Process for the production of a cation exchange diaphragm and the diaphragm obtained by this process

Claim 2

A process for the production of a cation exchange diaphragm, wherein in a first stage of grafted copolymer powder is prepared by grafting styrene and/or its derivatives onto a polyethylene powder by exposing a suspension of said polyethylene and styrene and/or its derivatives to irradiation by means of ionizing rays so as to obtain a grafting degree of the monomers on the polyethylene polymer of 15 to 60%, in a second stage the grafted copolymer powder is brought into the form of a thin film by dissolving the grafted copolymer powder in an organic solvent, by pouring the thus obtained solution onto a support and then evaporating the solvent and in a third stage cation exchanger groups are fixed to the thus obtained grafted copolymer film.

Claim 3

A process according to claim 1, wherein the grain size of the polyethylene powder used in the first stage is below 100 μm and is preferably between 5 and 50 μm.

Claim 4

A process according to claim 1, wherein the polyethylene powder used in the first stage has a grain size between 10 and 20 μm.

Claim 5

A process according to claim 1, wherein the styrene and/or its derivatives are grafted onto the polyethylene under ionizing radiation, the irradiation dose being 1000 to 5000 Gy.

Claim 6

A process according to claim 4, wherein in the second stage the grafted polyethylene powder is dissolved in a solvent constituted by perhydronaphthalene, xylene or a chloronaphthalene.

Claim 7

A cation exchange diaphragm obtained by the process of claim 1, wherein it comprises a grafted copolymer film on which are fixed cation exchanger groups, wherein its exchange capacity exceeds 0.5 milliequivalents per gram (meq/g) and is preferably above 1.75 meq/g, its resistivity is below 100Ω.cm, preferably below 70Ω.cm and its swelling in water exceeds 30% and preferably exceeds 60% compared with the dry mass.

Claim 8

A diaphragm according to claim 6, wherein its exchange capacity is between 1.75 and 4 meq/g, its resistivity is between 70 and 20Ω.cm and its swelling in water is between 60 and 100% relative to the dry mass.

Claim 9

A diaphragm according to claims 6 or 7, wherein its thickness is between 30 and 150 μm.

Claim 10

A diaphragm according to claim 6, wherein the grafted copolymer comprises 13 to 37.5% by weight of units from one or more monomers chosen from the group containing styrene, α-methylstyrene, α-bromostyrene, α-chlorostyrene, chloromethylstyrene, bromomethylstyrene and divinylbenzene at 62.5 to 87% by weight of polyethylene.

Claim 11

A cation exchange diaphragm having an exchange capacity exceeding 0.5 milliequivalents per gram (meq/g) and preferably 1.75 meq/g, a resistivity below 100 Ω.cm, preferably below 70Ω.cm and a swelling in water exceeding 30% and preferably exceeding 60% compared with the dry mass, obtained by a process comprising: (a) preparing a grafted copolymer powder by exposing a suspension of a polyethylene powder in a solution of ethylenically unsaturated monomers consisting of styrene and/or one or more of its derivatives to irradiation by means of ionizing rays so as to obtain a grafting degree of the monomers on the polymer of 15 to 60%, (b) bringing into the form of a thin film the grafted copolymer powder by dissolving the grafted copolymer powder in an organic solvent, by pouring the thus obtained solution onto a support and then evaporating the solvent, and (c) fixing cation exchanger groups to the thus obtained grafted copolymer film.

Claim 12

A cation exchange diaphragm having an exchange capacity exceeding 0.5 milliequivalents per gram (meq/g) and preferably 1.75 meq/g, a resistivity below 100 Ω.cm, preferably below 70Ω.cm and a swelling in water exceeding 30% and preferably exceeding 60% compared with the dry mass, obtained by a process comprising: (a) preparing a grafted copolymer powder by exposing a suspension of a polyethylene powder in a solution of ethylenically unsaturated monomers consisting of styrene and/or one or more of its derivatives to irradiation by means of ionizing rays so as to obtain a grafting degree of the monomers on the polymer of 15 to 60%, (b) bringing into the form of a thin film the grafted copolymer powder by dissolving the grafted copolymer powder in an organic solvent, by pouring the thus obtained solution onto a support and then evaporating the solvent, and (c) fixing cation exchanger groups to the thus obtained grafted copolymer film.

Claim 13

A cation exchange diaphragm according to claim 10, wherein the grain size of the polymer powder used in stage (a) is below 100 μm and is preferably between 5 and 50 μm.

Claim 14

A cation exchange diaphragm according to claim 10, wherein the polymer powder used in stage (a) has a grain size between 10 and 20 μm.

Claim 15

A cation exchange diaphragm according to claim 10, wherein the grafted copolymer film is reinforced in stage (b) by incorporating into it a fabric portion.

Claim 16

A cation exchange diaphragm according to claim 10, wherein the styrene and/or its derivatives are grafted onto the polyethylene under ionizing radiation, the irradiation dose being 1000 to 5000 Gy.

Claim 17

A cation exchange diaphragm according to claim 10, wherein in stage (b) the grafted polyethylene powder is dissolved in a solvent constituted by perhydronaphthalene, xylene or a chloronaphthalene.

Claim 18

A cation exchange diaphragm according to claim 10, wherein in stage (c) --HSO 3 cation exchanger groups are fixed to the grafted copolymer film by immersing the latter in a chlorosulphonic, concentrated sulphuric or fuming sulphuric acid bath.

Claim 19

A diaphragm according to claim 10, having an exchange capacity between 1.75 and 4 meq/g, a resistivity between 70 and 20Ω.cm and a swelling in water between 60 and 100% relative to the dry mass.

Claim 20

A diaphragm according to claim 10 having a thickness between 30 and 150 μm.

Claim 21

A diaphragm according to claim 10, wherein the grafted copolymer comprises 13 to 37.5% by weight of units from one or more monomers chosen from the group containing styrene, α-methylstyrene, α-bromostyrene, α-chlorostyrene, chloromethylstyrene, bromomethylstyrene and divinylbenzene at 62.5 to 87% by weight of polyethylene.