Abstract: A pressurized or forced circulation electrolysis cell comprising a cell housing containing at least one pair of electrodes which is a cathode and an anode, a current collector and an ion exchange membrane having a surface area of at least about 40 ft.sup.2 having the improvement which comprises an electrically conductive, hydraulically permeable resilient mattress substantially coplanar with and contacting on one side the current collector and coplanar with and contacting on the other side an electrode. The mattress comprises at least six non-aligned layers of woven and crimped metal fibers having a resiliency product of greater than 100 (inches).sup.2 /psi according to the formula:RP=10,000.times.NS.times.CHwherein RP represents the resiliency product in (inches).sup.2 /psi, NS is the negative slope of the mattress height versus compressive load of the mattress, and CH is the compressive height over the range that the mattress will be compressed in millimeters.

Abstract: A membrane-electrode structure for use in an electrochemical cell comprising an ion exchange membrane with a cathode layer and several intermediate layers between the cathode and the membrane. The intermediate layers comprises at least two layers or zones of inorganic solid particles and an organic polymer binder. The intermediate layer or zone adjacent to the membrane comprises more than 50% by weight of inorganic particles and the other layers or zones have 50% by weight or less of inorganic particles.

Abstract: In an electrolyzer system having metallic supply and discharge piping subjected to shunt currents, the improvement which comprises a removable target electrode in the section of said piping subjected to said shunt currents, said target electrode having a lower overvoltage than the metallic piping being protected.

Abstract: Cathodes useful in an electrolytic cell, such as a chlor-alkali cell, are disclosed which have a metallic-surfaced substrate coated with a catalytic coating composition. In one aspect, the catalytic coating includes a base layer of at least one primary electrocatalytic metal with particles of at least one electrocatalytic metal oxide entrapped therein. In another aspect, at least one upper oxide layer is formed on the base layer. Each upper oxide layer includes a substantially heterogeneous mixture of at least one primary electrocatalytic metal oxide and at least one secondary electrocatalytic metal oxide. The catalytic coatings are tightly adherent to the underlying substrate, resist loss during cell operation and exhibit low hydrogen overvoltage potentials. Disclosed are methods for preparing the above-described cathodes.

Abstract: Cathodes useful in electrolytic cells, such as a chlor-alkali cell, are disclosed which have a metallic-surfaced substrate coated with an electrocatalytic coating. The electrocatalytic coating includes palladium and at least one primary electrocatalytic metal, such as a platinum group metal. The coating optionally includes at least one secondary electrocatalytic metal, such as nickel, cobalt, iron, copper, manganese, molybdenum, cadmium, chromium, tin and silicon. Also disclosed is non-electrolytic reduction method for preparing the cathodes. The method provides a tightly adherent coating, improves electrocatalyst loading and reduces cathode production costs.

Abstract: Cathodes useful in electrolytic cells, such as a chlor-alkali cell, are disclosed which have a metallic-surfaced substrate coated with an electrocatalytic coating. The electrocatalytic coating includes palladium and at least one primary electrocatlaytic metal, such as a platinum group metal. The coating optionally includes at least one secondary electrocatalytic metal, such as nickel, cobalt, iron, copper, manganese, molybdenum, cadmium, chromium, tin and silicon. Also disclosed is a non-electrolytic reduction method for preparing the cathodes. The method provides a tightly adherent coating, improves electrocatalyst loading and reduces cathode production costs.

Abstract: Cathodes useful in an electrolytic cell, such as a chlor-alkali cell, are disclosed which have a metallic-surfaced substrate coated with a catalytic coating composition. In one aspect, the catalytic coating includes a base layer of at least one primary electrocatalytic metal with particles of at least one electrocatalytic metal oxide entrapped therein. In another aspect, at least one upper oxide layer is formed on the base layer. Each upper oxide layer includes a substantially heterogeneous mixture of at least one primary electrocatalytic metal oxide and at least one secondary electrocatalytic metal oxide. The catalytic coatings are tightly adherent to the underlying substrate, resist loss during cell operation and exhibit low hydrogen overvoltage potentials. Also disclosed are methods for preparing the cathodes.

Abstract: A membrane unit for use in an electrolytic cell comprising a combination of a membrane material and a reinforcing material around only the gasket-bearing surface of the membrane material. Damage to the gasket bearing surface of the membrane structure is minimized when the membrane unit is employed in, for example, electrolytic cells of the filter press-type.

Abstract: A membrane unit for use in an electrolytic cell comprising a combination of a first layer of membrane material and a second layer including a sealing material and a metallic insert around only the gasket-bearing surface of the membrane material. Damage to the gasket-bearing surface of the membrane structure is minimized when the membrane unit is employed in, for example, electrolytic cells of the filter press-type.

Abstract: The invention is a method for preparing electrocatalytic oxides and applying them to substrates that cannot be heated to temperatures sufficiently high to convert electrocatalytic salts into electrocatalytic oxide comprising:(a) dissolving Ru salt(s) and Ni salt(s) in a solvent to form an electrocatalytic salt solution;(b) evaporating the solvent from the electrocatalytic salt solution, leaving a electrocatalytic salt residue;(c) heating the electrocatalytic salt residue in the presence of oxygen to a temperature and for a time sufficient to convert substantially all of the electrocatalytic salt into a electrocatalytic oxide; and(d) bonding the so-formed electrocatalytic oxide to a substrate that would be detrimentally affected if it were to be heated to 480.degree.-500.degree. C.

