Epoxy methacrylate based adhesive for fuel cell flow field plates

1. An electrically conductive adhesive for bonding an anode flow field plate and a cathode flow field plate together to form a bipolar plate assembly for a fuel cell, the adhesive comprising:

epoxy methacrylate resin in an amount ranging from about 3 to 70% by weight;

styrene in an amount ranging from about 0 to 20% by weight;

isobornylacrylate in an amount ranging from about 0 to 20% by weight;

non-fibrous carbon particles in an amount ranging from about 11 to 30% by weight;

a non-conductive rheology modifier;

a radical initiator;

a stabilizer; and

carbon fibres in an amount ranging from 0 to less than 2% by weight.

2. The adhesive of claim 1 wherein the adhesive is essentially free of carbon fibres.

3. The adhesive of claim 1 wherein the amounts of the epoxy methacrylate resin, styrene, and isobornylacrylate are about 50%, 10% and 10% respectively.

4. The adhesive of claim 1 wherein the adhesive additionally comprises trimethylolpropane trimethacrylate in an amount about 5% by weight.

5. The adhesive of claim 1 wherein the carbon particles are synthetic graphite in an amount about 22% by weight.

6. The adhesive of claim 1 wherein the average particle size of the carbon particles is in the range from about 5 to 15 micrometers.

7. The adhesive of claim 1 wherein the rheology modifier is in an amount from about 0.01 to 2% by weight.

8. The adhesive of claim 7 wherein the rheology modifier is amorphous silica in an amount about 0.8% by weight.

9. The adhesive of claim 1 wherein the radical initiator is in an amount from about 0.5 to 6% by weight.

10. The adhesive of claim 1 wherein the stabilizer is tert-butylhydroquinone in an amount up to about 1% by weight.

11. The adhesive of claim 1 wherein the Tg of the adhesive is greater than about 100° C.

12. A bipolar plate assembly for a fuel cell comprising an anode flow field plate and a cathode flow field plate bonded together with the adhesive of claim 1 .

13. The bipolar plate assembly of claim 12 wherein at least one of the flow field plates is made of flexible graphite, carbon, or metal.

14. The bipolar plate assembly of claim 13 wherein both the anode and cathode flow field plates are made of flexible graphite, carbon, or metal.

15. The bipolar plate assembly of claim 12 wherein the tensile strength of the bond is greater than about 40 MPa stress at break for a 0.5 square inch sample.

16. A fuel cell comprising the bipolar plate assembly of claim 12 .

17. The fuel cell of claim 16 wherein the fuel cell is a solid polymer electrolyte fuel cell.

18. A method for bonding an anode flow field plate and a cathode flow field plate together to form a bipolar plate assembly for a fuel cell comprising:

providing the anode flow field plate and the cathode flow field plate wherein the anode flow field plate comprises an anode flow field on one side, a coolant flow field on the other side, and a sealing surface on the coolant flow field side, and wherein the cathode flow field plate comprises a cathode flow field on one side, a coolant flow field on the other side, and a sealing surface on the coolant flow field side;

applying an amount of the adhesive of claim 1 to at least one of the flow field plates such that adhesive covers the sealing surfaces between the plates;

mating the coolant flow field sides of the anode and cathode flow field plates together in alignment; and

curing the adhesive, thereby bonding the anode and cathode flow field plates to make the bipolar plate assembly.

19. The method of claim 18 wherein an adhesive filled gap in the range from about 3 to 20 micrometers thick remains between the sealing surfaces of the plates after the bonding.

20. The method of claim 19 wherein an adhesive filled gap in the range from about 4 to 7 micrometers thick remains between the sealing surfaces of the plates after the bonding.

21. The method of claim 18 wherein the sealing surfaces of the anode and cathode flow field plates are essentially free of primer.

22. The method of claim 18 comprising applying the adhesive in a liquid carrier and drying the applied adhesive before mating the plates together.

23. The method of claim 22 wherein the liquid carrier is an organic solvent.

24. The method of claim 18 wherein the applying comprises roller coating.