Surface coating and texturing on stainless-steel plates to decrease the contact resistance by using screen printing

Stainless steel is an attractive material for use in bipolar plates of polymer-electrolyte-membrane fuel cells, except for its high interfacial contact resistance (ICR). Inexpensive surface treatment is required to decrease the ICR. A carbonaceous conductive composite was coated on stainless-steel plate surfaces by using a screen-printing technique. A grid-like texture of the same material as the coating was also printed on the coated plate surface. The cross section showed that conductive carbon particles were well dispersed in the coating layer, which favors through-plane electrical conductivity. The coated and textured plates exhibited a much lower ICR than that of bare stainless steel. The ICR of textured plates was lower than that of coated plates under lower compaction pressures. A single cell with coated and textured bipolar plates exhibited higher power densities than that of bare stainless-steel bipolar plates.