Tailoring flexible-segment-rich resin network structure by multi-step copolymerization for improved composite bipolar plate of proton exchange membrane fuel cell

Composite bipolar plates composed of conductivity fillers and resins are widely employed in stationary proton exchange membrane fuel cell (PEMFC) due to their high corrosion resistance in acidic environments. Phenol-formaldehyde resin is a commonly used adhesive in composite bipolar plates; while numerous benzene rings in phenol-formaldehyde resin result in the poor flexibility of composite bipolar plates. Embedding the flexible segment (–CHOH–CH₂-O-) in the resin network structure of phenol-formaldehyde resin by copolymerization with epoxy resin is an effective method for improving the defects of phenol-formaldehyde resin. In this contribution, to tailor flexible-segment-rich (–CHOH–CH₂-O-) resin network structure, the co-polymerization mechanism of phenol-formaldehyde resin and epoxy resin is investigated in detailed by in-situ Fourier Transform Infrared (FTIR), based on which an Alter-T strategy is proposed for flexible-segment-rich (–CHOH–CH₂-O-) resin network structure during composite bipolar plates fabrication process. The obtained composite bipolar plates consisted of graphite and flexible-segment-rich resin network structure delivers improved flexural strength (86.97 MPa), electrical conductivity (203.22 S cm⁻¹) and areal resistance (3.41 mΩ cm²) in comparison to previously reported composite bipolar plates with same components, which are also over the technical standard of the DOE. It is further demonstrated that enriching the flexible segment for improving the poor flexibility of resin network structure is of great importance to enhance the performance of the composite bipolar plates.