Methods and systems are provided for manufacturing a membrane separator for a redox flow battery. In one example, the membrane separator is fabricate by a calendering process. The membrane separator may be configured with a polymer network to provide selectivity for ion transport across the membrane separator. The membrane separator may be further adapted with an integrated spacer in contact with a negative electrolyte.

A modular flow battery includes a battery stack container housing a plurality of redox flow battery stacks in fluid communication with at least one pair of electrolyte containers including an anolyte container for holding an anolyte and a catholyte container for holding a catholyte. Additional pairs of electrolyte containers can be connected to the battery stack container to increase an amount of energy that can be stored by the modular flow battery system. Respective housings enclosing each of the battery stack container and the electrolyte containers are configured for operation in a stacked configuration. In this manner, the energy storage capacity of the modular flow battery system can be further increased with substantially no increase in a lateral area occupied by the system.

The invention relates to a flow field plate (1) for a fuel cell, consisting of a synthetic resin (A-B) with fillers that comprise at least graphite (C) and/or carbon black. The flow field plate (1) according to the invention is characterized in that a polyurethane resin (PUR) is used as the synthetic resin (A-B).

A redox flow battery system includes an anolyte; a catholyte; a first electrode structure including a first electrode, a second electrode, and a base disposed between the first and second electrodes, the base including a thermoplastic material and conductive elements disposed in the thermoplastic material, wherein at least one of the first electrode or the second electrode is thermally bonded to the base by heating the base to soften the thermoplastic material and pressing the at least one of the first electrode or the second electrode into the thermoplastic material of the base; a first half-cell in which the first electrode is in contact with the anolyte; and a second half-cell in which the second electrode is in contact with the catholyte.

A redox flow battery system includes an anolyte; a catholyte; a first electrode structure including a first electrode, a second electrode, and a base disposed between the first and second electrodes, the base including a thermoplastic material and conductive elements disposed in the thermoplastic material, wherein at least one of the first electrode or the second electrode is thermally bonded to the base by heating the base to soften the thermoplastic material and pressing the at least one of the first electrode or the second electrode into the thermoplastic material of the base; a first half-cell in which the first electrode is in contact with the anolyte; and a second half-cell in which the second electrode is in contact with the catholyte.

Thermoset bulk molding compounds (BMC) useful for making electrically conductive components such as bipolar plates for fuel cells are described. The thermoset bulk molding compounds incorporate graphene nanoplatelets to increase the through-plane electrical conductivity by at least 20% compared to BMCs without the graphene nanoplatelets. Additionally, these compositions have low shrinkage, low density for lightweight parts, and are easily processed. The compositions can be used to prepare a variety of electrically conductive components, including bipolar plates for fuel cells and chemical storage batteries that operate at temperatures of less than 100° C.

Thermoset bulk molding compounds (BMC) useful for making electrically conductive components such as bipolar plates for fuel cells are described. The thermoset bulk molding compounds incorporate graphene nanoplatelets to increase the through-plane electrical conductivity by at least 20% compared to BMCs without the graphene nanoplatelets. Additionally, these compositions have low shrinkage, low density for lightweight parts, and are easily processed. The compositions can be used to prepare a variety of electrically conductive components, including bipolar plates for fuel cells and chemical storage batteries that operate at temperatures of less than 100° C.

A process for depositing a metal-adhesive, hydrophobic and electrically conductive coating based on electrically conductive microparticles and on a polymer matrix P comprising at least one thermoplastic fluoropolymer P1 and a thermosetting resin P2, comprises: in a first container, dissolve the polymer P1 in an organic solvent; in a second container, disperse the electrically conductive microparticles in an organic solvent; add, in the first container, the thermosetting resin P2 in the liquid state; mix the contents of the containers, then deposit the mixture on the substrate; crosslink the resin P2 and remove the solvents, to obtain a first coating; then impregnate the surface of the substrate with an additional resin solution P2 dissolved in a third solvent, which is a solvent of the resin P2 and a non-solvent of the polymer P1; eliminate the third solvent and crosslink while compressing the additional resin P2 in order to obtain the targeted final coating.

A process for depositing a metal-adhesive, hydrophobic and electrically conductive coating based on electrically conductive microparticles and on a polymer matrix P comprising at least one thermoplastic fluoropolymer P1 and a thermosetting resin P2, comprises: in a first container, dissolve the polymer P1 in an organic solvent; in a second container, disperse the electrically conductive microparticles in an organic solvent; add, in the first container, the thermosetting resin P2 in the liquid state; mix the contents of the containers, then deposit the mixture on the substrate; crosslink the resin P2 and remove the solvents, to obtain a first coating; then impregnate the surface of the substrate with an additional resin solution P2 dissolved in a third solvent, which is a solvent of the resin P2 and a non-solvent of the polymer P1; eliminate the third solvent and crosslink while compressing the additional resin P2 in order to obtain the targeted final coating.

A method for producing a separator plate, where thermoplastic polymer material and a powder of electro-conductive filler, ECF is kneaded at a kneading temperature above a glass transition temperature for the thermoplastic polymer material but below a melting temperature for the thermoplastic polymer material in order to provide a malleable but not molten compound and for causing fibrillization in the thermoplastic polymer material prior to hot-compacting the sheet in a press-form to form a separator plate. A production facility for practicing the method is also disclosed.