Method of assembling a bipolar electrode having friction welded conductor/connector means and bipolar electrode formed thereby

Claim 2

In a method of assembling a backplate for a bipolar electrolytic cell wherein a conductor/connector having titanium member and a copper member is inserted in said backplate and an anode and cathode are connected to said conductor/connector, the improvement comprising friction welding the titanium member of the conductor/connector to the copper member thereof in the substantial absence of a liquid metal phase.

Claim 3

The method of claim 1 wherein a catholyte-resistant steel member is friction welded to the opposite end of said copper member.

Claim 4

In a method of assembling a backplate for a bipolar electrolytic cell wherein anodes are connected to titanium member of a conductor/connector extending through the backplate and cathodes are connected to a catholyte-resistant steel member of the conductor/connector, the improvement comprising: friction welding the titanium member of the copper member whereby to form a titanium-copper bond; friction welding the catholyte-resistant steel member to the opposite end of said copper member whereby to form a steel-copper bond; inserting the conductor/connector in an opening in said backplate whereby the titanium portion thereof protrudes through the anolyte-facing surface of the backplate.

Claim 5

In a method of assembling a backplate for a bipolar electrolytic cell wherein anodes are connected to titanium member of a conductor/connector extending through the backplate and cathodes are connected to a catholyte-resistant steel member of the conductor/connector, the improvement comprising: friction welding the titanium member of the copper member whereby to form a titanium-copper bond; friction welding the catholyte-resistant steel member to the opposite end of said copper member whereby to form a steel-copper bond; inserting the conductor/connector in an opening in said backplate whereby the titanium portion thereof protrudes through the anolyte-facing surface of the backplate.

Claim 6

In a method of assembling a backplate for a bipolar electrolytic cell wherein anodes are connected to an anolyte-resistant titanium member of a conductor/connector extending through the backplate and cathodes are connected to a catholyte-resistant steel member of the conductor/connector, the improvement comprising: friction welding the titanium member to the copper member whereby to form a copper-titanium bond; friction welding the catholyte-resistant steel member to the opposite end of said copper member whereby to form a steel-copper bond; covering a portion of the length of the copper member of the conductor/connector with a catholyte-resistant steel sheath; friction welding the catholyte-resistant steel sheath to the catholyte-resistant steel member at the end of said copper member whereby a portion of said copper member is clad with the catholyte-resistant steel sheath; inserting the clad copper-titanium conductor into an opening in said backplate whereby the clad portion protrudes through the catholyte-resistant surface of the backplate and the titanium portion thereof protrudes through the anolyte-resistant surface of the backplate; joining a cathode to the catholyte-resistant steel member of said conductor; and joining an anode to the titanium member.

Claim 7

In a method of assembling a backplate for a bipolar electrolytic cell wherein anodes are connected to an anolyte-resistant titanium member of a conductor/connector extending through the backplate and cathodes are connected to a catholyte-resistant steel member of the conductor/connector, the improvement comprising: friction welding the titanium member to the copper member whereby to form a copper-titanium bond; friction welding the catholyte-resistant steel member to the opposite end of said copper member whereby to form a steel-copper bond; covering a portion of the length of the copper member of the conductor/connector with a catholyte-resistant steel sheath; friction welding the catholyte-resistant steel sheath to the catholyte-resistant steel member at the end of said copper member whereby a portion of said copper member is clad with the catholyte-resistant steel sheath; inserting the clad copper-titanium conductor into an opening in said backplate whereby the clad portion protrudes through the catholyte-resistant surface of the backplate and the titanium portion thereof protrudes through the anolyte-resistant surface of the backplate; joining a cathode to the catholyte-resistant steel member of said conductor; and joining an anode to the titanium member.

Claim 8

In a method of assembling a backplate for a bipolar electrolytic cell wherein anodes are connected to an anolyte-resistant titanium member of a conductor/connector extending through the backplate and cathodes are connected to a catholyte-resistant steel member of the conductor/connector, the improvement comprising: providing a relative rotational velocity between the copper member and the titanium member of from about 1,000 to about 5, 000 revolutions per minute while maintaining an impressed pressure of from about 5,000 to about 15,000 pounds per square inch therebetween, whereby to friction weld said titanium and copper members; friction welding the catholyte-resistant steel member to the opposite end of said copper member; inserting the conductor/connector through an opening in said backplate whereby the titanium portion thereof protrudes through the anolyte-facing surface of the backplate.

