TECHNOLOGYVSPPS Mesh Separators

Why Switch from PPS Mesh to IONZERA

Name: IONZERA Gas Separator Membrane
Brand: IONZERA
Availability: InStock
Rating: 4.8 (12 reviews)

PPS mesh reinforcement adds cost, limits pore uniformity, and creates supply chain dependency. IONZERA eliminates all three problems with a self-supporting nanocomposite structure.

The Problem with PPS Mesh Reinforcement

Polyphenylene sulfide (PPS) mesh fabric is used as a structural reinforcement layer in several commercial AWE separators, most notably Zirfon PERL UTP 500. The mesh provides mechanical support to the ceramic-polymer composite, but it introduces significant drawbacks that become more acute as the hydrogen industry scales.

PPS mesh is a specialty material with limited global suppliers. It adds substantial cost to every square meter of separator produced, and its presence in the membrane cross-section disrupts the uniformity of the pore structure, creating regions of higher and lower ionic resistance.

How IONZERA Achieves Mesh-Free Construction

IONZERA uses a PSU (polysulfone) matrix with TiO₂ nanoparticles and graphene oxide (GO) nanosheets to create a self-supporting membrane without any fabric reinforcement. The key to this approach is the synergistic interaction between the polymer matrix and the nanofillers:

Polysulfone provides inherent mechanical strength and chemical stability in concentrated KOH

TiO₂ nanoparticles act as both hydrophilic fillers and structural reinforcement at the nanoscale

Graphene oxide nanosheets provide additional mechanical strength through their high aspect ratio and strong interfacial bonding with PSU

Result: 2.7 MPa tensile strength at 350–410 μm thickness - stronger than PPS mesh-reinforced separators at 500 μm

Nanocomposite Structure

PSU-TiO₂-GO

Cost and Supply Chain Benefits

Eliminating PPS mesh from the separator construction provides immediate and compounding cost advantages:

Direct material cost savings - PPS mesh fabric is one of the most expensive components in mesh-reinforced separators

Simplified manufacturing - no mesh alignment, tensioning, or lamination steps required

Reduced supply chain risk - no dependency on specialty PPS fabric suppliers

Lower membrane weight - thinner, mesh-free construction reduces shipping and handling costs

Area Resistance

3x LOWER

Thickness

20% THINNER

Performance Advantages of Mesh-Free Design

Beyond cost savings, the absence of PPS mesh directly improves electrochemical performance. Without a mesh disrupting the pore network, IONZERA achieves more uniform pore distribution across the entire membrane area. This translates to more consistent ion transport, lower area resistance (0.09–0.1 Ω·cm² vs 0.30 Ω·cm² for mesh-reinforced Zirfon), and more predictable performance across large-format cells.

No PPS Mesh Cost

Eliminate the most expensive material component in conventional AWE separators

Uniform Pore Structure

No mesh-induced pore disruption - more consistent ion transport across the entire membrane

2.7 MPa Tensile Strength

Stronger than mesh-reinforced alternatives despite 20–30% thinner profile

EXPLORE MORE

ComparisonsIONZERA vs Zirfon (Full Comparison)vsIONZERA: Asbestos-Free Separator Alternative vsIONZERA vs ZrO₂-Based Separators vsCost-Performance Analysis vs Imports vsComposite vs Ceramic-Only Separators

SpecsMesh-FreeMesh-Free Porous Composite Separator 0.09-0.1 Ω·cm²Low Area Resistance Separator for 30wt% KOH PSU-TiO2-GOPSU-TiO₂-GO Nanocomposite Membrane

ApplicationsEnergyIONZERA for Alkaline Water Electrolysis (AWE)ResearchIONZERA for Electrolyser Stack OEM Integration EnergyIONZERA for Green Hydrogen Production

Ready to Start

Ready to Evaluate IONZERA?

Request a sample to test IONZERA in your application. Our engineering team will support you through qualification and integration.

Request Mesh-Free Sample