Electrochemical cell having gas pressurized contact between laminar, gas diffusion electrode and current collector

Claim 2

An electrochemical cell comprising an electrode assembly consisting of a gas diffusion electrode and an electrically conductive current collector means (A) said gas diffusion electrode being laminar and having an electrically conductive, porous hydrophilic layer comprising a conductive carbon and a polymeric binder thereof and a porous, hydrophobic layer comprising a hydrophobic polymer and (B) said electrically conductive current collector means being in contact with said hydropholic layer and wherein said cell includes means for maintaining solely by gas pressure said hydrophilic layer of said electrode in contact with said current collector means.

Claim 3

The electrode assembly of claim 1 wherein said polymeric binder and said hydrophobic polymer comprise a thermoplastic halocarbon polymer.

Claim 4

The electrode of claim 2 wherein said thermoplastic halocarbon polymer is selected from the group consisting of at least one of polymers of tetrafluoroethylene, fluorinated ethylene propylene, copolymers thereof having the moieties (--CX.sub.1 X.sub.2 --CX.sub.3 CX.sub.4 --, and (--CY.sub.1 Y.sub.2 --CY.sub.3 Y.sub.4 --), and homopolymers having the moieties (--CY.sub.1 Y.sub.2 --CY.sub.3 F--) wherein X 1 , X 2 , X 3 , X 4 , Y 1 , Y 2 , Y 3 , and Y 4 are selected from the group consisting of fluorine, chlorine, and hydrogen, at least of said X and Y being fluorine.

Claim 5

The electrode of claim 3 wherein said thermoplastic halocarbon polymer is a fluorocarbon polymer selected from the group consisting of at least one of copolymers having an ethylene moiety and a fluorocarbon moiety chosen from the group consisting of (--CFH--CH.sub.2 --), (--CF.sub.2 CH.sub.2 --), (--CF.sub.2 --CFH--), (--CF.sub.2 --CF.sub.2 --), and (--CF.sub.2 --CClF--).

Claim 6

The electrode of claim 4 wherein said current collector means comprises a metal mesh and a support structure wherein said metal mesh is prepared from a metal selected from the group consisting of stainless steel, nickel, platinum group metals, valve metals, and mixtures thereof.

Claim 7

The electrode of claim 5 wherein said metal mesh is prepared from a material selected from the group consisting of silver, silver-coated nickel, silver-coated steel, and silver-coated valve metals.

Claim 8

The electrode of claim 6 wherein said conductive carbon is carbon black having a particle size of about 0.01 to about 0.05 microns.

Claim 9

The electrode of claim 6 wherein said carbon black is admixed with at least one electrochemically active catalyst.

Claim 10

The electrode of claim 8 wherein said catalyst is a precious metal catalyst selected from at least one of the group consisting of platinum, silver, palladium, and rhodium.

Claim 11

In an electrochemical reaction process conducted in an electrochemical cell comprising a gas compartment, a semi-permeable membrane disposed between a cathode and an anode so as to form a catholyte compartment and an anolyte compartment, said catholyte compartment containing said cathode and a volume of catholyte, said anolyte compartment containing said anode and a volume of anolyte, the adjacent surfaces of said anode and said cathode being spaced apart sufficiently for said membrane to fit freely therebetween, the process improvement comprising: utilizing a gas diffusion electrode assembly consisting of (1) a gas diffusion laminar electrode having an electrically conductive, porous hydrophilic layer comprising conductive carbon and a polymeric binder therefor, and a porous, hydrophobic layer comprising a hydrophobic polymer and (2) an electrically conductive current collector means in contact with said hydrophilic layer whereby the electrical potential required to operate said electrochemical cell is reduced by establishing and maintaining sales by gas pressure said hydrophilic layer of said electrode in contact with said current collector means.

Claim 12

In an electrochemical reaction process conducted in an electrochemical cell comprising a gas compartment, a semi-permeable membrane disposed between a cathode and an anode so as to form a catholyte compartment and an anolyte compartment, said catholyte compartment containing said cathode and a volume of catholyte, said anolyte compartment containing said anode and a volume of anolyte, the adjacent surfaces of said anode and said cathode being spaced apart sufficiently for said membrane to fit freely therebetween, the process improvement comprising: utilizing a gas diffusion electrode assembly consisting of (1) a gas diffusion laminar electrode having an electrically conductive, porous hydrophilic layer comprising conductive carbon and a polymeric binder therefor, and a porous, hydrophobic layer comprising a hydrophobic polymer and (2) an electrically conductive current collector means in contact with said hydrophilic layer whereby the electrical potential required to operate said electrochemical cell is reduced by establishing and maintaining sales by gas pressure said hydrophilic layer of said electrode in contact with said current collector means.

Claim 13

The process of claim 10 wherein said cell is an electrolytic cell, said electrode is a cathode, and said anolyte compartment contains an aqueous solution of an alkali metal halide and said catholyte compartment contains an aqueous solution of an alkali metal hydroxide and said semi-permeable membrane is an asbestos diaphragm or an ion-exchange permselective membrane.

Claim 14

The process of claim 11 wherein said polymeric binder and said hydrophobic polymer each comprises at least one thermoplastic halocarbon polymer.

