Abstract: A metal coating of typically a valve metal, especially a titanium metal coating, is applied by thermal spraying to the surface of concrete, most particularly steel-reinforced concrete. The metal such as titanium may be sprayed by any one of several thermal spraying techniques including flame spray, electric-arc spray, plasma spray, high-velocity oxyfuel spray, or detonation gun spray. The metal coating should be tightly adhered to the concrete and desirably will have a porosity to facilitate extensive coating of the metal itself, as well as facilitate any activation that may be needed for the metal. Such activation can be in the form of an electrochemically active material which allows the coating to function in electrochemically active form. One coating option is to apply a solution onto the spray-applied metal, then polarize the metal anodically to effect deposition of active material on the metal.

Abstract: A cell, particularly a membrane cell, that will generally be oriented in an at least substantially vertical positioning, is provided with an array of blade electrodes. The blade electrodes are Delta shape in cross-section, having a flat back face and forwardly sloping sides meeting at a forward edge. Such electrodes can be secured to a current distributor bar, typically on a flat front face of the bar. The forward edge of an electrode blade may be placed opposite a counter electrode of the same or different structure, with a membrane separator usually interposed therebetween. Electrical connection can be made to the electrode blades from the distributor bar, and to the distributor bar through boss electrical connectors. Baffles, which may also be secured to the distributor bar, help establish a front chamber, containing the electrode blades, in front of the baffles, and a back chamber behind the baffles. Electrolyte circulates through the front chamber and recirculates through the back chamber.

Abstract: Methods, and various apparatus therefor, are disclosed for the electrolytic treatment of an acidic solution. Generally the method comprises: (a) providing an electrolytic cell, the cell comprising: (i) an anode chamber and an anode therein; (ii) a cathode chamber and a cathode therein; and (iii) a diaphragm. Usually the diaphragm is of a non-isotropic fibrous mat comprising 5-70 weight percent organic halocarbon polymer fiber in adherent combination with about 30-95 weight percent of finely divided inorganic particulate impacted into said fiber during fiber formation, the diaphragm having a weight per unit of surface area of about 3-12 kilograms per square meter. The method can continue by (b) introducing the acidic solution into the cell; (c) impressing a current on the anode and the cathode causing the migration of ions through the diaphragm; and (d) recovering a product of the electrolytic treatment from the anode chamber, or the cathode chamber, or from both chambers.

Abstract: A process is disclosed, as well as apparatus useful therefor, for continuously electroplating a strip of reticulated foam using multiple electroplating zones that each contain electroplating bath. In each zone there is a cathode and an anode. In at least one electroplating zone there is an insoluble anode, typically as the sole anode. In some of the electroplating zones soluble anodes may be used. As a first cathode, there can be provided a cathode roll outside of the electroplating bath. The reticulated foam is guided in the bath past the anodes, as well as past cathodes, e.g., including a cathode roll which may be positioned outside of the bath. The resulting electroplated foam emerging from the bath has an improved electroplate weight distribution and the process achieves enhanced efficiencies and economies of operation.

Abstract: An electrode, electrochemical cell, and electrochemical processes are disclosed. The electrode is a porous, multi-layered electrode which can have an element in flexible, strip form wound around a central, usually flat plate core, which core may serve as a current distributor. In any form, each layer can be represented by a very thin, highly flexible metal mesh. This can be a fine, as opposed to a coarse, mesh which has extremely thin strands and small voids. The electrode will have an active coating. For utilizing this electrode, the cell in one form will be a monopolar cell providing upward, parallel electrolyte flow through the porous, multi-layered electrode. A representative cell can have such electrode at least substantially filling an electrode chamber. The cells can be contained in a cell box that will provide the desired flow-through relationship for the electrolyte to the electrode.

Abstract: An electrode, electrochemical cell, and electrochemical processes are disclosed. The electrode is a porous, multi-layered electrode which can have an element in flexible, strip form wound around a central, usually flat plate core, which core may serve as a current distributor. In any form, each layer can be represented by a very thin, highly flexible metal mesh. This can be a fine, as opposed to a coarse, mesh which has extremely thin strands and small voids. The electrode will have an active coating. For utilizing this electrode, the cell in one form will be a monopolar cell providing upward, parallel electrolyte flow through the porous, multi-layered electrode. A representative cell can have such electrode at least substantially filling an electrode chamber. The cells can be contained in a cell box that will provide the desired flow-through relationship for the electrolyte to the electrode.

