An alternative preparation of bipolar plate materials for proton exchange membrane fuel cell was polymer composites prepared with conductive fillers. The study of the morphology, electrical conductivity, physical and mechanical properties of polymer composite prepared in this work showed that synergistic effect of acetylene black and carbon fiber in polymer composites provided higher electrical conductivity than that of the single filler in polymer composites. The polymer composites of acetylene black 20 wt% with carbon fiber 30 wt%, acetylene black 30 wt% with carbon fiber 20 wt% and acetylene black 40 wt% with carbon fiber 10 wt% possess the highest electrical conductivity of 3.3 S/cm. The cost evaluation of polymer composites showed that polymer composites of acetylene black 40 wt% with carbon fiber 10 wt% had the lowest cost. The conductivity of polymer composites can be improved by adding zinc sterate 5 phr and titanium dioxide 3 phr in polymer composites acetylene black 40 wt% with carbon fiber 10 wt%. It provides the best electrical conductivity of 5 S/cm. Zinc sterate and titanium dioxide increased the density and hardness, but decreased the water absorption and flexural strength of polymer composites.
