US4666579A — Structural frame for a solid polymer electrolyte …

Claim 1

Independent Claim 219 words

A structural frame adapted for use in an electrolytic cell comprising: an organic plastic member with a plurality of horizontally and vertically spaced-apart shoulders protruding outwardly from opposing generally coplanar first and second surfaces of said plastic member; at least one electrically conductive insert extending from an exterior face of a shoulder on the first surface of the plastic member, through the plastic member, to an exterior face of a shoulder on the second surface of the plastic member, wherein each of said shoulders annularly encircle and support said insert; an electrically conductive, substantially completely hydraulically impermeable second cover resistant to the corrosive effects of electrolyte matingly contacted with the second surface of said plastic member and adapted to minimize contact between the electrolyte and said plastic member within the cell; an electrically conductive, substantially completely hydraulically impermeable first cover resistant to the corrosive effects of electrolyte matingly contacted with the first surface of said plastic member and adapted to minimize contact between the electrolyte and said plastic member within the cell; a hydraulically permeable, electrically conductive, current collector adjacent to and contacting the first cover; an ion exchange membrane adjacent to and contacting the current collector; and an electrically conductive, electrocatalytic material bonded to or embedded in the surface of the ion exchange membrane contacting the current collector.

Claim 2

Dependent Claim 219 words

A structural frame adapted for use in an electrolytic cell comprising: an organic plastic member with a plurality of horizontally and vertically spaced-apart shoulders protruding outwardly from opposing generally coplanar first and second surfaces of said plastic member; at least one electrically conductive insert extending from an exterior face of a shoulder on the first surface of the plastic member, through the plastic member, to an exterior face of a shoulder on the second surface of the plastic member, wherein each of said shoulders annularly encircle and support said insert; an electrically conductive, substantially completely hydraulically impermeable second cover resistant to the corrosive effects of electrolyte matingly contacted with the second surface of said plastic member and adapted to minimize contact between the electrolyte and said plastic member within the cell; an electrically conductive, substantially completely hydraulically impermeable first cover resistant to the corrosive effects of electrolyte matingly contacted with the first surface of said plastic member and adapted to minimize contact between the electrolyte and said plastic member within the cell; a hydraulically permeable, electrically conductive, current collector adjacent to and contacting the first cover; an ion exchange membrane adjacent to and contacting the current collector; and an electrically conductive, electrocatalytic material bonded to or embedded in the surface of the ion exchange membrane contacting the current collector.

Claim 3

Dependent Claim 25 words

The frame of claim 1 wherein the second cover is a metal selected from the group consisting of titanium, tantalum, zirconium, tungsten, and alloys thereof.

Claim 4

Dependent Claim 29 words

The frame of claim 1 wherein the first cover is a metal selected from the group consisting of iron, steel, stainless steel, nickel, lead, molybdenum, cobalt, and alloys thereof.

Claim 5

Dependent Claim 26 words

The frame of claim 1 wherein the insert is a metal selected from the group consisting of aluminum, copper, iron, steel, nickel, titanium, and alloys thereof.

Claim 6

Dependent Claim 17 words

The frame of claim: 1 wherein said second and first covers are attached directly to said insert.

Claim 7

Dependent Claim 60 words

The frame of claim 1 wherein the second cover is titanium, or an alloy thereof; at least a portion of said inserts are composed of a ferrous-containing material; and said cover is attached, by welding, to at least a portion of said ferrous-containing inserts through an intermediate metal which is weldable compatible with said titanium cover and said ferrous-containing insert.

Claim 8

Dependent Claim 35 words

The frame of claim 1 wherein the plastic is selected from the group consisting of polyethylene, polyproplylene, polyvinylchloride, polystyrene, polysulfone, styrene acrylonitrile, chlorinate polvinylchloride, acrylonitrile, butadiene and styrene copolymers, epoxy, vinyl esters, polyesters, and fluoroplastics.

Claim 9

Dependent Claim 27 words

The frame of claim 1 wherein the plastic contains an additive selected from the group consisting of fiberglass, graphite fibers, talc, glass beads, asbestos, and pulverized mica.

Claim 10

Dependent Claim 20 words

The frame of claim 8 wherein the plastic contains from about 5 to about 75 weight percent of the additive.

Claim 11

Dependent Claim 20 words

The frame of claim 1 wherein the plastic contains an additive to reduce thermally induced expansion of said plastic member.

Claim 12

Dependent Claim 26 words

The frame of claim 1 wherein said plastic member has a peripheral flange extending outwardly from the second and the first surfaces of said plastic member.

Claim 13

Dependent Claim 21 words

The frame of claim 11 wherein the flange extends outwardly from the plastic member about the same distance as said insert.

