US4457815A — Electrolytic cell, permionic membrane, and method…

Claim 1

Independent Claim 70 words

In an electrolytic cell having an anolyte compartment with an anode therein, a catholyte compartment with a cathode therein, and a permionic membrane therebetween, the permionic membrane having a porous film thereon, the improvement wherein the porous film comprises a random mixture of electrocatalyst particles and separate non-conductive surface catalyst particles, said electrocatalyst particles having an electrical conductivity of more than 10 ohm-centimeters) -1 , and said particles being hydrophillic.

Claim 2

Dependent Claim 70 words

In an electrolytic cell having an anolyte compartment with an anode therein, a catholyte compartment with a cathode therein, and a permionic membrane therebetween, the permionic membrane having a porous film thereon, the improvement wherein the porous film comprises a random mixture of electrocatalyst particles and separate non-conductive surface catalyst particles, said electrocatalyst particles having an electrical conductivity of more than 10 ohm-centimeters) -1 , and said particles being hydrophillic.

Claim 3

Dependent Claim 20 words

The electrolytic cell of claim 1 wherein the porous film is bonded to the permionic membrane with a fluorocarbon polymer.

Claim 4

Dependent Claim 21 words

The electrolytic cell of claim 1 wherein the porous film has a porosity of from about 10 to about 99 percent.

Claim 5

Dependent Claim 20 words

The electrolytic cell of claim 1 wherein the porous film has a thickness of about 0.01 to about 300 microns.

Claim 6

Dependent Claim 31 words

The electrolytic cell of claim 1 wherein the porous film contains from about 0.1 milligram per square centimeter to about 100 milligrams per square centimeter of total surface catalyst and electrocatalyst.

Claim 7

Dependent Claim 26 words

The electrolytic cell of claim 1 wherein the porous film contains from about 1 to about 95 weight percent electrocatalyst, basis total surface catalyst and electrocatalyst.

Claim 8

Dependent Claim 19 words

The electrolytic cell of claim 1 wherein the porous film is on the cathodic surface of the permionic membrane.

Claim 9

Dependent Claim 27 words

The electrolytic cell of claim 7 wherein the surface catalyst is chosen from the group consisting of oxides of titanium, tantalum, tungsten, zirconium, columbium, and mixtures thereof.

Claim 10

Dependent Claim 23 words

The electrolytic cell of claim 7 wherein the electrocatalyst is chosen from the group consisting of Group VIII transition metals and mixtures thereof.

Claim 11

Dependent Claim 16 words

The electrolytic cell of claim 7 wherein the cathode is the electrocatalyst in the porous surface.

Claim 12

Dependent Claim 16 words

The electrolytic cell of claim 7 wherein the cathode is in contact with the porous surface.

Claim 13

Dependent Claim 15 words

The electrolytic cell of claim 7 wherein the cathode is spaced from the porous surface.

Claim 14

Dependent Claim 19 words

The electrolytic cell of claim 1 wherein the porous surface is on the anodic surface of the permionic membrane.

Claim 15

Dependent Claim 27 words

The electrolytic cell of claim 13 wherein the surface catalyst is chosen from the group consisting of oxides of titanium, tantalum, tungsten, zirconium, columbium, and mixtures thereof.

Claim 16

Dependent Claim 24 words

The electrolytic cell of claim 13 wherein the electrocatalyst is chosen from the group consisting of platinum group metals, oxides thereof, and oxycompounds thereof.

Claim 17

Dependent Claim 16 words

The electrolytic cell of claim 13 wherein the anode is the electrocatalyst in the porous surface.

Claim 18

Dependent Claim 16 words

The electrolytic cell of claim 13 wherein the anode is in contact with the porous surface.

Claim 19

Dependent Claim 15 words

The electrolytic cell of claim 13 wherein the anode is spaced from the porous surface.

Claim 20

Dependent Claim 223 words

The electrolytic cell of claim 1 wherein the permionic membrane is a fluorocarbon polymer having the moieties: (CF.sub.2 --CXX') and (CF.sub.2 --CXY) where: X is chosen from the group consisting of --F, --Cl, --H, and --CF 3 ; X' is chosen from the group consisting of --F, --Cl, --H, --CF 3 , and (CF 2 ) m CF, where m is an integer from 1 to 5; Y is chosen from the group consisting of --A, --φA, --P--A, and --O--(CF 2 ) n --(P,Q,R)--A, where P is (--CF 2 ) (CXX') b (CF 2 ) c , Q is (--CF 2 --O--CXX') d and R is (--CXX'--O--CF 2 ) e ; (P,Q,R) is or contains one or more of P, Q, and R, n is 0 or 1; a,b,c,d, and e are integers from 0 to 6; φ is a phenylene group and A is chosen from the group consisting of --COOH, --CN, --COF, --COCl, --COOR, --COOM, --CONR 2 R 3 , --SO 3 H, --PO 3 H 2 , and PO 2 H 2 , where R 1 is a C 1 to C 10 alkyl group, and R 2 and R 3 are chosen from the group consisting of --H, and C 1 to C 10 alkyl groups; and M is chosen from the group consisting of --H and alkali metals.

