Automotive Experiences

Articles

Activated Carbon as a Functional and Sustainable Filler in Composite Bipolar Plates For Fuel Cell Applications

Iswandi , Suherman , Tino Hermanto , Yopan Rahmad Aldori , Muhammad Idris , Abu Bakar Sulong

Published
May 14, 2026

Vol. 9 No. 1 (2026)
Pages 257-270

DOI

Open Access
Share

Abstract

Bipolar plate is a key component that determines a fuel cell's performance and service life. Carbon-based polymer composite materials were developed as lightweight, easy-to-process alternatives to metal. The use of carbon-based fillers in polymer composites has grown rapidly as an alternative to bipolar plate materials in fuel cell applications, especially to meet performance targets set by the U.S. Department of Energy (DOE). DOE requires high electrical conductivity (≥100 S/cm in the in-plane direction and ≥10 S/cm in the through-plane direction), low density, adequate mechanical strength, and good corrosion resistance and chemical stability. Recent studies have shown that the addition of carbon fillers, such as graphite, carbon black, graphene, and activated carbon (AC), can increase electrical conductivity by forming conductive percolation networks in polymer matrices. This study evaluates the potential of AC from household waste in the form of coconut shells as fillers in polypropylene (PP) composites for bipolar plate applications. AC is synthesized through carbonization and activation processes, then mixed into a PP matrix with PP/AC compositions of 100/0, 90/10, 80/20, and 70/30 percent by weight. The focus of the study is the effect of composition variation on density and bending strength. The test results show that increasing the AC fraction tends to decrease the composite density. The maximum density was obtained at a 90/10 (by weight) PP/AC composition of 0.9 g/cm³, indicating more effective filling of the pore matrix by AC particles. On the other hand, bending strength shows a downward trend. The maximum flexural strength is achieved at an AC composition of 34.58 MPa at 10% weight, indicating optimal dispersion and stress transfer between the matrix and the filler. The addition of AC above the composition causes a decrease in bending strength due to potential particle agglomeration, cavities, and the limited mobility of polymer chains. Electrical conductivity tends to increase with the addition of AC due to the formation of a network of electrical currents between carbon particles within cavities, reaching a maximum of 5 S/cm at 30% by weight of AC. The electrical conductivity obtained showed better improvement than several research results on polymeric materials using the hot-press method, with a value of 1.7 S/cm, using graphite filler materials up to 60% by weight. These findings confirm that AC from coconut shells has the potential to serve as a sustainable filler for fuel cell bipolar plates, with an optimal composition that balances density and mechanical properties.

Keywords

Polypropylene; Activated carbon; Density; Flexural strength; Electrical conductivity