Abstract: The invention is a dampening device for use in a vertically disposed electrochemical cell unit of the type at least having: (a) a peripheral flange which defines at least one electrode chamber, said peripheral flange having a upper, substantially horizontally disposed flange portion, a lower substantially horizontally disposed flange portion, and two disposed side flange portions; and (b) at least one outlet port passing through the upper horizontally disposed flange portion or through one of the two vertical side flange portions or through the lower flange portion and connecting the exterior of the cell with the electrode chamber.

Abstract: An alkali metal salt solution is electrolyzed in an electrolytic cell with at least two electrode compartments adapted to being separated by a membrane. At least one electrode compartment contains at least one means defining a space adapted to receive a portion of membrane surface during operation of the cell. By maintaining the pressure higher in one electrode compartment than the other the membrane portion is pushed toward and into the membrane receiving space such that any wrinkles formed on the membrane are removed.

Abstract: The invention is a method comprising:welding a titanium sheet having a thickness of less than about 2 millimeters to a ferrous material through a weldably compatible intermediate material and a titanium intermediate.

Abstract: A flat plate bipolar electrolytic cell frame unit has a plurality of connectors removably attachable to the centerboard. Anode and cathode plate supports or ribs have outer plate supporting edges and are cooperable with the connectors, when the latter are secured to the centerboard, to enable adjustment of the ribs to preselected positions whereat their edges define preselected planes, such that when the anode and cathode plates are subsequently welded to said edges and assembled with the connectors to the centerboard, the anode and cathode plates of adjacent bipolar cell units are parallel and closely spaced by a predetermined distance. The connectors are removably secured to the centerboard and the ribs are welded at their adjusted positions to their respective connectors. Thereafter the welded together connectors and ribs are removed from the centerboard to enable unencumbered welding of the anode and cathode plates to said edges of the anode and cathode ribs respectively.

Abstract: The invention is an electrochemical article suitable for use in monopolar or bipolar electrochemical cells comprising:an organic, planar plastic member having a plurality of horizontally and vertically spaced-apart shoulders protruding outwardly from opposing generally coplanar surfaces of said planar plastic member;at least one electrically conductive insert extending from an exterior face of a shoulder on a first surface of the planar plastic member, through the planar plastic member, to an exterior face of a shoulder on a second surface of the planar plastic member, wherein each of said shoulders annularly encircles and supports each of said inserts;an electrically conductive, substantially completely hydraulically impermeable protective liner resistant to the corrosive effects of electrolyte matingly contacted with the first surface of said planar plastic member and adapted to minimize contact between the electrolyte and said planar plastic member within the cell; andan electrical connection means electri

Abstract: The invention is an electrolytic unit comprised of a plurality of parts connected in a manner to form a substantially planar electrolytic unit comprising:a central support element component, a plurality of bosses on each side of the support component projecting outward from said support component;a peripheral flange structure composed of at least one piece and having an internal surface which sealably receives and attached to at least a portion of the external peripheral surfaces of the support unit.

Abstract: The invention is a structural frame adapted for use in an electrochemical cell comprising:a plastic member with a plurality of horizontally and vertically spaced-apart shoulders protruding outwardly from opposing generally parallel 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 encircles and supports each of said insert;an electrically conductive, substantially completely hydraulically impermeable cover resistant to the corrosive effects of the electrolyte matingly contacting the first surface of said plastic member and with at least a portion of the inserts, said cover being adapted to minimize contact between the electrolyte and said plastic member;a gas permeable current collector positioned substantially parallel to the second

Abstract: The invention is a method for making an electrolytic unit havinga substantially planar, plastic, plastic member;a plurality of horizontally and vertically spaced apart shoulders on each side of the plastic member projecting outwardly therefrom and annularly encircling and supporting a plurality of electrically conductive inserts which extend from an exterior face of a shoulder on one surface of the plastic member, through the plastic member, to an exterior face of a shoulder on an opposite surface of the plastic member; anda frame structure composed of at least one piece and having an internal surface which sealably receives the external peripheral edges of the plastic member;said method comprising:attaching in any order:(a) a plurality of horizontally and vertically spaced apart shoulders to the plastic member;(b) at least one portion of the frame structure to the peripheral edges of the plastic member; and(c) a plurality of cover pieces to at least a portion of the horizontally and vertically spaced apart s

Abstract: An electrochemical cell structure frame and cell utilizing same comprising an organic plastic member having electrically conductive inserts extending through annular shoulders on respective coplanar surfaces of the plastic member. Electrically conductive, hydraulically impermeable anolyte and catholyte resistant covers matingly contact each respective coplanar surface of the plastic member. An electrically conductive, hydraulically permeable current collector is positioned substantially coplanar with and contacts at least a portion of one of the covers. An electrically conductive, hydraulically permeable, resilient mattress is positioned substantially coplanar with and contacts at least a portion of a side of the current collector opposite the side of the current collector which contacts the cover. A catalytically active electrode is positioned substantially coplanar with and contacts at least a portion of a side of the mattress opposite the side of the mattress which contacts the current collector.

Abstract: The present invention is a structural frame particularly suitable for use in an electrochemical cell. The frame comprises an organic plastic member with a plurality of horizontally and vertically spaced-apart shoulders protruding outwardly from opposing generally coplanar anolyte and catholyte surfaces of the plastic member. Each of the shoulders annularly encircles and supports an electrically conductive insert extending from an exterior face of a shoulder on the catholyte surface of the plastic member, through the plastic member, to an exterior face of a shoulder on the anolyte surface of the plastic member.An electrically conductive substantially completely hydraulically impermeable anolyte cover is matingly affixed to the anolyte surface of the plastic member and adapted to minimize contact between the anolyte and the plastic member. The anolyte cover is resistant to the corrosive effects of the anolyte.