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| High performance plastics Bipolar Plates like PEEK, PEI, PSU, PPS with characteristics like lightweight, corrosion resistance, and ease of processing, are accelerating the replacement of metal materials and driving the transition of water electrolysis hydrogen production (AWE & PEM) towards higher efficiency and lower costs. | |||||||||
In water electrolysis hydrogen production technology, the electrolyzer is the core equipment, and its performance directly determines the hydrogen production efficiency and cost. Traditional metal bipolar plates (such as carbon steel and stainless steel) have become a key bottleneck limiting the lifespan and energy efficiency of electrolyzers due to issues such as corrosion, heavy weight, and complex processing. Against this backdrop, high-performance engineering plastics, represented by polyetherimide (PEI), polysulfone (PSU), polyphenylene sulfide (PPS), and polyetheretherketone (PEEK), are accelerating the replacement of metals. With characteristics such as lightweight, corrosion resistance, and ease of processing, these plastics are driving the transition of hydrogen energy equipment towards higher efficiency and lower costs.
https://www.linkedin.com/pulse/hydrogen-energy-bipolar-plate-material-innovation-peipsuppspeek-hbh3c/?published=t
PEEK Bipolar Plates for Hydrogen Electrolyzer : The "All-Rounder" with High Temperature and Corrosion Resistance
PEEK, a benchmark for specialty engineering plastics, maintains stable performance at temperatures up to 260°C and is resistant to strong acids and alkalis. With a density only 1/3 that of aluminum and a tensile strength of 70% that of steel, PEEK can be combined with carbon fiber (CF/PEEK) to significantly improve its rigidity and impact resistance. This has been validated in the lightweighting of Tesla’s humanoid robot joints. In the hydrogen energy field, PEEK can be used to manufacture bipolar plates and sealing components, avoiding electrochemical corrosion of metals while reducing the overall weight of the electrolyzer by 30%-50%. Domestic companies such as Zhongyan Co. have already achieved large-scale production, reducing costs by 40% compared to imported products, laying the foundation for broader application.
PSU Bipolar Plates for Hydrogen Electrolyzer : The "Corrosion Resistance Pioneer" in Alkaline Environments
Polysulfone (PSU) has outstanding alkali resistance and dimensional stability, with a long-term operating temperature of up to 180°C, making it suitable for the harsh conditions of alkaline electrolyzers. Its insulating properties prevent short-circuiting of the bipolar plates, eliminating the need for additional nickel plating, which simplifies the production process. Companies like Fluorine Hydrogen Energy have successfully developed PSU-based bipolar plates, reducing weight by 60% compared to traditional carbon steel and improving electrolyzer efficiency by 5%-8% through structural optimization that reduces flow channel resistance.
PPS Bipolar Plates for Hydrogen Electrolyzer : The "Main Force of Lightweighting" with High Cost-Performance
Polyphenylene sulfide (PPS) has a density of only 1.36g/cm³ and a heat distortion temperature exceeding 260°C, offering excellent rigidity and chemical resistance. Compared to PEEK, PPS is 30%-50% more cost-effective and has a high domestic production rate (e.g., New Hope Chemical has a capacity of 22,000 tons/year), making it suitable for large-scale applications. In alkaline electrolyzers, PPS bipolar plates can withstand long-term corrosion from high-concentration KOH solutions. With a papillary structure design, they reduce contact resistance by over 15%, making PPS the material of choice for the mid-to-low-end market.
PEI Bipolar Plates for Hydrogen Electrolyzer : The "Innovative Choice" with High Strength and Functionality
Polyetherimide (PEI) has a glass transition temperature of 215°C and a tensile strength exceeding 100MPa, with excellent flame retardancy and dielectric properties. Through modification, PEI can provide both conductive and insulating functions. In proton exchange membrane (PEM) electrolyzers, PEI-based bipolar plates can integrate flow channel and sealing functions, reducing the number of components by 30% and significantly enhancing system compactness.
Material Transition from Metals to Non-Metals: A Key Path to Performance Improvement and Cost Reduction in Hydrogen Energy Equipment
The shift from metals to non-metals in material choice represents not only a leap in the performance of hydrogen energy equipment but also a crucial pathway for industrial cost reduction and efficiency enhancement. With the technological breakthroughs and process maturation of materials such as PEI, PSU, PPS, and PEEK, electrolyzers are entering a new stage of being lighter, more efficient, and more economical. This is injecting core momentum into the global hydrogen energy market, supporting grid parity and energy transition efforts.