Claim 21

Dependent Claim 83 words

The electrolytic cell of claim 19 wherein Y is chosen from the group consisting of (CF 2 ) x A, --O(CF 2 ) x A, (OCF 2 CFZ) y A, (OCF 2 CFZ) x (OCF 2 CF 2 )A, and --O--CF 2 (CF 2 OCFZ) y (CF 2 ) y (CF 2 OCFR) z where x, y, and z are 1 to 10, and Z and R are chosen from the group consisting of --F and C 1 to C 10 alkyl groups.

Claim 22

Dependent Claim 27 words

The electrolytic cell of claim 20 wherein A is chosen from the group consisting of --COOH, --CN, --COF, --COCl, --COOR, --COOM, and CONR 2 R 3 .

Claim 23

Dependent Claim 83 words

In a permionic membrane formed of a fluorocarbon polymer having pendant ionic groups, said permionic membrane adapted for use between an anode and a cathode in an electrolytic cell to carry out an electrolytic reaction, said permionic membrane having a porous film of particles on at least one surface thereof, the improvement wherein the porous film comprises a random mixture of electrocatalyst particles and separate non-conductive surface catalyst particles, said electrocatalyst particles having an electrical conductivity of more than 10 (ohm-centimeters) -1 .

Claim 24

Dependent Claim 83 words

In a permionic membrane formed of a fluorocarbon polymer having pendant ionic groups, said permionic membrane adapted for use between an anode and a cathode in an electrolytic cell to carry out an electrolytic reaction, said permionic membrane having a porous film of particles on at least one surface thereof, the improvement wherein the porous film comprises a random mixture of electrocatalyst particles and separate non-conductive surface catalyst particles, said electrocatalyst particles having an electrical conductivity of more than 10 (ohm-centimeters) -1 .

Claim 25

Dependent Claim 20 words

The permionic membrane of claim 22 wherein the porous film is bonded to the permionic membrane with a fluorocarbon polymer.

Claim 26

Dependent Claim 21 words

The permionic membrane of claim 22 wherein the porous film has a porosity of from about 10 to about 99 percent.

Claim 27

Dependent Claim 20 words

The permionic membrane of claim 22 wherein the porous film has a thickness of about 0.01 to about 300 microns.

Claim 28

Dependent Claim 31 words

The permionic membrane of claim 22 wherein the porous film contains from about 0.1 milligrams per square centimeter to about 100 milligrams per square centimeter of total surface catalyst and electrocatalyst.

Claim 29

Dependent Claim 26 words

The permionic membrane of claim 22 wherein the porous film contains from about 1 to about 95 weight percent electrocatalyst, basis total surface catalyst and electrocatalyst.

Claim 30

Dependent Claim 27 words

The permionic membrane of claim 22 wherein the porous film is on the cathodic surface of the permionic membrane, said cathodic surface intended to face a cathode.

Claim 31

Dependent Claim 27 words

The permionic membrane of claim 28 wherein the surface catalyst is chosen from the group consisting of oxides of titanium, tantalum, tungsten, zirconium, columbium, and mixtures thereof.

Claim 32

Dependent Claim 23 words

The permionic membrane of claim 28 wherein the electrocatalyst is chosen from the group consisting of Group VIII transition metals and mixtures thereof.

Claim 33

Dependent Claim 16 words

The permionic membrane of claim 28 wherein the cathode is the electrocatalyst in the porous surface.

Claim 34

Dependent Claim 16 words

The permionic membrane of claim 28 wherein the cathode is in contact with the porous surface.

Claim 35

Dependent Claim 15 words

The permionic membrane of claim 28 wherein the cathode is spaced from the porous surface.

Claim 36

Dependent Claim 27 words

The permionic membrane of claim 28 wherein the porous surface is on the anodic surface of the permionic membrane, said anodic surface intended to face an anode.

