures (Tg ~ 180°C), high thermal degradation temperatures (T2 ~ 415°C), and in-plane conductivity of 200-500 S/cm with carbon fillers as low as 50 wt%. These composites also showed strong mechanical properties, such as flexural modulus, flexural strength, and impact strength, which either met or exceeded the targets. In addition, these composites showed excellent thermal conductivity greater than 50 W/m/K, small values of linear coefficient of thermal expansion, and dramatically reduced oxygen permeation rate. The values of mechanical and thermal properties and electrical conductivity of the composites did not change upon exposure to boiling water, aqueous sulfuric acid solution and hydrogen peroxide solution, indicating that the composites provided long-term reliability and durability under PEM fuel cell operating conditions. Experimental data show that the composites developed in this study are suitable for application as bipolar plates in PEM fuel cells.
Committee: Sadhan Jana (Advisor)
Subjects: Engineering, Chemical