In water electrolysis hydrogen production technology, the electrolyzer is the core equipment, and its performance directly determines the hydrogen production efficiency and cost. Traditional metal bipolar plates (such as carbon steel and stainless steel) have become a key bottleneck limiting the lifespan and energy efficiency of electrolyzers due to issues such as corrosion, heavy weight, and complex processing. Against this backdrop, high-performance engineering plastics, represented by polyetherimide (PEI), polysulfone (PSU), polyphenylene sulfide (PPS), and polyetheretherketone (PEEK), are accelerating the replacement of metals. With characteristics such as lightweight, corrosion resistance, and ease of processing, these plastics are driving the transition of hydrogen energy equipment towards higher efficiency and lower costs.
https://www.linkedin.com/pulse/hydrogen-energy-bipolar-plate-material-innovation-peipsuppspeek-hbh3c/?published=t
PEEK Bipolar Plates for Hydrogen Electrolyzer : The "All-Rounder" with High Temperature and Corrosion Resistance
PEEK, a benchmark for specialty engineering plastics, maintains stable performance at temperatures up to 260°C and is resistant to strong acids and alkalis. With a density only 1/3 that of aluminum and a tensile strength of 70% that of steel, PEEK can be combined with carbon fiber (CF/PEEK) to significantly improve its rigidity and impact resistance. This has been validated in the lightweighting of Tesla’s humanoid robot joints. In the hydrogen energy field, PEEK can be used to manufacture bipolar plates and sealing components, avoiding electrochemical corrosion of metals while reducing the overall weight of the electrolyzer by 30%-50%. Domestic companies such as Zhongyan Co. have already achieved large-scale production, reducing costs by 40% compared to imported products, laying the foundation for broader application.
PSU Bipolar Plates for Hydrogen Electrolyzer : The "Corrosion Resistance Pioneer" in Alkaline Environments
Polysulfone (PSU) has outstanding alkali resistance and dimensional stability, with a long-term operating temperature of up to 180°C, making it suitable for the harsh conditions of alkaline electrolyzers. Its insulating properties prevent short-circuiting of the bipolar plates, eliminating the need for additional nickel plating, which simplifies the production process. Companies like Fluorine Hydrogen Energy have successfully developed PSU-based bipolar plates, reducing weight by 60% compared to traditional carbon steel and improving electrolyzer efficiency by 5%-8% through structural optimization that reduces flow channel resistance.
PPS Bipolar Plates for Hydrogen Electrolyzer : The "Main Force of Lightweighting" with High Cost-Performance
Polyphenylene sulfide (PPS) has a density of only 1.36g/cm³ and a heat distortion temperature exceeding 260°C, offering excellent rigidity and chemical resistance. Compared to PEEK, PPS is 30%-50% more cost-effective and has a high domestic production rate (e.g., New Hope Chemical has a capacity of 22,000 tons/year), making it suitable for large-scale applications. In alkaline electrolyzers, PPS bipolar plates can withstand long-term corrosion from high-concentration KOH solutions. With a papillary structure design, they reduce contact resistance by over 15%, making PPS the material of choice for the mid-to-low-end market.
PEI Bipolar Plates for Hydrogen Electrolyzer : The "Innovative Choice" with High Strength and Functionality
Polyetherimide (PEI) has a glass transition temperature of 215°C and a tensile strength exceeding 100MPa, with excellent flame retardancy and dielectric properties. Through modification, PEI can provide both conductive and insulating functions. In proton exchange membrane (PEM) electrolyzers, PEI-based bipolar plates can integrate flow channel and sealing functions, reducing the number of components by 30% and significantly enhancing system compactness.
Material Transition from Metals to Non-Metals: A Key Path to Performance Improvement and Cost Reduction in Hydrogen Energy Equipment
The shift from metals to non-metals in material choice represents not only a leap in the performance of hydrogen energy equipment but also a crucial pathway for industrial cost reduction and efficiency enhancement. With the technological breakthroughs and process maturation of materials such as PEI, PSU, PPS, and PEEK, electrolyzers are entering a new stage of being lighter, more efficient, and more economical. This is injecting core momentum into the global hydrogen energy market, supporting grid parity and energy transition efforts.