Claim 37

Dependent Claim 27 words

The permionic membrane of claim 22 wherein the surface catalyst is chosen from the group consisting of oxides of titanium, tantalum, tungsten, zirconium, columbium, and mixtures thereof.

Claim 38

Dependent Claim 24 words

The permionic membrane of claim 34 wherein the electrocatalyst is chosen from the group consisting of platinum group metals, oxides thereof, and oxycompounds thereof.

Claim 39

Dependent Claim 16 words

The permionic membrane of claim 33 wherein the anode is the electrocatalyst in the porous surface.

Claim 40

Dependent Claim 16 words

The permionic membrane of claim 33 wherein the anode is in contact with the porous surface.

Claim 41

Dependent Claim 15 words

The permionic membrane of claim 33 wherein the anode is spaced from the porous surface.

Claim 42

Dependent Claim 219 words

The permionic membrane of claim 1 wherein the fluorocarbon polymer has the moieties: (CF.sub.2 --CXX') and (CF.sub.2 --CXY) where: X is chosen from the group consisting of --F, --Cl, --H, and --CF 3 ; X' is chosen from the group consisting of --F, --Cl, --H, --CF 3 , and (CF 2 ) m CF, where m is an integer from 1 to 5; Y is chosen from the group consisting of --A, --φA, --P--A, and --O--(CF 2 ) n --(P,Q,R)--A, where P is (--CF 2 ) (CXX') b (CF 2 ) c , Q is (--CF 2 --O--CXX') d and R is (--CXX'--O--CF 2 ) e ; (P,Q,R) is or contains one or more of P, Q, and R, n is 0 or 1; a,b,c,d, and e are integers from 0 to 6; φ is a phenylene group and A is chosen from the group consisting of --COOH, --CN, --COF, --COCl, --COOR, --COOM, --CONR 2 R 3 , --SO 3 H, --PO 3 H 2 , and PO 2 H 2 , where R 1 is a C 1 to C 10 alkyl group, and R 2 and R 3 are chosen from the group consisting of --H, and C 1 to C 19 alkyl groups; and M is chosen from the group consisting of --H and alkali metals.

Claim 43

Dependent Claim 83 words

The permionic membrane of claim 39 wherein Y is chosen from the group consisting of (CF 2 ) x A, --O(CF 2 ) x A, (OCF 2 CFZ) y A, (OCF 2 CFZ) x (OCF 2 CF 2 )A, and --O--CF 2 (CF 2 OCFZ) y (CF 2 ) y (CF 2 OCFR) z where x, y, and z are 1 to 10, and Z and R are chosen from the group consisting of --F and C 1 to C 10 alkyl groups.

Claim 44

Dependent Claim 108 words

In a method of electrolyzing an alkali metal chloride brine in an electrolytic cell having an anolyte compartment with an anode therein, a catholyte with a cathode therein, and a permionic membrane therebeween, said permionic membrane having a porous film thereon, which method comprises feeding alkali metal chloride brine to the anolyte compartment, passing an electrical current from the anode to the cathode, and recovering chlorine from the anolyte compartment, the improvement wherein the porous film comprises a random mixture of electrocatalyst particles and separate non-conductive surface catalyst particles, said electrocatalyst particles having an electrical conductivity of more than 10 (ohm-centimeters) -1 , and said particles being hydrophillic.

Claim 45

Dependent Claim 108 words

In a method of electrolyzing an alkali metal chloride brine in an electrolytic cell having an anolyte compartment with an anode therein, a catholyte with a cathode therein, and a permionic membrane therebeween, said permionic membrane having a porous film thereon, which method comprises feeding alkali metal chloride brine to the anolyte compartment, passing an electrical current from the anode to the cathode, and recovering chlorine from the anolyte compartment, the improvement wherein the porous film comprises a random mixture of electrocatalyst particles and separate non-conductive surface catalyst particles, said electrocatalyst particles having an electrical conductivity of more than 10 (ohm-centimeters) -1 , and said particles being hydrophillic.

Claim 46

Dependent Claim 27 words

The permionic membrane of claim 40 wherein A is chosen from the group consisting of --COOH, --CN, --COF, --COCl, --COOR, --COOM, and CONR 2 R 3 .

Claim 47

Dependent Claim 19 words

The method of claim 42 wherein the porous film is bonded to the permionic membrane with a fluorocarbon polymer.

Claim 48

Dependent Claim 20 words

The method of claim 42 wherein the porous film has a porosity of from about 10 to about 99 percent.

Claim 49

Dependent Claim 19 words

The method of claim 42 wherein the porous film has a thickness of about 0.01 to about 300 microns.