Claim 15

The process of claim 12 wherein said thermoplastic halocarbon polymer is selected from the group consisting of at least one of polymers of tetrafluoroethylene, fluorinated ethylene propylene, copolymers thereof having the moieties (--CX.sub.1 X.sub.2 --CX.sub.3 CX.sub.4 --) and (--CY.sub.1 Y.sub.2 --CY.sub.3 Y.sub.4 --), and homopolymers having the moieties (--CY.sub.1 Y.sub.2 --CY.sub.3 F--) wherein X 1 , X 2 , X 3 , X 4 , Y 1 , Y 2 , Y 3 , and Y 4 are selected from the group consisting of fluorine, chlorine, and hydrogen, at least one of said X and Y being fluorine.

Claim 16

The process of claim 13 wherein said thermoplastic halocarbon polymer is a fluorocarbon polymer selected from the group consisting of at least one of copolymers having an ethylene moiety and a fluorocarbon moiety chosen from the group consisting of (--CFH--CH.sub.2 --), (--CF.sub.2 --CH.sub.2 --), (--CF.sub.2 --CFH--), (--CF.sub.2 --CF.sub.2 --), and (--CF.sub.2 --CClF--).

Claim 17

The process of claim 14 wherein said current collector means comprises a metal mesh and a support structure wherein said metal mesh is prepared from a metal selected from the group consisting of stainless steel, nickel, platinum group metals, valve metals, and mixtures thereof.

Claim 18

The process of claim 14 wherein said metal mesh is prepared from a material selected from the group consisting of silver, silver-coated nickel, silver-coated steel, and silver-coated valve metals.

Claim 19

The process of claim 16 wherein said carbon black has a particle size of about 0.01 to about 0.05 microns.

Claim 20

The process of claim 16 wherein said carbon black is admixed with at least one electrochemically active catalyst.

Claim 21

The process of claim 18 wherein said electrochemically active catalyst is a precious metal catalyst selected from at least one of the group consisting of platinum, silver, palladium, and rhodium.

Claim 22

In a process for the electrolysis of an alkali metal halide brine wherein an aqueous brine is introduced into an anode compartment of an electrolytic cell containing a gas compartment; water or aqueous alkali metal hydroxide is introduced into a cathode compartment of the cell; said cathode and anode compartments are separated by a semi-permeable membrane; halogen and depleted brine are withdrawn through a common first conduit from the anode compartment to a brine collection point; and alkali metal hydroxide solution is withdrawn through a second conduit from the cathode compartment to an alkali metal hydroxide solution collection point; the improvement comprising providing as the cathode of said electrolytic cell, a laminar, gas diffusion cathode comprising an electrically conductive, porous hydrophilic layer and a porous hydrophobic layer adjacent to said gas compartment wherein gas pressure applied to said hydrophilic layer at a pressure is solely sufficient to force said cathode against a current collector means so as to make and maintain electrical contact in order to minimize the electrical potential required for electrolysis.

Claim 23

In a process for the electrolysis of an alkali metal halide brine wherein an aqueous brine is introduced into an anode compartment of an electrolytic cell containing a gas compartment; water or aqueous alkali metal hydroxide is introduced into a cathode compartment of the cell; said cathode and anode compartments are separated by a semi-permeable membrane; halogen and depleted brine are withdrawn through a common first conduit from the anode compartment to a brine collection point; and alkali metal hydroxide solution is withdrawn through a second conduit from the cathode compartment to an alkali metal hydroxide solution collection point; the improvement comprising providing as the cathode of said electrolytic cell, a laminar, gas diffusion cathode comprising an electrically conductive, porous hydrophilic layer and a porous hydrophobic layer adjacent to said gas compartment wherein gas pressure applied to said hydrophilic layer at a pressure is solely sufficient to force said cathode against a current collector means so as to make and maintain electrical contact in order to minimize the electrical potential required for electrolysis.

Claim 24

The process of claim 20 wherein said hydrophilic layer comprises a conductive carbon and a polymeric binder therefor, and said hydrophobic layer comprises a hydrophobic polymer.

Claim 25

The process of claim 21 wherein said polymeric binder and said hydrophobic polymer comprise a thermoplastic halocarbon polymer selected from the group consisting of at least one of polymers of tetrafluoroethylene, fluorinated ethylene propylene, copolymers thereof having the moieties (--CX.sub.1 X.sub.2 --CX.sub.3 CX.sub.4 --) and (--CY.sub.1 Y.sub.2 --CY.sub.3 Y.sub.4 --), and homopolymers having the moieties (--CY.sub.1 Y.sub.2 --CY.sub.3 F--) wherein X 1 , X 2 , X 3 , X 4 , Y 1 , Y 2 Y 3 , and Y 4 are selected from the group consisting of fluorine, chlorine, and hydrogen, at least one of said X and Y being fluorine.

Claim 26

The process of claim 22 wherein said halocarbon polymer is a fluorocarbon polymer selected from the group consisting of at least one of copolymers having an ethylene moiety and a fluorocarbon moiety chosen from the group consisting of (--CFH--CH.sub.2 --), (--CF.sub.2 --CH.sub.2 --), (--CF.sub.2 --CFH--), (--CF.sub.2 --CF.sub.2 --), and (--CF.sub.2 --CClF--).

Claim 27

The process of claim 23 wherein said conductive carbon is carbon black and said gas is air or oxygen.

Claim 28

The process of claim 24 wherein said conductive carbon is admixed with an electrochemically active precious metal catalyst selected from at least one of the group consisting of platinum, silver, palladium, and rhodium and wherein said alkali metal halide is sodium chloride and said alkali metal hydroxide is sodium hydroxide.