Claim 14

Dependent Claim 59 words

An electrolytic cell comprising: a plurality of the structural frames of claim 1 removably and sealably positioned in a generally coplanar relationship with each other and each of said plastic members being spaced apart by a second electrode on one side of each of said frames and a first electrode on an opposing side of each of said frames.

Claim 15

Dependent Claim 42 words

The cell of claim 13 wherein each of said second and first covers are welded to at least a portion of said inserts the second electrode and the first electrode are welded to the respective covers at locations adjacent to said inserts.

Claim 16

Dependent Claim 35 words

The cell of claim 14 wherein the plastic is selected from the group consisting of polyethylene, polypropylene, polyvinylchloride, chlorinated polyvinylchloride, acrylonitrile, polystyrene, polysulfone, styrene acrylonitrile, butadiene and styrene copolymers, epoxy, vinyl esters, polyesters, and fluoroplastics.

Claim 17

Dependent Claim 29 words

The cell of claim 14 wherein the plastic contains an additive selected from the group consisting of fiberglass, graphite fibers, carbon fibers, talc, glass beads, asbestos, and pulverized mica.

Claim 18

Dependent Claim 20 words

The cell of claim 16 wherein the plastic contains from about 5 to about 75 weight percent of the additive.

Claim 19

Dependent Claim 26 words

The cell of claim 16 wherein said plastic member has a peripheral flange extending outwardly from the second and the first surfaces of the plastic member.

Claim 20

Dependent Claim 23 words

The cell of claim 13 wherein the second cover is selected from the group of materials consisting of titanium, tantalum, zirconium, and tungsten.

Claim 21

Dependent Claim 29 words

The cell of claim 13 wherein the first cover is selected from the group of materials consisting of iron, steel, stainless steel, nickel, lead, molybdenum, cobalt, and alloys thereof.

Claim 22

Dependent Claim 26 words

The cell of claim 13 wherein the insert is selected from the group of materials consisting of aluminum, copper, iron, steel, nickel, titanium, and alloys thereof.

Claim 23

Dependent Claim 17 words

The cell of claim 13 wherein said second and first covers are welded directly to said insert.

Claim 24

Dependent Claim 37 words

The cell of claim 13 wherein the second cover is titanium or an alloy thereof, said insert is a ferrous-containing material and a vanadium disk is positioned between, and welded to, said second cover and said insert.

Claim 25

Dependent Claim 20 words

The cell of claim 13 wherein the plastic contains an additive to reduce thermally induced expansion of said plastic member.

Claim 26

Dependent Claim 26 words

The cell of claim 13 wherein said plastic member has a peripheral flange extending outwardly from the second and the first surfaces of said plastic member.

Claim 27

Dependent Claim 21 words

The cell of claim 25 wherein the flange extends outwardly from the plastic member about the same distance as said inserts.

Claim 28

Dependent Claim 155 words

A structural frame adapted for use in a chlor-alkali electrolytic cell for producing gaseous chlorine and an aqueous alkali metal hydroxide solution from an aqueous alkali metal chloride brine comprising: a glass filled polypropylene member with a plurality of horizontally and vertically spaced-apart shoulders protruding outwardly from opposing generally coplanar second and first surfaces of said polypropylene member; at least one electrically conductive steel insert extending through said polypropylene member such that said insert is generally annularly encircled by a shoulder on each opposing surfaces of said polypropylene member; a substantially completely hydraulically impermeable titanium second cover matingly affixed to the second surface of said polypropylene member and adapted to minimize contact between the electrolyte and said polypropylene member within the cell; and a substantially completely hydraulically impermeable nickel first cover matingly affixed to the first surface of said polypropylene member and adapted to minimize contact between the electrolyte and said polypropylene within the cell.

Claim 29

Dependent Claim 155 words

A structural frame adapted for use in a chlor-alkali electrolytic cell for producing gaseous chlorine and an aqueous alkali metal hydroxide solution from an aqueous alkali metal chloride brine comprising: a glass filled polypropylene member with a plurality of horizontally and vertically spaced-apart shoulders protruding outwardly from opposing generally coplanar second and first surfaces of said polypropylene member; at least one electrically conductive steel insert extending through said polypropylene member such that said insert is generally annularly encircled by a shoulder on each opposing surfaces of said polypropylene member; a substantially completely hydraulically impermeable titanium second cover matingly affixed to the second surface of said polypropylene member and adapted to minimize contact between the electrolyte and said polypropylene member within the cell; and a substantially completely hydraulically impermeable nickel first cover matingly affixed to the first surface of said polypropylene member and adapted to minimize contact between the electrolyte and said polypropylene within the cell.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1990-05-18	1990-11-17	1991-05-19	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1994-05-18	1994-11-17	1995-05-19	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	1998-05-18	1998-11-17	1999-05-19	$7700.00	Window Closed / Lapsed

Structural frame for a solid polymer electrolyte electrochemical cell

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