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Bipolar plates for PEM fuel cells: A review

Article  in  International Journal of Hydrogen Energy · September 2005

DOI: 10.1016/j.ijhydene.2005.04.016

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 International Journal of Hydrogen Energy 30 (2005) 1297 – 1302
www.elsevier.com/locate/ijhydene

Bipolar plates for PEM fuel cells: A review

Allen Hermanna,∗ , Tapas Chaudhuria, b , Priscila Spagnolb
a Department of Physics, University of Colorado, Boulder, CO 80309-0390, USA
b National Renewable Energy Laboratory, Golden, CO 80401, USA

Available online 2 June 2005

Abstract
Bipolar plates (BPs) are a key component of proton exchange membrane (PEM) fuel cells with multifunctional character.
They uniformly distribute fuel gas and air, conduct electrical current from cell to cell, remove heat from the active area, and
prevent leakage of gases and coolant. BPs also significantly contribute to the volume, weight and cost of PEM fuel cell stacks.
Hence, there are vigorous efforts worldwide to find suitable materials for BPs. The materials include non-porous graphite,
coated metallic sheets, polymer composites, etc. This paper reviews various types of materials, in use and proposed, for BPs
and critically examines their physical and chemical properties.
䉷 2005 International Association for Hydrogen Energy. Published by Elsevier Ltd. All rights reserved.

1. Introduction inexpensive, lightweight materials and must be easily (and

Fuel cells are expected to play a major role in the econ-
omy of this century and for the foreseeable future [1]. It
is anticipated that the development and deployment of eco-
nomical and reliable fuel cells would usher in the sustain-
able hydrogen age [2]. The polymer electrolyte membrane
fuel cell (PEMFC) is a cell of choice for future automotive
propulsion applications, in part because of its modestly low
operation temperature (< 100 ◦ C) [3]. The PEMFC system
is an energy system that can convert hydrogen and oxygen
(or air) to electricity with water as the only byproduct, and
hence is also of great interest [4] from an environmental
point of view.
A significant part of the PEMFC fuel cell stack is the
bipolar plates (BPs) [5], which account for about 80% of
total weight and 45% of stack cost [6]. They are designed
to accomplish many functions, such as distribute reactants
uniformly over the active areas, remove heat from the active
areas, carry current from cell to cell and prevent leakage of
reactants and coolant. Furthermore, the plates must be of
inexpensively) manufactured. Efforts are underway to de-
velop BP materials that satisfy these demands. The main
materials studied to date include [7] electro graphite, sheet
metal (coated and uncoated) and graphite polymer compos-
ites.
In a recent review, Mehta and Cooper [7] analyzed the
design and manufacturing of proton exchange membrane
(PEM) fuel cells for vehicular application and also discussed
the engineering aspects of BP materials. Earlier, Borup and
Vanderborgh [5] briefly reviewed different BP materials.
While conducting detailed design analysis of BP for PEM
fuel cells, Cooper [8] also elucidated a number of properties
desirable in a BP material.
Multifaceted characteristics of BP and amalgamation of
different physical and chemical properties have brought to
light a host of new materials. This review provides a current
overview of BP materials and their characteristics.
2. BPs and their material properties

∗ Corresponding author. A typical PEM fuel cell (Fig. 1) essentially consists of an

E-mail address: Allen.hermann@colorado.edu (A. Hermann). anode backing, membrane/electrode assembly (MEA) and

0360-3199/$30.00 䉷 2005 International Association for Hydrogen Energy. Published by Elsevier Ltd. All rights reserved.
doi:10.1016/j.ijhydene.2005.04.016
1298 A. Hermann et al. / International Journal of Hydrogen Energy 30 (2005) 1297 – 1302

Hydrogen
flow field e-
Air and
water out

Bipolar Plate Bipolar Plate

(Anode) (Cathode)

+ -
O2 + 4H + 4e 2H2O
+ -
2H2 4H + 4e

Air (oxygen)
Hydrogen flow field
outlet

Anode Cathode
backing backing

Membrane/
Electrode
Assembly

Fig. 1. Schematic diagram of a polymer electrolyte membrane fuel cell.

