Processing methods for conductive polymer composite bipolar plates: Effect on plate quality and performance

Abstract Conductive polymer composites (CPCs) have been identified as viable replacements for graphite and metals for polymer electrolyte membrane fuel cell (PEMFC) bipolar plates (BPs). One important factor, apart from composite formulation, that affects the quality and properties of CPC BPs is the processing route. Therefore, understanding the possible processing methods for different matrix–filler combinations and their effects on the quality and properties of the plates can help in controlling and improving the final performance of BPs. This paper reviews the blending and molding techniques for CPC BPs, with a focus on relationship between formulation and processing method. The effects of processing route and conditions on microstructural features of CPC BPs, which affect the performance of the plates are also discussed. Finally, directions for further studies with potential to advance the development of quality and high‐performance CPC BPs are highlighted. Identified key areas for further research include control of filler orientation to improve through‐plane conductivity, correlation between processing parameters and dimensional accuracy of molded plates, and additive manufacturing of composite BPs.