Integrated ALK rectangular corrugated electrode flow field and preparation method thereof
By integrating the design of the ALK rectangular corrugated electrode flow field, the problems of catalyst shedding and high resistance of the ALK electrolyzer electrode are solved, realizing efficient hydrogen production and high-purity hydrogen production, and reducing energy consumption and cost.
Patent Information
- Application Number
- CN202511771186.5
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-11-28
- Publication Date
- 2026-02-03
AI Technical Summary
Existing ALK electrolyzer electrodes suffer from catalyst shedding, wire breakage and tangling risks, and high resistance issues, resulting in low hydrogen production efficiency, high energy consumption, and decreased gas purity.
The integrated ALK rectangular corrugated electrode flow field is adopted. The microporous rectangular corrugated electrode mesh formed by stamping and expansion is integrated with the electrode plate and sealing ring to eliminate the overlapping points of the woven mesh, reduce the contact resistance, and promote gas permeation through the small hole design.
It improved hydrogen production efficiency, reduced energy consumption, enhanced mechanical properties and gas purity, simplified production processes, reduced material and labor costs, and improved operational stability.
Smart Images
Figure CN121451209A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of electrolytic hydrogen production technology, and in particular to an integrated ALK rectangular corrugated electrode flow field. Background Technology
[0002] The electrodes of the ALK (Alkaline Water Electrolysis) electrolyzer are the core components of alkaline water electrolysis for hydrogen production technology, and their performance directly determines the electrolyzer's hydrogen production efficiency, stability, and lifespan. In a complete electrolyzer, the electrodes (anode and cathode) work together with the diaphragm, electrode plates, etc. The electrolyzer consists of multiple chambers, each containing an electrode plate (one side as the anode, the other as the cathode) and a diaphragm. The electrode plate is responsible for conducting electrons, while the diaphragm isolates the produced hydrogen and oxygen. Please refer to [reference needed]. Figure 1 Currently, the electrodes of the ALK electrolytic cell use woven nickel mesh as a carrier. The woven nickel mesh is composed of 40-mesh nickel wires with a diameter of 0.19mm, which are interwoven and coated with Raney nickel.
[0003] It has the following shortcomings: 1. Catalyst detachment due to fretting friction. In the electrolysis chamber, the flow of alkaline solution and the precipitation of bubbles can cause fretting of the carrier. High-frequency friction between the filaments due to the interlaced structure causes the Raney nickel catalyst particles sprayed on the surface to detach. This reduces the reaction sites, and the detached catalyst directly exposes the nickel wire substrate, reducing the effective catalytic area and decreasing the efficiency of the hydrogen-oxygen evolution reaction. The reduced reaction activity requires higher overvoltage compensation, increasing the power consumption per unit of hydrogen production, and thus increasing energy consumption. 2. Risk of membrane penetration due to broken wires and knots. Wire breakage cannot be completely avoided during the production of the electrode carrier (braided nickel mesh). Once a wire breaks, it needs to be knotted, and two sharp points will appear at the knot, posing a risk of membrane penetration. The sharp points piercing the membrane cause hydrogen and oxygen gas crosstalk, reducing gas purity and affecting subsequent applications. Local short circuits may also cause hot spots, accelerating membrane aging. 3. High resistance problem of the braiding process. The braided nickel mesh has high resistance due to the interfacial resistance at the contact points of the wires. Summary of the Invention
[0004] The purpose of this invention is to address the shortcomings of existing technologies by proposing an integrated ALK rectangular corrugated electrode flow field.
[0005] To achieve the above objectives, the present invention adopts the following technical solution: The integrated ALK rectangular corrugated electrode flow field includes an electrode plate, a sealing ring, a rectangular corrugated electrode mesh, and a diaphragm, wherein the rectangular corrugated electrode mesh is formed by stamping and expansion.
[0006] Preferably, the electrode plate includes a first electrode plate and a second electrode plate, the sealing ring includes a first sealing ring and a second sealing ring, and the rectangular corrugated electrode mesh includes a first rectangular corrugated nickel electrode mesh and a second rectangular corrugated nickel electrode mesh, wherein the first electrode plate, the first sealing ring, the first rectangular corrugated nickel electrode mesh, the diaphragm, the second rectangular corrugated nickel electrode mesh, the second sealing ring, and the second electrode plate are arranged in sequence.
[0007] Furthermore, the present invention also discloses a method for preparing the integrated ALK rectangular corrugated electrode flow field, comprising the following steps: S1. Microporous rectangular corrugated electrode mesh is prepared by stamping expansion method. High-purity nickel foil with a thickness of 0.1-0.3mm is selected. After pretreatment, it is sheared and stretched by a mesh forming equipment to form a nickel mesh, and then the rectangular corrugated electrode structure is processed.
[0008] S2. Electrode flow channel processing: flow channel grooves and rectangular corrugated electrode mesh mounting holes are simultaneously punched out on the electrode plate to form the electrode plate.
[0009] S3. Place the sealing ring at the edge of the contact surface between the electrode plate and the rectangular corrugated electrode mesh, and fix it using the groove of the electrode plate and the elasticity of the sealing ring itself.