Claim 9

In a method of assembling a backplate for a bipolar electrolytic cell wherein anodes are connected to an anolyte-resistant titanium member of a conductor/connector extending through the backplate and cathodes are connected to a catholyte-resistant steel member of the conductor/connector, the improvement comprising: providing a relative rotational velocity between the copper member and the titanium member of from about 1,000 to about 5, 000 revolutions per minute while maintaining an impressed pressure of from about 5,000 to about 15,000 pounds per square inch therebetween, whereby to friction weld said titanium and copper members; friction welding the catholyte-resistant steel member to the opposite end of said copper member; inserting the conductor/connector through an opening in said backplate whereby the titanium portion thereof protrudes through the anolyte-facing surface of the backplate.

Claim 10

IN A BACKPLATE COMPRISING A CATHOLYTE-RESISTANT STEEL PLATE, A CATHODE PROJECTING FROM THE CATHOLYTE-RESISTANT STEEL PLATE, AN ANOLYTE-RESISTANT TITANIUM SHEET, AN ANODE PROJECTING FROM THE ANOLYTE-RESISTANT TITANIUM SHEET, AND MEANS FOR CONDUCTING ELECTRICAL CURRENT FROM SAID CATHODE TO SAID ANODE AND CONNECTING SAID ANODE AND CATHODE TO SAID BACKPLAE, THE IMPROVEMENT WHEREIN SAID CONDUCTING AND CONNECTING MEANS COMPRISES: A COPPER MEMBER, A CATHOLYTE-RESISTANT STEEL MEMBER FRICTION WELDED TO ONE END OF SAID COPPER MEMBER, AND AN ANOLYTE-RESISTANT TITANIUM MEMBER BONDED TO THE OPPOSITE END OF SAID COPPER MEMBER, THE BOND BETWEEN SAID ANOLYTE-RESISTANT TITANIUM MEMBER AND SAID COPPER MEMBER HAVING AN ELECTRICAL CONDUCTIVITY OF GREATER THAN ABOUT 1.5X10**4 MHO AND HAVING SUBSTANTIALLY NO THIRD PHASE BETWEEN THE COPPER MEMBER AND THE ANOLYTE-RESISTANT TITANIUM MEMBER.

Claim 11

IN A BACKPLATE COMPRISING A CATHOLYTE-RESISTANT STEEL PLATE, A CATHODE PROJECTING FROM THE CATHOLYTE-RESISTANT STEEL PLATE, AN ANOLYTE-RESISTANT TITANIUM SHEET, AN ANODE PROJECTING FROM THE ANOLYTE-RESISTANT TITANIUM SHEET, AND MEANS FOR CONDUCTING ELECTRICAL CURRENT FROM SAID CATHODE TO SAID ANODE AND CONNECTING SAID ANODE AND CATHODE TO SAID BACKPLAE, THE IMPROVEMENT WHEREIN SAID CONDUCTING AND CONNECTING MEANS COMPRISES: A COPPER MEMBER, A CATHOLYTE-RESISTANT STEEL MEMBER FRICTION WELDED TO ONE END OF SAID COPPER MEMBER, AND AN ANOLYTE-RESISTANT TITANIUM MEMBER BONDED TO THE OPPOSITE END OF SAID COPPER MEMBER, THE BOND BETWEEN SAID ANOLYTE-RESISTANT TITANIUM MEMBER AND SAID COPPER MEMBER HAVING AN ELECTRICAL CONDUCTIVITY OF GREATER THAN ABOUT 1.5X10**4 MHO AND HAVING SUBSTANTIALLY NO THIRD PHASE BETWEEN THE COPPER MEMBER AND THE ANOLYTE-RESISTANT TITANIUM MEMBER.

Claim 12

In a backplate comprising a catholyte-resistant steel surface, an anolyte-resistant surface, a cathode projecting from the catholyte-resistant surface, an anode projecting from the anolyte-resistant surface, and means for conducting electrical current from said cathode to said anode and for connecting said anode and said cathode to said backplate, the improvement wherein said conducting and connecting means comprises: a copper member; a catholyte-resistant steel member friction welded to the cathodic end of said copper member; and a titanium member friction welded to the opposite end of said copper member.

Claim 13

In a backplate comprising a catholyte-resistant steel surface, an anolyte-resistant surface, a cathode projecting from the catholyte-resistant surface, an anode projecting from the anolyte-resistant surface, and means for conducting electrical current from said cathode to said anode and for connecting said anode and said cathode to said backplate, the improvement wherein said conducting and connecting means comprises: a copper member; a catholyte-resistant steel member friction welded to the cathodic end of said copper member; and a titanium member friction welded to the opposite end of said copper member.