cathode backing sandwiched between two BPs (anode and The materials investigated so far can be broadly classified
cathode) [9]. The BPs have the following functions to as:
perform:
1. Non-metal: non-porous graphite/electrographite.
(1) To distribute the fuel and oxidant within the cell. 2. Metals: non-coated and coated.
(2) To facilitate water management within the cell. 3. Composites: polymer–carbon and polymer–metal.
(3) To separate individual cells in the stack.
(4) To carry current away from the cell. The detailed classification of BP materials is shown in
(5) To facilitate heat management. Fig. 2.

Hence, the materials that BPs are made of would have

different physical and chemical properties related to each
3. Non-porous graphite
function as listed in Table 1.
Other important physical properties of BP materials are:
Traditionally, the most commonly used BP material is
• Coefficient of thermal expansion. graphite, both natural as well as synthetic, because it has
• Density. excellent chemical stability to survive the fuel cell environ-
• Hydrophobicity. ment. It also has very low resistivity, resulting in highest
electrochemical power output. However, it is fraught with
For a material to qualify for BP, Borup and Vanderborgh problems of high cost, low mechanical strength and the need
[5] and Mehta and Cooper [7] have suggested the following for machining to form the flow channels [10]. Hence, the
criteria/properties: search is on for better alternatives as described below.

• Electrical conductivity: plate resistance < 0.01
cm2 .

• Thermal conductivity: as high as possible.
• Hydrogen/gas permeability: < 10−4 cm3 /s cm2 .
• Corrosion resistance: corrosion rate < 0.016 mA/cm2 .
• Compressive strength: > 22 lb/in2 .
• Density: < 5 gm/cm2 .
4. Metals
Metals, as sheets, are potential candidates for BP material
since they have good mechanical stability, electrical conduc-
tivity and thermal conductivity and can be easily stamped
 A. Hermann et al. / International Journal of Hydrogen Energy 30 (2005) 1297 – 1302 1299

Table 1
Physical and chemical properties of BP materials

Functions Physical or chemical properties

Distribution and management of fuel and H2 permeability (dry, non-porous plates),

oxidants and residual gases and liquids bubble pressure (wet, porous plates), corrosion resistance
Conduct electrical current Electrical conductivity
Facilitate heat management Thermal conductivity
Separate the individual cells in the stack Compressive strength

Bipolar plates

Non-metal Non-porous graphite

plates Stainless Steel
*Austenitic
*Ferritic
Non-coated

Metals Metal plates

Bases Coatings
Coated *Aluminum Carbon-based
*Titanium *Graphite
*Nickel *Conductive polymer
*Stainless Steel *Diamond-like
carbon
*Self-assembled
monopolymers
Metal-based
*Graphite, *Noble metals
polycarbonate, *Carbides
stainless steel *Nitrides
Metal
based

Composites
Resin Filler
Thermoplastics *Carbon/graphite
*Poly(vinylidene fluoride) *Carbon black
Carbon *Polypropylene *Coke-graphite
based *Polyethylene
Thermosets
*Epoxy resin
*Phenolic resins Fiber
*Furan resin *Carbon/graphite
*Vinyl ester *Cellulose
*Cotton flock

Fig. 2. Classification of materials for BPs used in PEM fuel cells.

