GREEN MOBILITY

Fuel Cells Bipolar Plate

Bipolar Plates (BPPs) for fuel cells are at the heart of Hydrogen conversion into electric power. This green technology is now ready at Interplex, based on your customized designs.

A critical factor in today’s advanced fuel cells is high-volume, high-quality production of the multiple Bipolar Plates (BPP) at the heart of the energy generation process in the fuel cell system.

Fabricated from corrosion-resistant SUS316L stainless steel, the Interplex BPPs support an extensive operational lifespan of over 8,000 hours. Their ultra-low contact resistance (< 2mΩ·cm² at 1Ma pressure levels) helps to significantly boost the efficiency levels of the fuel cell stacks they are used in and enables power densities to be raised. Distributing hydrogen and air effectively and reliably, they have thicknesses down to 0.8mm without leakage of gases or coolant.

Interplex is proud to embark on a journey to zero emissions with our valued customers. With our established expertise in producing metal BPPs for top-tier customers, we are well-positioned to deliver the industry’s demands today, and tackle those of tomorrow.

Features & Benefits

High-precision BPPs with Integrated Overmolded Gasket

Only ≤8% variation in the evenness with tight tolerances of flow channel thickness (across their active area)

Improved Fuel Cell System Performance and Lifespan

Supports an extensive operational lifespan of over 8,000 hours

Material: SUS316L Stainless Steel or Similar

Corrosion-resistant materials used

Ultra-low Contact Resistance

< 2mΩ·cm² at 1Ma pressure levels - significantly boost the efficiency levels of the fuel cell stacks; enables power densities to be raised

Vertically Integrated In-house Capabilities

In-house tool design and manufacturing and FEA before design – quick turnaround time to develop prototype samples and build first test stack

Enhanced Thickness, Product Space Estate

Raw material thicknesses as low as 0.8mm with enhanced plate flatness

Supports High-Volume Operations

Scalable technology and rapid ramp-up to high-volume production of millions of BPPs yearly

Reduced Production Lead-Time

Physical Vapor Deposition (PVD) coating of plates is done 20% faster than other suppliers

Types of Applications

Below are the types of application Fuel Cell Bipolar Plates are suited for:

Aerospace

Electric taxing systems for civil aviation aircraft

Automotive

Fuel cell vehicles (FCVs) including cars, trains and buses

Energy

Power generation, Heating systems for buildings

Commercial Transportation

Fuel cell vehicles (FCVs) including cars, trains and buses

Personal Mobility

Motorcycles, Electric Scooters, Bicycles

Industrial

Logistics vehicles including freight trucks, forklifts

Maritime

Vessels

Maritime

Vessels

Industrial

Logistics vehicles including freight trucks, forklifts

Personal Mobility

Motorcycles, Electric Scooters, Bicycles

Anatomy of a Fuel Cell BPP

Specifications

ParameterTypical Value RangeRemarks
Current CollectorsAL1100, C1100, NIckel
Dielectric LayersPlastic Resin:
PPA, PC/ABS, Nylon 6, XAREC, Noryl, Lupoy,
PBT, PA66
Thin Film:
Polyimide, Nomex, Lexan, Mylar,
Epoxy in various thicknesses
Battery Cell HolderC510 phosphor bronze, beryllium copper
Lead FramePPA, PC/ABS, Nylon 6, PA66, PBTService temperature of plastics ≤130°C
Surface Treatment of Current CollectorNickel plating optionFor anti-corrosion and welding purposes
Flammability RatingUL 94 V-0For battery cell holder and dielectric layers
ParameterTypical Value RangeRemarks
Battery Cell TypesCylindrical, prismatic, pouch 
Battery Module Connection TypesNut/bolt, pin/socket, customized configurations possible
Current Collector Sizes (W x L)100 x 100mm – 500 x 900mm
Current Collector Thickness0.254 – 3mm
Cell Terminal Thickness 0.125 – 0.3mm Laser Weld: Terminal thickness <0.3mm
Wire Bond: Various thicknesses possible
Cell Terminal Positional Tolerance:±0.127mm
Dielectric Layer Thickness0.127 – 0.3mm Pressure-sensitive and thermal-activated adhesive
Lead Frame Thickness0.64mm typical    For battery cell holder and dielectric layers
ParameterTypical Value RangeRemarks
Battery Module Voltage12 – 120V
Battery Module Capacity50 – 400Ah
Battery Module Energy0.60 – 48kWh
Module-to-module Connections<400A, off-shelf or customized
Current Density<15A/mm², maintaining <60°C with cooling
Dielectric Strength of Insulation Materials<7.5kV/0.025mm, ASTM D149
Dielectric Continuous Use Temperature<220°C
Voltage Sense Line<2A, 50V Cable, flex circuit, overmolded lead frame.
Temperature Sensing4.7kΩ at 25°C, thermistor placement
Overload Condition<200% for 10s without degradation

Gallery

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