[0010] S4. Align and stack the first electrode plate, the first sealing ring, the first rectangular corrugated nickel electrode mesh, the diaphragm, the second rectangular corrugated nickel electrode mesh, the second sealing ring, and the second electrode plate, and connect and fix them to form the integrated ALK rectangular corrugated electrode flow field.
[0011] Preferably, in step S1, the mesh forming and hole enlargement speed is ≤60 times / minute, and the die gap is 8%-10% of the material thickness.
[0012] Preferably, in step S1, the rectangular corrugated electrode mesh is annealed after meshing and hole enlargement, and then kept at 300°C for 30 minutes.
[0013] Preferably, the surface of the formed rectangular corrugated electrode mesh is activated by immersion in a 10% nitric acid solution.
[0014] The beneficial effects of this invention are: The integrated ALK rectangular corrugated electrode flow field developed in this application integrates the flow field and electrode into a single unit. The carrier is a single sheet of microporous rectangular corrugated electrode mesh formed by stamping and expansion, eliminating the overlapping points of traditional woven rectangular corrugated electrode meshes, significantly reducing contact resistance, and achieving integrated molding of the electrode plate, rectangular corrugated electrode mesh, and sealing ring, thus improving structural stability. The electrode-diaphragm contact surface adopts a small-pore design, which can promote the rapid penetration of reactive gas to the back side and reduce bubble retention. The microporous structure can enhance the flow of alkaline solution, reduce local concentration polarization, effectively suppress the risk of electrochemical corrosion, and improve mechanical properties. The overall weight is reduced by 20%-30%, reducing the risk of sealing failure caused by the deformation of the tank due to its own weight. Furthermore, the preparation method eliminates the need for a woven rectangular corrugated electrode mesh carrier, reducing material and production costs, simplifying assembly steps, eliminating separate welding and riveting processes, and reducing labor costs. It also has higher electrical density, good operational stability, and produces high-purity hydrogen. Attached Figure Description
[0015] Figure 1 The electrode used in the existing ALK electrolytic cell; Figure 2 This is a schematic diagram of the integrated ALK rectangular corrugated electrode flow field proposed in this invention; Figure 3 This is a schematic diagram of the rhomboid support mesh structure formed by the flow field of the integrated ALK rectangular corrugated electrode proposed in this invention. Figure 4 for Figure 3 A magnified view of a portion of the image; Figure 5 This is a schematic diagram of the elastic support structure formed by the flow field of the integrated ALK rectangular corrugated electrode proposed in this invention.
[0016] In the figure: 2 First electrode plate, 3 First sealing ring, 4 First rectangular corrugated nickel electrode mesh, 5 Diaphragm, 6 Second rectangular corrugated nickel electrode mesh, 7 Second sealing ring, 8 Second electrode plate. Detailed Implementation
[0017] Please refer to Figures 1-5An integrated ALK rectangular corrugated electrode flow field includes an electrode plate, a sealing ring, a rectangular corrugated electrode mesh, and a diaphragm 5. The rectangular corrugated electrode mesh is formed by stamping and expansion. The electrode plate includes a first electrode plate 2 and a second electrode plate 8. The sealing ring includes a first sealing ring 3 and a second sealing ring 7. The rectangular corrugated electrode mesh includes a first rectangular corrugated nickel electrode mesh 4 and a second rectangular corrugated nickel electrode mesh 6. The first electrode plate 2, the first sealing ring 3, the first rectangular corrugated nickel electrode mesh 4, the diaphragm 5, the second rectangular corrugated nickel electrode mesh 6, the second sealing ring 7, and the second electrode plate 8 are arranged sequentially. The rectangular corrugated electrode mesh has a wave structure, which provides a flatter area. The rectangular corrugated electrode mesh and the diaphragm 5 are coated with Raney nickel to achieve an integrated structure and superior performance.
[0018] Please refer to Figure 3-4 In one embodiment, a diamond-shaped support mesh structure is formed.
[0019] Please refer to Figure 5 In one embodiment, an elastic support structure is formed.
[0020] This application also provides a method for preparing the flow field of the integrated ALK rectangular corrugated electrode, including the following steps: S1. Prepare a microporous rectangular corrugated electrode mesh. Select a high-purity nickel foil with a thickness of 0.1-0.3 mm. After pretreatment, cut and stretch it using a mesh-making equipment to form a nickel mesh, and then process it into a rectangular corrugated electrode structure.
[0021] In this step, a rectangular corrugated electrode mesh is formed. The selected high-purity nickel foil has a purity greater than 99.6% and undergoes degreasing and cleaning to remove surface oil and ensure the quality of subsequent stamping. Stamping holes, such as round holes or diamond-shaped holes, are marked on the nickel foil using photolithography or laser engraving. The mesh enlargement speed is ≤60 times / minute. Then, annealing is performed, holding at 300℃ for 30 minutes to eliminate internal stress and restore the material's ductility. Finally, the formed rectangular corrugated electrode mesh undergoes surface activation treatment, immersing in a 10% nitric acid solution for 5-10 seconds to increase surface roughness and improve catalyst adhesion. This is followed by plasma cleaning to remove residual oxides and ensure subsequent bonding strength.
