Nickel Expanded Mesh for Support Layer in Alkaline Electrolyzers

Nickel expanded mesh for the support layer of alkaline electrolyzers is a key component between the bipolar plate and the electrode. Its core functions include mechanical support, uniform current collection, flow field optimization, and thermal management. It offers advantages of corrosion resistance, high electrical conductivity, efficient mass transfer, easy processing, and controllable cost. It can reduce energy consumption by 3–5% and improve long-term stability.

Core Functions

1. Mechanical SupportProvides rigid support for porous electrodes (e.g., nickel foam, nickel felt) and the membrane, preventing collapse or deformation under high pressure differential, ensuring structural integrity and tight fitting for zero-gap design.

2. Current CollectionActs as a low-resistance current collector to distribute external current uniformly across the electrode surface, reducing contact resistance and Joule heat, and improving energy efficiency.

3. Flow Field and Mass Transfer OptimizationThe 3D porous and mesh structure guides electrolyte flow, accelerates the rapid detachment of H₂/O₂ bubbles, reduces bubble coverage and mass transfer polarization, and lowers cell voltage and energy consumption.

4. Thermal ManagementHigh thermal conductivity quickly dissipates local Joule heat, avoiding hotspots and ensuring stable operation of the electrolyzer at high current densities.

5. Structural ProtectionIsolates the bipolar plate from the electrode, prevents damage to the plate coating, reduces membrane abrasion, and extends component service life.

Key Advantages

1. Excellent Corrosion ResistanceNickel forms a self-repairing passivation oxide layer in concentrated alkaline solutions (30–40% KOH). Annual corrosion rate < 0.02 mm. Suitable for high-temperature and strong alkaline environments, with a service life of more than 8000 hours.

2. High Conductivity & Low Contact ResistanceVolume resistivity ≤ 0.07 μΩ·m. Low contact resistance design reduces ohmic loss and improves electrolysis efficiency.

3. Efficient Mass Transfer & Bubble ManagementPorosity > 60%. Mesh and corrugated structures enhance bubble breakup and detachment, reduce mass transfer polarization, and optimize flow field uniformity.

4. Mechanical Strength & FormabilityTensile strength ≥ 400 MPa. Can be manufactured into rectangular corrugated, double-sided bridge-type structures, etc., balancing support rigidity and elastic conformity, suitable for roll-to-roll mass production.

5. Processing AdvantagesIntegrated stamping/expanding forming reduces assembly errors, suitable for GW-scale production lines, with lower overall cost.

6. Thermal Stability & Thermal ConductivityThermal conductivity > 90 W/(m·K). Maintains structural and conductive stability at high temperatures, delivering outstanding thermal management performance.