Composite Materials for Bipolar Plates in Fuel Cell Applications

Composite bipolar plates serve as both structural and conductive elements within proton exchange membrane fuel cells (PEMFCs), directing reactant flow and collecting current between cells. Traditionally manufactured from graphite or metal, these plates face trade-offs between weight, cost, corrosion resistance and manufacturability. Polymer-matrix composites, typically combining a thermoset or thermoplastic resin with conductive fillers such as graphite flakes, carbon fibres, carbon nanotubes or graphene, offer reduced mass, lower production cost and improved corrosion resistance. Key design challenges include achieving sufficient in-plane and through-plane conductivity, minimising interfacial contact resistance, maintaining mechanical integrity under compression and ensuring uniform dispersion of conductive pathways. Recent efforts have focused on hybrid filler systems, in situ growth or deposition of nanofillers on graphite substrates, surface treatments to enhance wettability and adhesion of coatings, and optimisation of processing parameters—such as moulding pressure, impregnation pressure and curing profiles—to preserve continuous graphite networks. Advances in filler morphology, filler–matrix interface engineering and layer-by-layer architectures have begun to meet or exceed United States Department of Energy targets for conductivity and flexural strength while reducing gas permeability and improving long-term durability. The global push towards hydrogen economy and decarbonisation underlines the strategic importance of cost-effective, high-performance composite bipolar plates in stationary and mobile fuel cell applications.

Research from Nature Portfolio

No recent Nature Portfolio content available.

Composite Materials for Bipolar Plates in Fuel Cell Applications publication trend

The graph below shows the total number of articles in composite materials for bipolar plates in fuel cell applications across all publications each year (not limited to Nature Index journals).

Technical terms

Composite bipolar plate: A multilayer structure combining conductive fillers with a polymer matrix to form the current collector and flow field in a fuel cell.

Proton exchange membrane fuel cell (PEMFC): An electrochemical device converting hydrogen and oxygen into water, heat and electricity via a proton-conducting polymer membrane.

Electrical conductivity: A measure of a material’s ability to transport electric charge, critical for efficient current collection in bipolar plates.

Interfacial contact resistance (ICR): The resistance encountered at the interface between the bipolar plate and gas diffusion layer, affecting overall cell performance.

Percolation threshold: The minimum filler concentration at which a continuous conductive network forms within the composite, enabling effective charge transport.

References

1. Current status of research on composite bipolar plates for proton exchange membrane fuel cells (PEMFCs): nanofillers and structure optimization. RSC Advances (2024).
2. Improved Performance of Composite Bipolar Plates for PEMFC Modified by Homogeneously Dispersed Multi-Walled Carbon Nanotube Networks Prepared by In Situ Chemical Deposition. Nanomaterials (2023).
3. Collective Enhancements on Thermal-Electrical and Mechanical Properties of Graphite-Based Composite Bipolar Plates through the Coupled Manipulations of Molding and Impregnation Pressures. Membranes (2022).