[0022] S2. Electrode flow channel processing: flow channel grooves and rectangular corrugated electrode mesh mounting holes are simultaneously punched out on the electrode plate to form the electrode plate.
[0023] In this step, the electrode plate is formed. The depth of the flow channel groove is 0.5-1mm, which is set according to the design requirements. In this application, the depth of the flow channel groove is 0.8mm, and a progressive die is used to achieve continuous processing.
[0024] S3. Place the sealing ring at the edge of the contact surface between the electrode plate and the rectangular corrugated electrode mesh, and fix it using the groove of the electrode plate and the elasticity of the sealing ring itself.
[0025] In this step, the sealing ring is made of fluororubber (FKM) or silicone and is pre-formed into a ring or segmented structure through injection molding.
[0026] S4. Align and stack the first electrode plate 2, the first sealing ring 3, the first rectangular corrugated nickel electrode mesh 4, the diaphragm 5, the second rectangular corrugated nickel electrode mesh 6, the second sealing ring 7, and the second electrode plate 8, and connect and fix them to form the integrated ALK rectangular corrugated electrode flow field.
[0027] In this step, the rectangular corrugated electrode mesh is stacked with the electrode plate and then connected and fixed.
[0028] The integrated ALK rectangular corrugated electrode flow field developed in this application integrates the flow field and electrode into a single unit. The carrier is a single sheet of microporous rectangular corrugated electrode mesh formed by stamping and expansion, eliminating the overlapping points of traditional woven rectangular corrugated electrode meshes, significantly reducing contact resistance. The integrated molding of the electrode plate, rectangular corrugated electrode mesh, and sealing ring improves structural stability. The electrode-diaphragm contact surface adopts a small-pore design, which can promote the rapid permeation of reactive gas to the back side and reduce bubble retention. The microporous structure can enhance the flow of alkaline solution, reduce local concentration polarization, effectively suppress the risk of electrochemical corrosion, and improve mechanical properties. The overall weight is reduced by 20%-30%, reducing the risk of sealing failure caused by the deformation of the tank due to its own weight. Furthermore, the preparation method eliminates the need for a woven rectangular corrugated electrode mesh carrier, reducing material and production costs, simplifying assembly steps, eliminating separate welding and riveting processes, and reducing labor costs. It also has higher electrical density, good operational stability, and produces high-purity hydrogen.
Claims
1. An integrated ALK rectangular corrugated electrode flow field, characterized in that, It includes an electrode plate, a sealing ring, a rectangular corrugated electrode mesh, and a diaphragm (5), wherein the rectangular corrugated electrode mesh is formed by stamping and expansion.
2. The integrated ALK rectangular corrugated electrode flow field according to claim 1, characterized in that, The electrode plate includes a first electrode plate (2) and a second electrode plate (8), the sealing ring includes a first sealing ring (3) and a second sealing ring (7), and the rectangular corrugated electrode mesh includes a first rectangular corrugated electrode nickel mesh (4) and a second rectangular corrugated electrode nickel mesh (6). The first electrode plate (2), the first sealing ring (3), the first rectangular corrugated electrode nickel mesh (4), the diaphragm (5), the second rectangular corrugated electrode nickel mesh (6), the second sealing ring (7), and the second electrode plate (8) are arranged in sequence.
3. The method for preparing the integrated ALK rectangular corrugated electrode flow field according to claim 2, characterized in that, Includes the following steps: S1. Fabrication of a microporous rectangular corrugated electrode mesh: High-purity nickel foil with a thickness of 0.1-0.3 mm is selected. After pretreatment, it is sheared and stretched using a mesh-making machine to form a nickel mesh, which is then processed into a rectangular corrugated electrode structure. S2. Electrode plate flow channel processing: Simultaneously punching flow channel grooves and rectangular corrugated electrode mesh mounting holes on the electrode plate to form the electrode plate. S3. Place the sealing ring at the edge of the contact surface between the electrode plate and the rectangular corrugated electrode mesh, and fix it in place using the groove of the electrode plate and the elasticity of the sealing ring itself. S4. Align and stack the first electrode plate, the first sealing ring, the first rectangular corrugated nickel electrode mesh, the diaphragm, the second rectangular corrugated nickel electrode mesh, the second sealing ring, and the second electrode plate, and connect and fix them to form the integrated ALK rectangular corrugated electrode flow field.
4. The method for preparing the integrated ALK rectangular corrugated electrode flow field according to claim 3, characterized in that, In step S1, the mesh enlargement speed is ≤60 times / minute.
5. The method for preparing the integrated ALK rectangular corrugated electrode flow field according to claim 3, characterized in that, In step S1, the rectangular corrugated electrode mesh is annealed after being enlarged and meshed, and then kept at 300°C for 30 minutes.
6. The integrated ALK rectangular corrugated electrode flow field according to claim 3, characterized in that, In step S1, the surface of the formed rectangular corrugated electrode mesh is activated by soaking it in a 10% nitric acid solution.