i think bale, like any other actor, can have chemistry if paired w/ the right co-star, but most of his roles have not required him to rely on his sex appeal. i don't think an actor who didn't have sexual charisma could have played patrick bateman. that character is a sociopath who uses his looks and charisma to his advantage. the thing with bale is that he's gone out of his way to avoid the rom-com path that other guys like gerard butler, eric bana, ryan reynolds, etc. have gone down. bale knows he's a good looking dude, but he doesn't want to be known for that.
when it comes to nolan, however, i totally agree with you. i love the guy's work, but he's one of the most sexless filmmakers to come down the pike in years. and that's why it totally unsurprised me that he cast hathaway. sure, she's pretty, but she's a sexual poodle. IMO, someone like olivia wilde would've been perfect for the part. she has the effortless sexuality and confidence that screams selina kyle, but i can imagine nolan saying, "i dunno, she's a bit too hot, i think."