Abstract: An existing, usually used radial lead anode in an electroplating cell is machined to a specific radius. This provides a curved, machined surface for the lead anode to serve as a support structure. A thin gauge, dimensionally stable sheet anode of a multitude of side-by-side strip anodes is formed, with each strip anode being typically formed to a larger radius then the radius of the support structure. The sheet anode strips may be precurved into a series of chords. The strip anodes are flexed into place onto the surface of the lead support structure. Fastening these strips and the support structure together can be accomplished by a series of fastening means attached to the back of each strip anode, which means can project into or through holes in the lead support structure. Electrical connection can be provided, such as through the fastening means, with the lead support structure serving as a current distributor member.

Abstract: Electrodes in plate form can be electrocatalytically coated and secured to a current distributor, such as by welding to a base plate, and may be serviceable, e.g., as anodes, in cells electrolyzing brine. Recoating of plate electrodes can require removal from the cell, removal of old coating, application of fresh coating, then returning and securing the freshly coated electrodes to the cell. There are now provided envelopes for covering the original electrode plates. The original plates thus do not need to be separated from a base member of the cell. The envelopes can have an electrocatalytic coating on their outer surfaces. The resulting electrodes are thus a combination of an old inner plate and a new outer envelope, with an outer surface coating on the envelope. The envelopes can be secured to the inner plate and/or to a current distributor such as a base plate.

Abstract: An anode for cathodically-protected steel-reinforced concrete is embedded in an ion-conductive overlay on the concrete structure. The anode comprises at least one sheet of highly expanded valve metal mesh having a pattern of voids defined by a network of valve metal strands connected at a multiplicity of nodes. This provides a redundancy of current-carrying paths through the mesh which ensures effective current distribution throughout the mesh even in the event of possible breakage of a number of individual strands. The surface of the valve metal mesh carries an electrochemically active coating. At least one current distribution member is welded to the valve metal mesh. The entire area of the structure to be protected, excluding non-protected openings for obstacles and the like, is covered by a single piece of the mesh, or several pieces in close proximity with one another.

Abstract: A porous product, typically a metal foam sheet, is produced as a tailored, engineered product. The porous product can have enhanced strength, as well as more desirable electrical and mechanical properties. The product which first exists typically as a flexible, generally polymeric foam sheet in strip form, which strip is produced in the longitudinal direction, is stretched in a direction other than its direction of production. The porous product can have pores which would be anisotropic in form in usual production, which are stretched to at least substantially isotropic form. The product can even be tailored to have pores which are anisotropic in the direction of the stretch. Thus, an engineered product can be produced which, for example, as an open-cell metal foam prepared from a polymeric foam can have conductivity, both thermal and electrical, as well as strength and ductility, tailored for greater uniformity and performance.

Abstract: A method of preparing electrodes is now described, which electrodes have enhanced adhesion of subsequently applied coatings combined with excellent coating service life. In the method, a substrate metal, such as a valve metal as represented by titanium, is provided with a highly desirable rough surface characteristic for subsequent coating application. This can be achieved by various operations including etching to ensure a roughened surface morphology. In subsequent operations, a barrier layer is provided on the surface of enhanced morphology. This may be achieved by operations including heating, as well as including thermal decomposition of a layer precursor. Subsequent coatings provide enhanced lifetime even in the most rugged commercial environments.

Abstract: An anode for cathodically-protected steel-reinforced concrete is embedded in an ion-conductive overlay on the concrete structure. The anode comprises at least one sheet of highly expanded valve metal mesh having a pattern of voids defined by a network of valve metal strands connected at a multiplicity of nodes. This provides a redundancy of current-carrying paths through the mesh which ensures effective current distribution throughout the mesh even in the event of possible breakage of a number of individual strands. The surface of the valve metal mesh carries an electrochemically active coating. At least one current distribution member is welded to the valve metal mesh. The entire area of the structure to be protected, excluding non-protected openings for obstacles and the like, is covered by a single piece of the mesh, or several pieces in close proximity with one another.

Abstract: Electrodes in plate form can be electrocatalytically coated and secured to a current distributor, such as by welding to a base plate, and may be serviceable, e.g., as anodes, in cells electrolyzing brine. Recoating of plate electrodes can require removal from the cell, removal of old coating, application of fresh coating, then returning and securing the freshly coated electrodes to the cell. There is now provided a covering innovation for the original electrode plates. In the covering innovation, the original plates do not need to be separated from a base member of the cell. In the method of covering, there is utilized an outer envelope member, tightly engaging the original plate electrode. The envelopes can have an electrocatalytic coating on their outer surfaces. The resulting electrodes are thus a combination of an old inner plate and a new outer envelope, with an outer surface coating on the envelope. The envelopes can be secured to the inner plate and/or to a current distributor such as a base plate.