Claim 50

Dependent Claim 30 words

The method of claim 42 wherein the porous film contains from about 0.1 milligram per square centimeter to about 100 milligrams per square centimeter of total surface catalyst and electrocatalyst.

Claim 51

Dependent Claim 25 words

The method of claim 42 wherein the porous film contains from about 1 to about 95 weight percent electrocatalyst, basis total surface catalyst and electrocatalyst.

Claim 52

Dependent Claim 18 words

The method of claim 42 wherein the porous film is on the cathodic surface of the permionic membrane.

Claim 53

Dependent Claim 26 words

The method of claim 48 wherein the surface catalyst is chosen from the group consisting of oxides of titanium, tantalum, tungsten, zirconium, columbium, and mixtures thereof.

Claim 54

Dependent Claim 22 words

The method of claim 49 wherein the electrocatalyst is chosen from the group consisting of Group VIII transition metals and mixtures thereof.

Claim 55

Dependent Claim 15 words

The method of claim 49 wherein the cathode is the electrocatalyst in the porous surface.

Claim 56

Dependent Claim 15 words

The method of claim 49 wherein the cathode is in contact with the porous surface.

Claim 57

Dependent Claim 14 words

The method of claim 49 wherein the cathode is spaced from the porous surface.

Claim 58

Dependent Claim 18 words

The method of claim 42 wherein the porous surface is on the anodic surface of the permionic membrane.

Claim 59

Dependent Claim 26 words

The method of claim 54 wherein the surface catalyst is chosen from the group consisting of oxides of titanium, tantalum, tungsten, zirconium, columbium, and mixtures thereof.

Claim 60

Dependent Claim 23 words

The method of claim 55 wherein the electrocatalyst is chosen from the group consisting of platinum group metals, oxides thereof, and oxycompounds thereof.

Claim 61

Dependent Claim 15 words

The method of claim 55 wherein the anode is the electrocatalyst in the porous surface.

Claim 62

Dependent Claim 15 words

The method of claim 55 wherein the anode is in contact with the porous surface.

Claim 63

Dependent Claim 14 words

The method of claim 55 wherein the anode is spaced from the porous surface.

Claim 64

Dependent Claim 222 words

The method of claim 60 wherein the permionic membrane is a fluorocarbon polymer having the moieties: (CF.sub.2 --CXX') and (CF.sub.2 --CXY) where: X is chosen from the group consisting of --F, --Cl, --H, and --CF 3 ; X' is chosen from the group consisting of --F, --Cl, --H, --CF 3 , and (CF 2 ) m CF, where m is an integer from 1 to 5; Y is chosen from the group consisting of --A, --φA, --P--A, and --O--(CF 2 ) n --(P,Q,R)--A, where P is (--CF 2 ) (CXX') b (CF 2 ) c , Q is (--CF 2 --O--CXX') d and R is (--CXX'--O--CF 2 ) e ; (P,Q,R) is or contains one or more of P, Q, and R, n is 0 or 1; a,b,c,d, and e are integers from 0 to 6; φ is a phenylene group and A is chosen from the group consisting of --COOH, --CN, --COF, --COCl, --COOR, --COOM, --CONR 2 R 3 , --SO 3 H, --PO 3 H 2 , and PO 2 H 2 , where R 1 is a C 1 to C 10 alkyl group, and R 2 and R 3 are chosen from the group consisting of --H, and C 1 to C 19 alkyl groups; and m is chosen from the group consisting of --H and alkali metals.

Claim 65

Dependent Claim 82 words

The method of claim 61 wherein Y is chosen from the group consisting of (CF 2 ) x A, --O(CF 2 ) x A, (OCF 2 CFZ) y A, (OCF 2 CFZ) x (OCF 2 CF 2 )A, and --O--CF 2 (CF 2 OCFZ) y (CF 2 ) y (CF 2 OCFR) z where x, y, and z are 1 to 10, and Z and R are chosen from the group consisting of --F and C 1 to C 10 alkyl groups.

Claim 66

Dependent Claim 26 words

The method of claim 61 wherein A is chosen from the group consisting of --COOH, --CN, --COF, --COCl, --COOR, --COOM, and CONR 2 R 3 .

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1987-07-03	1988-01-02	1988-07-03	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1991-07-03	1992-01-02	1992-07-03	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1995-07-03	1996-01-02	1996-07-03	$7700.00	Window Closed / Lapsed

Electrolytic cell, permionic membrane, and method of electrolysis

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