Editorial Comment

T. CAMPBELL, Managing Editor

Bipolar plates are essential components of proton exchange membrane, solid oxide, molten carbonate, direct methanol and phosphoric acid fuel cells. They are responsible for transporting reactant gases, carrying the current from the membrane electrode assembly to the end plates, managing heat and water, and separating the individual cells.¹ These plates are typically made of carbon, metal or composite. 

Graphite is a common material used; however, because bipolar plates are among the most expensive components of a hydrogen (H₂) fuel cell, companies are working on methods to reduce the costs. For example, Ballard has developed thin, flexible graphite bipolar plates that reduce plate materials while enabling high-power density stacks. The company expects its plate manufacturing processes and the introduction of new lower-cost material suppliers to result in a cost savings of up to 70%. 

Manufacturing bipolar plates requires extreme accuracy and precision. Consequently, Cell Impact has developed a process to develop low-cost, high-quality plates using laser welding to join an anode and cathode plate into the bipolar plate. Lowering the cost of bipolar plates can significantly reduce the cost of widespread adoption of H₂ technologies. The company’s facility in Karlskoga, Sweden, is on track to be one of the largest customized bipolar plate production facilities in the world. 

According to Valuates Reports, the bipolar plates market is projected to have a compound annual growth rate (CAGR) of 11.9% by 2029. In 2022, the market was valued at $397 MM and is expected to reach $880 MM by 2029.² This is likely due to the increased interest in H₂ fuel cell vehicles (e.g., forklifts, cars, ships, trucks). 

Bipolar plates are also used in electrolyzers. Dana Inc. has developed metallic bipolar plates engineered to maximize the performance and accelerate the commercialization of proton exchange membrane electrolyzers. The company plans to commence high-volume production later this year and expects to produce up to 8 MM/yr metallic bipolar plates.H₂T

LITERATURE CITED

¹ T. Aubrey, C. Louis, B. Leonard, J. Jasna, et al., “An overview of bipolar plates in proton exchange membrane fuel cells,” Journal of Renewable and Sustainable Energy, March 2021, online: https://doi.org/10.1063/5.0031447 

² Valuates Reports, “Global bipolar plates market research report 2023,” June 2023, online: https://reports.valuates.com/market-reports/QYRE-Auto-7M11055/global-bipolar-plates-sales