to desired shape to accommodate the flow channels. How-
ever, as BPs are exposed to an operating environment with
a pH of 2–3 at temperatures of around 80 ◦ C, metal plates
are prone to corrosion or dissolution. The dissolved metal
ions may lead to poisoning of PEM membrane and hence
lowering of ionic conductivity. Moreover, a corrosion layer
on the surface of a BP increases the electrical resistance and
decreases the output of the cell. In the light of these issues,
two types of metallic plates have been studied, non-coated
and coated with a protective layer. Metals investigated in-
clude aluminum, stainless steel, titanium and nickel.
4.1. Non-coated
Stainless steels (SSs) are the only material in this cat-
egory to have received considerable attention due to their
relatively high strength, high chemical stability, low gas
permeability, wide range of alloy choice, and applicabil-
ity to mass production and low cost [5]. Major concerns
have been extent of corrosion (and its products) and the
contact resistance of the surface passivation film. Can-
didate SSs have been tested and used as BPs by differ-
ent authors [11–13], which showed that corrosion rate
is low and PEM cell output is stable for thousands of
hours.
Recent studies by Wang et al. [14,15] at the National
Renewable Energy Laboratory, Golden (USA) show that
SS is a strong candidate for BP material. They have
found that both austenitic (349TM ) and ferritic (AISI446)
SS with high Cr content can be suitable for BP, al-
though AISI446 requires some improvement in contact
resistance.
1300 A. Hermann et al. / International Journal of Hydrogen Energy 30 (2005) 1297 – 1302

Table 2 product yet due to issues pertaining to corrosion and contact

Coating materials for metallic BPs resistance.
Coatings Base plate
materials
5. Polymer composite plates
Al SS Ti Ni

Conductive polymer [5] NS

Diamond-like carbon [5] NS
Gold [16,17] × any shape and size, which makes them attractive for PEM
Graphite foil [20] × × × fuel stacks. Composite plates can be categorized as metal-
Graphite topcoat [20] × × × ×
Indium tin oxide [21] × Los Alamos National Laboratory has developed a metal-
Lead oxide [21] × based composite BP [22] based on porous graphite, polycar-
Organic monopolymer [5] NS
Silicon carbide [21] × graphite plates is not as time consuming or expensive as
Titanium–aluminum [21] ×
Titanium nitride [21] ×
Oxides [18] ×
Chromium nitride [19] Ni/Cr
NS, not specified.
4.2. Coated
Aluminum, stainless steel, titanium and nickel are con-
sidered as possible alternative materials for BP in PEM fuel
cells. To avoid corrosion, metallic BPs are coated with pro-
tective coating layers. Coatings should be conductive and ad-
here to the base metal without exposing it [5]. Further the co-
efficient of thermal expansion of the base metal and the coat-
ing should be as close as possible to eliminate the formation
of micro-pores and micro-cracks in coatings due to unequal
expansion [16]. Two types of coatings, carbon-based and
metal-based, have been investigated [5,7,16]. Carbon-based
coatings include graphite, conductive polymer, diamond-like
carbon and organic self-assembled monopolymers. Noble
metals, metal nitrides and metal carbides are some of the
metal-based coatings. Table 2 presents different types of BP
coatings investigated.
Recently, there has been keen interest in the use of coated
SS (316L) as BPs [17,18]. Wind et al. [17] have shown that
the performance of BP made from gold-coated SS 316L is
similar to that of graphite. Lee et al. [18] have suggested an
electrochemical surface treatment of SS 316L to deposit a
suitable coating.
Coatings of metallic BP have not been sufficiently viable
due to pinhole defects. To make defect-free coatings, Brady
et al. [19] have recently developed a preferential thermal
nitridation process to form pinhole free CrN/Cr 2 N coating
on a model Ni–Cr alloy, which show promise with excel-
lent corrosion resistance and negligible contact resistance.
However, application of this type of coating on stainless or
any other steel is yet to be demonstrated.
The above reveals that even though there has been much
effort to develop SS (non-coated and coated) bipolar plates,
mostly for vehicular applications, there is no commercial
Polymer composites offer alternative routes to BP mate-
rials. Composites are lightweight and can be molded into
or carbon-based.
bonate plastic and stainless steel. Since producing porous
producing non-porous graphite plates, it can be used while
the impermeability is provided by the stainless steel and
polycarbonate parts. Stainless steel also provides rigidity to
the structure while the graphite resists corrosion. The poly-
carbonate provides chemical resistance and can be molded
to any shape to provide for gaskets and manifolding. The
layered plate appears to be a very good alternative from sta-
bility and cost standpoints.
There has been extensive study on the use of carbon-
based composite bipolar plates in fuel cells. Table 3 presents
some of the notable ones. As shown, carbon composite bipo-
lar plates have been made using thermoplastic [polypropy-
lene, polyethylene, poly(vinylidene fluoride)] or thermoset-
ting resins (phenolics, epoxies and vinyl esters) with fillers
and with or without fiber reinforcement.
Recent literature [33–36] shows some interesting progress
in graphite–polymer composites. Middelman et al. [33] re-
ported the development of conductive composite material
with excellent properties and a process for large-scale pro-
duction of BP. Cho et al. [34] have developed carbon com-
posite BPs whose long-term performances are comparable
with graphite. Injection molding of low-cost BP based on
a thermoplastic and a carbon compound was reported by
Heinzel et al. [35]. Kuan et al. [36] have developed vinyl
ester—graphite composite BPs by a bulk-moulding com-
pound process with properties similar to graphite plates.
Polymer–graphite composite BPs are now available
in the market and sold by companies, such as DuPont,
H2 Economy, ICM Plastics, NedStack, etc. which shows
that this route is maturing.
6. Discussion
Prospective materials for BPs of PEM fuel cells have been
reviewed. From the utilitarian point of view, the benefits and
drawbacks of each type of BP material are summarized in
Table 4.
For graphite/carbon composites, the materials are
reaching a maturity stage, which is evident by the fact that
BPs are now available commercially. However, the electrical
 A. Hermann et al. / International Journal of Hydrogen Energy 30 (2005) 1297 – 1302 1301