References

  1. [1] R. Dungani, S. S. Munawar, T. Karliati, J. Malik, and P. Aditiawati, “Study of characterization of activated carbon from coconut shells on various particle scales as filler agent in composite materials,” Journal of the Korean Wood Science and Technology, vol. 50, no. 4, pp. 256–271, 2022, doi: 10.5658/wood.2022.50.4.256.
  2. [2] S. R. Anggita and A. Y. P. Prahesti, “Effect of Carbonization Temperature on Pore Formation and Adsorption Ability of Coconut Shell Activated Carbon with KOH Activator,” Jurnal Fisika dan Aplikasinya, vol. 21, no. 3, pp. 83–86, 2025, doi: 10.12962%2Fj24604682.v21i3.21624.
  3. [3] Y. Yasdi, D. Ussarvi, R. Rinaldi, F. Juita, and S. E. Cahyani, “Coconut shell-based activated carbon preparation and its adsorption efficacy in reducing BOD from The Real Wastewater from Kitchen Restaurant (RWKR): Characteristics, Sorption Capacity, and Isotherm Model,” Jurnal Presipitasi: Media Komunikasi dan Pengembangan Teknik Lingkungan; Vol 18, No 1 (2021): March 2021DO - 10.14710/presipitasi.v18i1.116-130, Mar. 2021, doi: 10.14710/presipitasi.v18i1.116-130.
  4. [4] Y. D. Herlambang et al., “Trends, Advances, and Future Directions in Fuel Cell Electric Vehicle Performance: A Bibliometric Analysis Using the PAGER Framework,” Automotive Experiences, vol. 8, no. 1, pp. 72–97, Apr. 2025, doi: 10.31603/ae.13111.
  5. [5] Y. D. Herlambang et al., “Application of a PEM Fuel Cell Engine as a Small-Scale Power Generator for Small Cars with Different Fuel Concentrations,” Automotive Experiences, vol. 6, no. 2, pp. 273–289, Aug. 2023, doi: 10.31603/ae.9225.
  6. [6] H. M. Irshad and S. Shahgaldi, “Comprehensive review of bipolar plates for proton exchange membrane fuel cells with a focus on materials, processing methods and characteristics,” International Journal of Hydrogen Energy, vol. 111, pp. 462–487, Mar. 2025, doi: 10.1016/j.ijhydene.2025.02.300.
  7. [7] A. Gomez-Sanchez, V. A. Franco-Luján, H. M. Alfaro-López, L. Hernández-Sánchez, H. Cruz-Martínez, and D. I. Medina, “Carbon Material-Reinforced Polymer Composites for Bipolar Plates in Polymer Electrolyte Membrane Fuel Cells,” Polymers, vol. 16, no. 5, p. 671, Mar. 2024, doi: 10.3390/polym16050671.
  8. [8] I. Iswandi and D. Setyanto, “Tensile Strength Analysis of Polyethene Terephthalate Polymer Composites Filled with Activated Carbon for Fuel Cell Applications,” IRA Jurnal Teknik Mesin dan Aplikasinya (IRAJTMA), vol. 4, no. 3 SE-Scientific Article, pp. 289–296, Dec. 2025, doi: 10.56862/irajtma.v4i3.319.
  9. [9] M. Tariq, Utkarsh, N. A. Syed, A. H. Behravesh, R. Pop-Iliev, and G. Rizvi, “Optimization of Filler Compositions of Electrically Conductive Polypropylene Composites for the Manufacturing of Bipolar Plates,” Polymers, vol. 15, no. 14, p. 3076, 2023, doi: 10.3390/polym15143076.
  10. [10] L. Messing et al., “Carbon Bipolar Plates in PEM Water Electrolysis: Bust or Must?,” Advanced Energy Materials, vol. 14, Jul. 2024, doi: 10.1002/aenm.202402308.
  11. [11] H. Zarmawan, T. Hermanto, and I. Hermawan, “Analysis of Bending Strength of Composite Materials in Bipolar Plates for Fuel Cell Technology,” Journal of Electrical and System Control Engineering, vol. 8, no. 2, 2025, doi: 10.31289/jesce.v6i2.14227.
  12. [12] S. Gopinath, P. Muthiah, R. Vasanth, and J. Nihasdeen, “Optimization and validation of process parameters on compression molded activated charcoal - Epoxy composites for fuel cell bipolar plates,” AIP Conference Proceedings, vol. 2270, no. 1, p. 40012, Nov. 2020, doi: 10.1063/5.0019853.
  13. [13] Y. Khalil, N. Hopkinson, A. J. Kowalski, and J. P. A. Fairclough, “Investigating the Feasibility of Processing Activated Carbon/UHMWPE Polymer Composite Using Laser Powder Bed Fusion,” Polymers, vol. 14, no. 16, p. 3320, Aug. 2022, doi: 10.3390/polym14163320.
  14. [14] M. Hala, J. Mališ, M. Paidar, and K. Bouzek, “Characterization of Commercial Polymer–Carbon Composite Bipolar Plates Used in PEM Fuel Cells,” Membranes, vol. 12, no. 11, p. 1050, Oct. 2022, doi: 10.3390/membranes12111050.
  15. [15] J. H. Lee, Y. K. Jang, C. E. Hong, N. H. Kim, P. Li, and H. K. Lee, “Effect of carbon fillers on properties of polymer composite bipolar plates of fuel cells,” Journal of Power Sources, vol. 193, no. 2, pp. 523–529, Sep. 2009, doi: 10.1016/j.jpowsour.2009.04.029.
  16. [16] N. Ul Hassan, B. Tunaboylu, and A. M. Soydan, “A Competitive Design and Material Consideration for Fabrication of Polymer Electrolyte Membrane Fuel Cell Bipolar Plates,” Designs, vol. 3, no. 1, p. 13, Feb. 2019, doi: 10.3390/designs3010013.
  17. [17] Y.-J. Yim and B.-J. Kim, “Preparation and Characterization of Activated Carbon/Polymer Composites: A Review,” Polymers, vol. 15, no. 16, p. 3472, Aug. 2023, doi: 10.3390/polym15163472.