Abstract: Methods, and various apparatus therefor, are disclosed for the electrolytic treatment of an acidic solution. Generally the method comprises: (a) providing an electrolytic cell, the cell comprising: (i) an anode chamber and an anode therein; (ii) a cathode chamber and a cathode therein; and (iii) a diaphragm. Usually the diaphragm is of a non-isotropic fibrous mat comprising 5-70 weight percent organic halocarbon polymer fiber in adherent combination with about 30-95 weight percent of finely divided inorganic particulate impacted into said fiber during fiber formation, the diaphragm having a weight per unit of surface area of about 3-12 kilograms per square meter. The method can continue by (b) introducing the acidic solution into the cell; (c) impressing a current on the anode and the cathode causing the migration of ions through the diaphragm; and (d) recovering a product of the electrolytic treatment from the anode chamber, or the cathode chamber, or from both chambers.

Abstract: An electrode assembly which will find use such as in electroplating, is made from a hollow and thin walled, elongate and deflectable outer metal electrode member. This member is usually rounded, e.g., typically circular, in cross-section and has major inner and outer faces. Representative of this outer member would be a titanium tube. The electrode assembly also has a removable and elongate, inner metal electrical current distributor member. This inner current distributor member will typically be rectangular in cross-section. Representative of this inner member is a rectangular copper bar. As assembled, this typical assembly can have the edges on the outer face of the copper bar engage the inner face of the titanium tube. In putting together this particular assembly, the hollow tube is compressed, such as from circular to elliptical shape. The copper bar current distributor is inserted into this misshapen tube.

Abstract: A method of preparing electrodes is now described, which electrodes have enhanced adhesion of subsequently applied coatings combined with excellent coating service life. In the method a substrate metal, such as a valve metal as represented by titanium, is provided with a highly desirable rough surface characteristic for subsequent coating application. This can be achieved by various operations including etching and melt spray application of metal or ceramic oxide to ensure a roughened surface morphology. In subsequent operations: a barrier layer is provided on the surface of enhanced morphology. This may be achieved by operations including heating, as well as including thermal decomposition of a layer precursor. Subsequent coatings provide enhanced lifetime even in the most rugged commercial environments.

Abstract: A metal surface is now described having enhanced adhesion of subsequently applied coatings. The substrate metal of the article, such as a valve metal as represented by titanium, is provided with a highly desirable surface characteristic for subsequent coating application. This can be initiated by selection of a metal of desirable metallurgy and heat history, including prior heat treatment to provide surface grain boundaries which may be most readily etched. In subsequent etching operation, the surface is made to exhibit well defined, three dimensional grains with deep grain boundaries. Subsequently applied coatings, by penetrating into the etched intergranular valleys, are desirably locked onto the metal substrate surface and provide enhanced lifetime even in rugged commercial environments.

Abstract: Methods, and various apparatus therefor, are disclosed for the electrolytic treatment of an acidic solution. Generally the method comprises: (a) providing an electrolytic cell, the cell comprising: (i) an anode chamber and an anode therein; (ii) a cathode chamber and a cathode therein; and (iii) a diaphragm. Usually the diaphragm is of a non-isotropic fibrous mat comprising 5-70 weight percent organic halocarbon polymer fiber in adherent combination with about 30-95 weight percent of finely divided inorganic particulate impacted into said fiber during fiber formation, the diaphragm having a weight per unit of surface area of about 3-12 kilograms per square meter. The method can continue by (b) introducing the acidic solution into the cell; (c) impressing a current on the anode and the cathode causing the migration of ions through the diaphragm; and (d) recovering a product of the electrolytic treatment from the anode chamber, or the cathode chamber, or from both chambers.

Abstract: Electrodes in plate form can be electrocatalytically coated and secured to a current distributor, such as by welding to a base plate, and may be serviceable, e.g., as anodes, in cells electrolyzing brine. Recoating of plate electrodes can require removal from the cell, removal of old coating, application of fresh coating, then returning and securing the freshly coated electrodes to the cell. There are now provided envelopes for covering the original electrode plates. The original plates thus do not need to be separated from a base member of the cell. The envelopes can have an electrocatalytic coating on their outer surfaces. The resulting electrodes are thus a combination of an old inner plate and a new outer envelope, with an outer surface coating on the envelope. The envelopes can be secured to the inner plate and/or to a current distributor such as a base plate.

Abstract: Electrodes such as mesh electrodes can be in configurations where they are separated from electrode back pans by standoffs. The mesh electrodes are very adherently secured to the standoffs. When the electrodes are in need of repair, removal and refurbishing can be a problem. There is now disclosed a method of electrode repair which in large part retains original structure by first removing the mesh electrode and then at least substantially the top of the standoff. A replacement standoff assembly is placed against the retained portion of the original standoff and secured thereto. Refurbished or new electrode mesh can be adhered to the resulting replacement standoff. This may include welding of mesh electrode strands utilizing weld nuggets which are substantially the size of the strands. The refurbishing technique can maintain original separation distances between the back pan and the electrode.