Table 3
Different types of carbon composite materials used in BPs

Resin Filler Fiber

Poly(vinylidene fluoride) Carbon/graphite particles

Poly(vinylidene fluoride) Carbon/graphite particles Carbon/graphite fibers
Polypropylene Carbon black, graphite powder
Mixture of epoxy resin and amine hardener Graphite powder
Phenyl-aldehyde resol or novolac Graphite powder Graphite fibers
Phenyl-aldehyde resol or novolac Coke-graphite particles
Reichhold 24-655 phenolic resin Graphite powder Cellulose fibers (not rayon and
cellulose acetate)
Phenol resin or furan resin Graphite powder Cellulose fibers (not rayon
and cellulose acetate)
Phenolic resin Carbon fiber (PAN-based)
Vinyl ester Graphite powder Cotton flock (graphite/carbon,
glass, cotton and polymers)
Vinyl ester [36] Graphite powder

Refs. [23–36].

Table 4
Characteristics of different types of bipolar plates

Graphite (machined) Metal Graphite composites

Benefits
Stability High thermal conductivity Lower contact resistance
Low specific density Recyclable High corrosion resistance
Low contact resistance with electrodes Consistency of product
High corrosion resistance

Drawbacks
Expensive to machine Needs coating Low bulk electrical conductivity
Brittle Membrane poisoning
Thick Formation of insulating surface oxide

conductivities of these composites are still below the target.
For example, Middelman et al. [33] reported about 20 S/cm,
which is below the target of > 100 S/cm [7]. DuPont’s BPs
(T8 series) [37] have a bulk conductivity of 25–33 S/cm.
Recent interest has been on low-cost production of BPs with
consistent and acceptable physical and chemical properties.
The use of metals as BPs is important for the vehicular
industry. Metals offer lower thickness and weight and im-
proved electrical and thermal conductivities. The use of SS
would make it cost effective. However, it is clear from the
investigations that non-coated SS is still having the problem
of a surface-insulating layer. A thin coating of a chemically
stable and electrically conducting film is required before it
can be used as BPs.
There is significant ongoing research on both coated metal
plates and polymer–graphite composites. Even though there
has been significant progress in both the materials, they are
yet to attain the long-term reliability and power densities
achievable by non-porous graphite. Economics, manufac-
turability and long-term reliability will ultimately decide the
fate of the materials.
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