  18. [18] J. A. King, B. A. Johnson, M. D. Via, and C. J. Ciarkowski, “Electrical conductivity of carbon‐filled polypropylene‐based resins,” Journal of Applied Polymer Science, vol. 112, no. 1, pp. 425–433, Apr. 2009, doi: 10.1002/app.29422.
  19. [19] N. A. M. Radzuan, A. B. Sulong, T. Husaini, E. H. Majlan, M. I. Rosli, and M. F. Aman, “Fabrication of multi-filler MCF/MWCNT/SG-based bipolar plates,” Ceramics International, vol. 45, no. 6, pp. 7413–7418, Apr. 2019, doi: 10.1016/j.ceramint.2019.01.028.
  20. [20] A. B. S. Iswandi and J. Sahari, “Effect Of Graphite/Polipropilene On The Electrical Conductivity Of Manufactured Bipolar Plate,” Malaysian Journal of Analytical Science, vol. 23, no. 2, pp. 238–245, 2019, doi: 10.17576/mjas-2019-2302-19.
  21. [21] A. S. Stepashkina, E. S. Tsobkallo, and A. N. Alyoshin, “Electrical conductivity modeling and research of polypropylene composites filled with carbon black,” Journal of Physics: Conference Series, vol. 572, no. 1, p. 12032, 2014, doi: 10.1088/1742-6596/572/1/012032.
  22. [22] N. Saadat, S. Jaffer, J. Tjong, K. Oksman, and M. Sain, “Enhancing performance of advanced fuel cell design with functional energy materials and process,” Journal of Materials Research and Technology, vol. 26, pp. 1723–1735, Sep. 2023, doi: 10.1016/j.jmrt.2023.07.272.
  23. [23] C. Li et al., “Preparation of polypropylene-based thermally conductive composites via multiple injection compression molding method,” Composites Communications, vol. 35, p. 101331, Nov. 2022, doi: 10.1016/j.coco.2022.101331.
  24. [24] T. Hickmann and O. Zielinski, “Bipolar Plates: Different Materials and Processing Methods for Their Usage in Fuel Cells,” E3S Web of Conferences, vol. 160, p. 01002, Mar. 2020, doi: 10.1051/e3sconf/202016001002.
  25. [25] ASTM, “ASTM D792-20: Standard Test Methods for Density and Specific Gravity (Relative Density) of Plastics by Displacement,” West Conshohocken, PA, USA, 2000.
  26. [26] L. Priya Muthe, K. Pickering, and C. Gauss, “Polylactide Composites Reinforced with Pre-Impregnated Natural Fibre and Continuous Cellulose Yarns for 3D Printing Applications,” Materials, vol. 17, no. 22, p. 5554, 2024, doi: 10.3390/ma17225554.
  27. [27] Iswandi, J. Sahari, A. B. Sulong, and Teuku Husaini, “Critical powder loading and rheological properties of polypropylene/graphite composite feedstock for bipolar plate application,” Malaysian Journal of Analytical Sciences, vol. 20, no. 3, pp. 687–696, 2016, doi: 10.17576/mjas-2016-2003-30.
  28. [28] H. P. S. Abdul Khalil, M. Jawaid, P. Firoozian, O. Y. Alothman, M. T. Paridah, and E. S. Zainudin, “Flexural properties of activated carbon filled epoxy nanocomposites,” Malaysian Journal of Analytical Sciences, vol. 18, no. 2, pp. 391–397, 2014.
  29. [29] A. Alabadi, S. Razzaque, Y. Yang, S. Chen, and B. Tan, “Highly porous activated carbon materials from carbonized biomass with high CO2 capturing capacity,” Chemical Engineering Journal, vol. 281, pp. 606–612, 2015, doi: 10.1016/j.cej.2015.06.032.
  30. [30] Uchechi C Mark, Innocent C Madufor, Henry C Obasi, and Udochukwu Mark, “Influence of filler loading on the mechanical and morphological properties of carbonized coconut shell particles reinforced polypropylene composites,” Journal of Composite Materials, vol. 54, no. 3, pp. 397–407, Feb. 2020, doi: 10.1177/0021998319856070.
  31. [31] J. Kawalerczyk, D. Dukarska, P. Antov, K. Stuper-Szablewska, D. Dziurka, and R. Mirski, “Activated Carbon from Coconut Shells as a Modifier of Urea–Formaldehyde Resin in Particleboard Production,” Applied Sciences, vol. 14, no. 13, p. 5627, Jun. 2024, doi: 10.3390/app14135627.
  32. [32] Z. Salleh, M. M. Islam, M. Y. M. Yusop, and M. A. M. M. Idrus, “Mechanical Properties of Activated Carbon (AC) Coconut Shell Reinforced Polypropylene Composites Encapsulated with Epoxy Resin,” APCBEE Procedia, vol. 9, pp. 92–96, 2014, doi: 10.1016/j.apcbee.2014.01.017.
  33. [33] X. Jiang and L. T. Drzal, “Exploring the potential of exfoliated graphene nanoplatelets as the conductive filler in polymeric nanocomposites for bipolar plates,” Journal of Power Sources, vol. 218, pp. 297–306, Nov. 2012, doi: 10.1016/j.jpowsour.2012.07.001.
Article Metrics
49
Views
34
Downloads

SCITE

DIMENSIONS

Publication Information
Published May 14, 2026
Section Articles
Copyright Copyright (c) 2026 Iswandi; Tino Hermanto; Yopan Rahmad Aldori, Muhammad Idris, Suherman Suherman, Abu Bakar Sulong
License Creative Commons License

This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.
Keywords
  • Polypropylene
  • Activated carbon
  • Density
  • Flexural strength
  • Electrical conductivity

Most read articles by the same author(s)