US4175023A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Combined cathode and diaphragm unit for electrolytic cells
Assignee: BASF Corp
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Filing: 1978-07-17
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Granted: 1979-11-20
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Expires: 1998-07-17
Abstract
Abstract An especially efficient and durable electrolytic cell is provided by utilizing a combined cathode and diaphragm unit wherein the cathode is made by spray coating a ferrous metal substrate with a powder metal having lower hydrogen overvoltage than said substrate to form a protected cathode surface having a larger surface area than the substrate, and vacuum depositing fluorinated hydrocarbon polymer fibers onto the spray coated surface of the cathode to form a fibrous diaphragm securely adhered thereto. Preferably, the cathode surface is made with nickel and the fluorinated hydrocarbon polymer is selected from the group consisting of homopolymers of chlorotrifluoroethylene and copolymers of chlorotrifluoroethylene and at least one compatible monomer with units of chlorotrifluoroethylene accounting for at least 80 percent of the monomeric units of said copolymer.
Inventors
- 👤 Shyam D. Argade
- 👤 Thomas G. Coker
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 00:28
CPC Classifications
C; C25; C25B; C25B9/00; C25B13/00; C25B13/04; C25B13/08
Claims Analysis
Total Claims: 18
Claim 1
Independent Claim
117 words
In a method for manufacturing a chlor-alkali electrolytic cell having a cathode and a fibrous diaphragm juxtaposed thereto, the improvement comprising spray coating by plasma spraying or flame spraying a ferrous metal substrate with a powder metal selected from the group consisting of nickel, cobalt, tungsten carbide and mixtures thereof in a manner that forms the cathode with the cathode surface having a larger true surface area than the geometric surface area of the substrate, and vacuum depositing fibers onto a spray coated surface of the cathode to form the fibrous diaphragm securely adhered thereto, said fibrous diaphragm being formed from a fibrous slurry in which a major portion of the fibers are an organic thermoplastic polymer.
Claim 2
Dependent Claim
117 words
In a method for manufacturing a chlor-alkali electrolytic cell having a cathode and a fibrous diaphragm juxtaposed thereto, the improvement comprising spray coating by plasma spraying or flame spraying a ferrous metal substrate with a powder metal selected from the group consisting of nickel, cobalt, tungsten carbide and mixtures thereof in a manner that forms the cathode with the cathode surface having a larger true surface area than the geometric surface area of the substrate, and vacuum depositing fibers onto a spray coated surface of the cathode to form the fibrous diaphragm securely adhered thereto, said fibrous diaphragm being formed from a fibrous slurry in which a major portion of the fibers are an organic thermoplastic polymer.
Claim 3
Dependent Claim
22 words
The method as defined in claim 1, wherein the substrate is spray coated by flame spraying the powder metal onto the substrate.
Claim 4
Dependent Claim
22 words
The method as defined in claim 1, wherein the substrate is spray coated by plasma spraying the powder metal onto the substrate.
Claim 5
Dependent Claim
13 words
The method as defined in claim 1, wherein the powder metal is nickel.
Claim 6
Dependent Claim
14 words
The method as defined in claim 1, wherein the diaphragm is homopolymer of chlorotrifluoroethylene.
Claim 7
Dependent Claim
31 words
The method as defined in claim 1, wherein the diaphragm is a copolymer containing chlorotrifluoroethylene and vinylidene fluoride and in which at least 80 percent of the monomeric units are chlorotrifluoroethylene.
Claim 8
Dependent Claim
18 words
The method as defined in claim 6, wherein the copolymer also contains a small amount of tetrafluoroethylene units.
Claim 9
Dependent Claim
107 words
In a chlor-alkali electrolysis cell having a cathode and a fibrous diaphragm juxtaposed thereto, a cathode and diaphragm comprising a cathode screen having a ferrous metal substrate, and a surface formed by spray coating a powder metal selected from the group consisting of nickel, cobalt, titanium carbide and mixtures thereof on said substrate, said powder metal having a lower hydrogen overvoltage than said substrate and having a larger true surface area than the geometric surface area of the substrate, and a fibrous diaphragm adhered to a surface of the cathode screen, said fibrous diaphragm comprising fibers the major portion of which are of an organic thermoplastic polymer.
Claim 10
Dependent Claim
107 words
In a chlor-alkali electrolysis cell having a cathode and a fibrous diaphragm juxtaposed thereto, a cathode and diaphragm comprising a cathode screen having a ferrous metal substrate, and a surface formed by spray coating a powder metal selected from the group consisting of nickel, cobalt, titanium carbide and mixtures thereof on said substrate, said powder metal having a lower hydrogen overvoltage than said substrate and having a larger true surface area than the geometric surface area of the substrate, and a fibrous diaphragm adhered to a surface of the cathode screen, said fibrous diaphragm comprising fibers the major portion of which are of an organic thermoplastic polymer.
Claim 11
Dependent Claim
22 words
The cell as defined in claim 8, wherein the substrate is spray coated by flame spraying the powder metal onto the substrate.
Claim 12
Dependent Claim
22 words
The cell as defined in claim 8, wherein the substrate is spray coated by plasma spraying the powder metal onto the substrate.
Claim 13
Dependent Claim
13 words
The cell as defined in claim 8, wherein the powder metal is nickel.
Claim 14
Dependent Claim
13 words
The cell as defined in claim 11, wherein the powder metal is nickel.
Claim 15
Dependent Claim
21 words
The cell as defined in claim 8, wherein the coating has a thickness of from about 0.001 to about 0.006 inches.
Claim 16
Dependent Claim
15 words
The cell as defined in claim 8, wherein the diaphragm is a homopolymer of chlorotrifluoroethylene.
Claim 17
Dependent Claim
31 words
The cell as defined in claim 8, wherein the diaphragm is a copolymer containing chlorotrifluoroethylene and vinylidene fluoride and in which at least 80 percent of the monomeric units are chlorotrifluoroethylene.
Claim 18
Dependent Claim
18 words
The cell as defined in claim 15, wherein the copolymer also contains a small amount of tetrafluoroethylene units.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1982-11-19 | 1983-05-21 | 1983-11-20 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1986-11-19 | 1987-05-21 | 1987-11-20 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1990-11-19 | 1991-05-21 | 1991-11-20 | $7700.00 | Window Closed / Lapsed |