Gradient Metallic Cushion for Ion Exchange Membrane Electrolytic Cell
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Solution Overview
Problem
The existing ion exchange membrane electrolytic cell using a gas diffusion electrode faces issues with excessive pressure on the ion exchange membrane, leading to potential damage and inefficiencies due to uneven repulsive forces across the cathode gas chamber, which can elevate electrolysis voltage and consume excessive materials.
Innovation Solution
A configuration where a metallic cushion with a repulsive force gradient is used, with the force being larger at the bottom and smaller at the top of the cathode gas chamber, made from materials like nickel or high nickel alloys, to evenly distribute pressure and minimize excessive pressure on the ion exchange membrane, utilizing either a wavy mat or coil design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a uniform cushion material is used throughout the cathode gas chamber, then the structure is simple and easy to manufacture, but the repulsive force is uneven causing excessive pressure at the top and insufficient pressure at the bottom
Solution Approach 1:
The cushion material is designed with spatially varying properties: the upper portion has lower repulsive force characteristics while the lower portion has higher repulsive force characteristics. This local differentiation compensates for the hydrostatic pressure gradient in the electrolyte, achieving uniform contact pressure across the ion exchange membrane surface without requiring complex control systems.
Solution Approach 2:
The cushion material structure intentionally introduces asymmetry in the vertical direction, with different compression characteristics at the top versus bottom. This asymmetric design matches the asymmetric pressure distribution caused by the electrolyte column, transforming a potential problem into a solution that achieves uniform membrane contact.
2Use of energy by moving object
If the cathode gas chamber thickness is reduced to minimize oxygen supply path, then the electrolysis voltage is reduced, but the repulsive force from the cushion material becomes excessive and damages the ion exchange membrane
Solution Approach 1:
The cushion material's repulsive force characteristic is differentiated by position: the upper portion is designed with lower repulsive force to accommodate the reduced chamber thickness, preventing excessive pressure on the membrane, while the lower portion maintains higher repulsive force to ensure adequate contact pressure.
3Object-affected harmful factors
If the cathode gas chamber thickness is increased to reduce repulsive force, then excessive pressure on the membrane is reduced, but the oxygen supply path increases and electrolysis voltage increases
Solution Approach 1:
The cushion material is designed with position-dependent repulsive force characteristics that match the local requirements: lower repulsive force in the upper region where membrane damage risk is highest, and higher repulsive force in the lower region where adequate contact pressure is needed, thereby maintaining optimal chamber thickness throughout.
4Ease of manufacture
If a simple uniform cushion material is used, then manufacturing is easy, but material is wasted in regions where excessive pressure is applied
Solution Approach 1:
The cushion material's structure is optimized locally: the upper portion uses material with lower repulsive force characteristics reducing material consumption, while the lower portion uses material with higher repulsive force characteristics ensuring adequate contact. This spatial optimization reduces overall material usage while maintaining performance.
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
This configuration ensures stable operation by preventing superfluous pressure on the ion exchange membrane, reducing material usage, and maintaining long-term performance by evenly distributing repulsive forces, thus minimizing voltage loss and extending the lifespan of the membrane.
Implementation Method 1
an elastic material (cushion material) is elastically accommodated in the cathode chamber so as to press the gas diffusion electrode to the anode through the ion exchange membrane by using the repulsive force generated therein
Implementation Method 2
brine is electrolyzed to produce hydroxide and chlorine by employing a so-called ion exchange membrane method
Implementation Method 3
a method which includes a reaction in which a gas diffusion electrode is used as a cathode to reduce oxygen
Implementation Method 4
The electrolytic cell main body is divided into an anode chamber and a cathode gas chamber which are separated from one another by an ion exchange membrane
Data Source
AI summary
A method of producing caustic soda or chlorine by employing an ion exchange membrane electrolytic cell. The method involves use of a cushion material 10 accommodated between a cathode gas chamber back plate 9 and a gas diffusion electrode 7 of an ion exchange membrane electrolytic cell 1 such that a repulsive force of the cushion material at the bottom part of the cathode gas chamber is larger than that at the top part. The excessive pressure applied to the ion exchange membrane is suppressed to prevent the generation of scratches or the like by decreasing the repulsive force of the cushion material toward the top in accordance with a differential pressure between an anode chamber pressure and a cathode gas chamber pressure.