Review On Bipolar Plate Geometric Design and Materials for Proton Exchange Membrane Fuel Cell Applications

Volume: 11 | Issue: 02 | Year 2025 | Subscription
International Journal of I.C. Engines and Gas Turbines
Received Date: 12/05/2025
Acceptance Date: 12/08/2025
Published On: 2025-12-16
First Page: 40
Last Page: 56

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By: Parthiban Siva Gurunathan, Karthikeyan Subramanian, and Venkatesh Kumar Velmurugan.

1-3 EV & Fuel Cell Team Lead, Department of Advanced Engineering, Ashok Leyland, Chennai, India.

Abstract

Abstract

Bipolar plates (BPs) are vital components in proton exchange membrane fuel cells (PEMFCs), performing multiple essential functions that directly influence system efficiency, durability, and overall operational performance. They ensure uniform distribution of reactant gases across the active area, provide electrical conductivity between adjacent cells, assist in effective thermal management by dissipating heat generated during electrochemical reactions, and maintain proper sealing to prevent leakage of gases and coolant. Among these roles, the design of flow-field channels within the bipolar plate is particularly significant, as it governs reactant transport, water management, and pressure drop across the cell, thereby impacting fuel cell efficiency, power output, and long-term stability. Recent research has focused on optimizing channel geometries, such as serpentine, parallel, and interdigitated designs, to enhance reactant distribution, mitigate flooding, and minimize pressure losses, while simultaneously addressing durability and cost challenges. Material selection for bipolar plates plays a decisive role in determining stack weight, volume, corrosion resistance, and manufacturing cost which are critical as PEMFC technology advances toward large-scale commercialization for automotive and stationary applications. Advanced materials including coated stainless steel, graphite composites, and polymer-based alternatives are being explored to achieve an optimal balance between electrical conductivity, mechanical strength, corrosion resistance, and economic viability. Computational modeling and simulation techniques are increasingly employed to predict flow behavior, pressure drop, and thermal gradients, enabling faster design iterations and reducing experimental costs. This paper provides a comprehensive review of these developments, emphasizing the interplay between geometric design, material innovation, and simulation-driven optimization in improving PEMFC performance and reliability. By analyzing current trends, unresolved challenges, and future prospects, the study aims to deliver valuable insights into next-generation bipolar plate technologies. These advancements are pivotal for achieving lightweight, high-performance, and cost-effective fuel cell stacks, thereby supporting global efforts toward sustainable energy solutions and accelerating the adoption of hydrogen-based mobility and power systems.

Keywords: Bipolar plate, Fluid flow design, Reactant distribution, Material selection, Surface Coatings, Fuel Cell Commercialization

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How to cite this article: Parthiban Siva Gurunathan, Karthikeyan Subramanian, and Venkatesh Kumar Velmurugan Review On Bipolar Plate Geometric Design and Materials for Proton Exchange Membrane Fuel Cell Applications. International Journal of I.C. Engines and Gas Turbines. 2025; 11(02): 40-56p.

How to cite this URL: Parthiban Siva Gurunathan, Karthikeyan Subramanian, and Venkatesh Kumar Velmurugan, Review On Bipolar Plate Geometric Design and Materials for Proton Exchange Membrane Fuel Cell Applications. International Journal of I.C. Engines and Gas Turbines. 2025; 11(02): 40-56p. Available from:https://journalspub.com/publication/ijsmfe/article=22012

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