Lightweight and Efficient: Exploring Low-Weight Bipolar Plates for Alkaline PEM Fuel Cells

Abstract

Alkaline proton exchange membrane (PEM) fuel cells have the potential to be highly efficient and environmentally sustainable energy sources. However, the performance and durability of these fuel cells are dependent to some extent on the bipolar plates used in their design. Bipolar plates play a crucial role in the electrochemical reactions within the fuel cell, and their design and material selection can greatly impact the efficiency and lifespan of the fuel cell.This study focuses on three key aspects of developing efficient and durable bipolar plates for alkaline PEM fuel cells. Firstly, the study emphasizes the importance of optimizing bipolar plate design and flow field to enhance the power output and limiting current density of the fuel cell. Computational fluid dynamics (CFD) simulations are employed to optimize the flow field design, which is found to be crucial in determining the performance of the fuel cell. The optimized flow field design enhances the current density and reduces the pressure drop, resulting in improved fuel cell efficiency.Secondly, the study investigates the potential of low-weight bipolar plates made with printed circuit boards (PCBs) as the matrix material. Traditional bipolar plates made with graphite or metal are often heavy and bulky, leading to increased material costs and decreased fuel cell efficiency. The use of PCBs as the matrix material results in a significant reduction in weight compared to traditional materials, without sacrificing performance. However, the alkaline environment in fuel cells can cause significant corrosion damage to the bipolar plates over time. To mitigate this issue, the PCBs are coated with a layer of Ni-P electroless coating to protect against corrosion.Thirdly, the study examines the effectiveness of corrosion protection measures using Ni-P electroless coating. The electroless coating significantly improves the corrosion resistance of the bipolar plates, thereby prolonging their lifespan and maintaining the performance of the fuel cell over time. The combination of low-weight bipolar plates made with PCBs and corrosion protection measures using Ni-P electroless coating has the potential to enhance the overall performance and durability of alkaline PEM fuel cells.Overall, this study highlights the importance of considering bipolar plate design, material selection, and corrosion protection measures in developing efficient and durable alkaline PEM fuel cells. The optimized flow field design enhances the current density and reduces the pressure drop, while the use of PCBs as the matrix material and Ni-P electroless coating as the corrosion protection measure significantly improve the fuel cell's efficiency and lifespan. These findings provide valuable insights for the development of next-generation fuel cells that are both high-performing and environmentally sustainable.