CORE

About the project:

The goal of this project was to develop metallic bipolar plates (BPs) with a novel polymer coating with aligned conductive particles suitable for the use in energy conversion devices with polymer exchange membrane (PEM). The effort was shared between three parties – University of Chemistry and Technology in Prague (UCTP), SINTEF AF and CondAlign. At CondAlign the main focus has been the development of the processes for the preparation of the coatings and the preparation itself. The preparation has been conducted in cooperation with project partner SINTEF. SINTEF and UCTP collaborated in the effort to characterize the samples in in-situ and ex-situ setups. Furthermore, a cost analysis model and a mathematical model of the PEM with stamped metallic BPs have been developed. Two generations of coating strategies have been demonstrated. The first utilizing resins that are cured by UV light and the second utilizing resins cured by heat / elevated temperature. Through the execution of the project activities, it has been demonstrated that preparation and manufacturing of durable coatings with aligned conductive particles is feasible and that functional coatings can be realized. Using the mathematical model, an optimized geometry of the flow field channels for stamped metallic bipolar plates has been proposed. Altogether, the results obtained widen the knowledge about the promising technology of PEM fuel cells with metallic BPs, opening a way for a potential commercialization.

2021

A comprehensive literature research has been performed, focusing on selection of the coating materials showing most promising properties for the desired application. In the next step, series of samples of polymeric films, as well as films deposited on the stainless steel simulating bipolar plated was produced. The target was also to set-up and validate corresponding characterization methods at the individual project partners. These experiments have shown, that the some of the last generation samples have achieved during this ex-situ testing parameters close, or already fulfilling project targets regarding the mentioned parameters. This is very promising considering the early stage of the project. Within the framework of the novel technology of the bipolar plates production and application technoeconomic feasibility study collection of necessary input data has started together with laying down ground work for the analysis and comparison of the proposed solutions. Another task represents mathematical modelling of a PEM type fuel cell. Within the first year of the project, two-dimensional model of the fuel cell was developed and implemented in the COMSOL Multiphysics environment.

2022

Following progress has been achieved within the second year of the project. Within WP1 optimisation of the materials used to produce protective layer continued also within the second year of the project. Based on the results achieved within the first year of the project and in close collaboration with WP2, new set of materials was proposed ensuring the film will not be only sufficiently conductive, but also corrosion resistant. Despite Czech and Norwegian side use slightly different experimental methodologies within this task, round robin has shown, the results follow identical trends. Whereas within this part of the WP2 basic characteristics of the prepared protective films were identified, within the second part of this WP corrosion stability of the metallic materials, or their modifications, were determined. This allowed to identify materials most promising for this particular application. Outputs from the previous two WPs play an important role in the WP3 focusing on techno-economic assessment of the approach to the bipolar plates production studied and simulation of the bipolar plate structure impact on the resulting fuel cell performance. Within the framework of the techno-economic analysis, the bill of material was chosen at this stage to provide basic comparison of competing approaches to the bipolar plate production. This approach represent optimal approach at this stage, as information allowing to define the production costs are still not sufficient to reach required accuracy of the data. WP4 was focused on the of coordination, management, communication. The part of the WP4 was securing publicity of the project; these activities such as a presentation at Open days and other public events are organized throughout the project duration in order to give visibility to the project implementation and its outputs.

2023

During the third year of the project, the main focus was on developing highly innovative bipolar plates made of stainless steel, covered with structured electrically conductive film. This film consists of a polymer matrix filled with electrically conductive particles aligned using an electrostatic field. Research efforts focused on improving film quality and on optimising methods for film application on the stainless steel support. Test results showed promising outcomes in terms of plate durability and performance. Also mathematical modelling, including technoeconomic analysis, progressed significantly. It allowed to obtain important new knowledge in this field. Beside this, a significant effort was dedicated to project management and promotion. Project outputs include scientific publications, functional sample, a patent application, and conference presentations. Despite publications delay caused by the intellectual property protection associated with a patent application, the project remains on track as per the approved project plan.

2024

The project is in its final phase, having reached key milestones with a focus on developing innovative bipolar plates made from stainless steel, coated with an electrically conductive film. This film, comprising a polymer matrix and conductive particles, was structured through an electric field. The project involved four work packages: production of a protective film, testing of the bipolar plates, mathematical modeling to optimize gas distribution, and techno-economic analysis of the protection technology. Management and dissemination of results were also critical components. In work package 1, experiments with the second generation of protective films were completed, including the use of gold-coated glass beads and ceramic fillers like TiN. CondAlign developed an industrial “roll-to-roll” process for film production. Work package 2 focused on characterizing the bipolar plates and collecting data for validation in mathematical models. This cooperation led to the preparation of three manuscripts, one of which has been accepted for publication, while two others are under review. Work package 3 completed the techno-economic analysis and refined a manuscript that was subsequently accepted. The final work package 4 focused on project coordination and dissemination efforts, including webinars and presentations at international conferences. These activities exceeded the planned scope, and due to ongoing reviews, an extension was requested to document results. Overall, the project progressed as planned, with significant achievements beyond expectations, except for delays in publishing due to patent protection.

Beneficiary and project partners:

Vysoká škola chemicko-technologická v Praze
SINTEF AS
CondAlign

The CORE project benefits from a € 1.3 mil. grant from Norway Grants and Technology Agency of the Czech Republic. The project is carried out under the KAPPA funding programme for applied research, experimental development and innovation, managed by the Technology Agency of the Czech Republic.