Knitted & Expanded Mesh as Elastic Supports for Alkaline Water Electrolyzers

The alkaline water electrolyzer, as the core unit for green hydrogen production, is constituted by components such as end plates, gaskets, bipolar plates, electrodes, and diaphragms, often integrating dozens to over a hundred electrolysis cells. In traditional designs, bipolar plates often feature either a nipple-based structure or a flat plate with a rigid support mesh. Both constitute a rigid support structure, which can easily cause diaphragm damage. Furthermore, they impede electrolyte flow, giving rise to uneven flow field distribution and limited electrolysis efficiency.

Comparison of two alkaline water electrolyzers

To overcome this bottleneck, an innovative elastic support mesh technology has been introduced. A nickel knitted mesh or expanded metal mesh is incorporated between the electrode and the bipolar plates, ensuring tight contact between the electrodes and the diaphragm. This approach not only effectively protects the diaphragm but also improves electrolyte flow and current distribution, thereby significantly enhancing both electrolysis efficiency and system durability.

Key Advantages:

Ensures tight contact among electrodes, bipolar plates, and diaphragms
Reduces gaps and electrolyte resistance, improving electrolysis efficiency
Provides uniform current distribution, preventing local polarization and reducing energy consumption
Protects the diaphragm from mechanical damage due to hard contact
Optimizes gas-liquid flow and heat transfer processes
This technology can reduce the number of electrolytic cells by 10% – 30%, enhancing overall cost-effectiveness.

The internal structure of alkaline water electrolyzer with elastic support network

Case 1: Nickel Knitted Mesh

Originally used as demister wire mesh, nickel knitted mesh has now been improved and adapted for use as an elastic support in electrolyzers.

Features

Corrugated knitted structure with three-dimensional porous form
Provides elastic cushioning effect
Combines both support and electrical conductivity

Specifications

Width: 10–2400 mm
Wire diameter / corrugation height: 0.15 mm / 6.0 mm; 0.19 mm / 7.5 mm (customizable)
Corrugation depth: 3.5–7 mm
Pattern: Herringbone / twill
Cell voltage reduction: approx. 150 mV

Advantages

Extended diaphragm lifespan
Enhanced gas-liquid flow and improved electrolysis stability

A piece of circular nickel knitted mesh on a black plastic bag

Case 2: Expanded Metal Mesh

Nickel expanded metal mesh (expanded metal mesh) is also an effective support material for flat-plate bipolar electrolyzers.

Features

Formed by stretching nickel plates
High mechanical strength and structural stability
Suitable for flat-plate bipolar electrolyzers

Advantages

Suppresses bubble accumulation and optimizes flow field
Increases electrochemical reaction area and improves current density

A detailed display of nickel expanded metal mesh

The elastic support mesh is an innovative electrode support technology for alkaline water electrolyzers. Utilizing both nickel knitted mesh and nickel expanded metal mesh solutions, it optimizes current distribution, protects the diaphragm, improves the flow field, and reduces the number of electrolytic cells. This leads to significantly higher electrolysis efficiency, extended component lifespan, and lower system costs.

As the hydrogen energy industry develops, the elastic support mesh will play a key role in high-performance alkaline water electrolyzers, providing vital support for achieving carbon peaking and carbon neutrality goals.