CARBON FIBER COMPOSITE FUEL CELL BIPOLAR PLATE

Composite fuel cell bipolar plates and methods for manufacturing bipolar plates are provided. A method for fabricating a composite fuel cell bipolar plate includes providing a spread-tow woven carbon fiber fabric having an upper layer of fibers and a lower layer of fibers, wherein the fabric has a thickness of less than 200 micrometers (μm); segmenting at least one of the layers of fibers at selected locations to form slits; forming the fabric and resin into a half plate shape to form a plurality of half plates, wherein each half plate comprises a series of lands and walls; and forming the bipolar plate by aligning and bonding respective lands of a first half plate and a second half plate.