Cation Exchange Membrane Layout for Low-Resistance Electrolysis
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Solution Overview
Problem
The existing cation exchange membranes used in alkali chloride electrolysis face issues with mechanical strength and electrolytic performance due to the blocking effect of reinforcing core materials, leading to pinhole formation and reduced electrical resistance, which affects the stability and efficiency of the electrolysis process.
Innovation Solution
A cation exchange membrane design featuring a fluorine-based polymer with two or more reinforcing core materials arranged in parallel, incorporating specific relationships between the distance and number of elution holes to enhance mechanical strength and electrolytic performance, including the use of a method involving sacrifice yarns and dummy yarns to create the elution holes during production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a woven fabric reinforcing core material is embedded in the membrane to improve mechanical strength, then the membrane strength is improved, but the reinforcing core material blocks cation flow and reduces electrical resistance
Solution Approach 1:
The patent introduces elution holes (porous structures) through the membrane thickness at regular intervals to create dedicated cation flow channels. These porous pathways allow cations to bypass the blocking effect of the woven fabric reinforcing core material, thereby reducing electrical resistance while maintaining the mechanical strength provided by the reinforcing structure.
2Loss of energy
If elution holes are formed in the membrane to reduce electrical resistance and improve ion mobility, then the electrical resistance is reduced, but the mechanical strength of the membrane is reduced
Solution Approach 1:
The patent segments the membrane structure by introducing discrete elution holes at specific intervals rather than creating a continuous porous structure. This segmentation allows the membrane to maintain mechanical integrity in regions between the holes while providing adequate ion transport pathways. The spaced arrangement of holes prevents excessive weakening of the overall membrane structure.
3Strength
If the reinforcing core material projects from the membrane surface to maintain reinforcement function, then the reinforcing function is maintained, but the resin covering is peeled off during vibration and the reinforcing core material is exposed
Solution Approach 1:
The patent embeds the woven fabric reinforcing core material entirely within the membrane thickness, nesting it between the anode-side and cathode-side resin layers. This nested configuration prevents the reinforcing core material from projecting outward, thereby eliminating the peeling issue during vibration while maintaining the reinforcing function through internal structural support.
4Loss of energy
If multiple elution holes are formed between adjacent reinforcing core materials to improve ion flow, then the electrical resistance is reduced, but the arrangement complexity increases
Solution Approach 1:
The patent employs asymmetric arrangement of elution holes relative to the reinforcing core materials, with holes positioned at optimized distances from adjacent core materials. This asymmetric positioning is determined by balancing ion transport efficiency with mechanical strength requirements, creating an optimized but not perfectly symmetric pattern that reduces electrical resistance while maintaining manufacturability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The membrane achieves improved mechanical strength and stable electrolytic performance over time, reducing the risk of pinhole formation and lowering electrolysis voltage by optimizing the arrangement of reinforcing core materials and elution holes, ensuring efficient ion flow and prolonged membrane durability.
Implementation Method 1
a membrane body (14) containing a fluorine-based polymer having an ion-exchange group
Implementation Method 2
a hole (hereinafter, referred to as an "elution hole") is formed in the cation exchange membrane for ensuring a flow channel for e.g., a cation and an electrolyte
Data Source
AI summary
A cation exchange membrane includes: a membrane body containing a fluorine-based polymer having an ion-exchange group; and two or more reinforcing core materials arranged approximately in parallel within the membrane body. The membrane body is provided with two or more elution holes formed between the reinforcing core materials adjacent to each other. A distance between the reinforcing core materials adjacent to each other is represented by a, a distance between the reinforcing core materials and the elution holes adjacent to each other is represented by b, a distance between the elution holes adjacent to each other is represented by c, and the number of the elution holes formed between the reinforcing core materials adjacent to each other is represented by n. The relationship represented by the following expression (1) or expression (2) are satisfied:b>a/(n+1) (1);c>a/(n+1) (2)