Fumed silica additives enables tunable wettability of the resin for improved composite bipolar plate

Composite bipolar plates (CBP) composed of resin and conductive filler are critical components in proton exchange membrane fuel cell (PEMFC) for achieving mechanical strength and electrical conductivity. The conductive filler entirely enveloped by resin is of significance for the flexibility of the CBP; while connected resin blocks the continued conductive channels and thus weakens the electrical properties of CBP. Herein, we propose a trade-off method between flexibility and conductivity of the CBP by wettability regulations of the resin, in which fumed silica additives are introduced into epoxy as composite adhesives. The abundant hydrogen bonds are demonstrated to be well-formed between epoxy and fumed silica for decreasing surface free energy (SFE) between resin and graphite. As a result, the composite adhesive with 2 % fumed silica delivers moderate wettability enabling much improved CBP, which exhibits high electrical conductivity of 233.33 S cm⁻¹ as well as flexural strength of 66.4 MPa. Moreover, the CBP also delivers improved areal specific resistance (5.34 mΩ cm²), thermal conductivity (10.58 W (m K)⁻¹), and corrosion behaviors (0.0701 A cm⁻²) which guarantee the operation of the PEMFC. This work provides new insight from the wettability regulation of resins for improved CBP, which is an easy-operating method and has great potential for application in practical CBP fabrication.