Development of Advanced Polymer/Graphite Nanocomposite Materials and Optimization of Their Processing Routes for the Industrial Manufacturing of Bipolar Plates for Proton Exchange Membrane Fuel Cells (PEMFCs)

PROJECT COST:

418 672 $

PRIMA CONTRIBUTION:

187 168 $

PROJECT DETAILS:

Proton exchange membrane fuel cell (PEMFC) technology has attracted increasing interest from researchers and policymakers, as its large-scale deployment can reduce dependence on fossil fuels and lower greenhouse gas emissions. Current research efforts mainly focus on improving PEMFC performance and reducing production costs.

The objective of the project led by Professor Frej Mighri, in partnership with two Québec-based industrial partners, Nouveau Monde Graphite (NMG) and Plastiques Gagnon, is to improve bipolar plates (BPPs)—one of the key components of PEMFCs—by developing a BPP material concept based on polymer/carbon nanocomposites combined with novel engineering solutions.

The four main objectives are: (i) to develop thermoplastic polymer nanocomposite formulations and evaluate their electrical and mechanical properties, as well as their processability by injection–compression molding and/or extrusion–compression molding; (ii) to assess the synergistic effects of NMG’s high-quality graphite combined with conductive fillers (carbon black, multi-walled carbon nanotubes, and graphene) on the electrical and mechanical properties; (iii) to investigate hydrogen–oxygen double percolation phenomena in polymers; and (iv) to evaluate the performance of optimized BPP prototypes through testing in PEM fuel cells.

These advanced materials will reduce the weight and manufacturing cost of PEMFCs while increasing their service life compared with metallic materials.

This project will also support the training of two doctoral students, one master’s student, and one postdoctoral fellow, contributing to the development of competitive products in a field that is important not only for the economy but also for environmental quality.

The Québec-based mining company NMG aims to become a strategic supplier of high-performance graphite to major global manufacturers of batteries and vehicles, with plans to initiate marketing activities related to PEMFCs in the short term.

This value chain will enable the valorization of NMG’s high-performance graphite and strengthen Plastiques Gagnon’s expertise in the manufacturing of thin bipolar plates using injection–compression molding, thereby positioning Québec and Canada in the strategic field of PEM fuel cells for the automotive industry.