Ion exchange membranes, electrochemical systems, and methods

• US 10,480,085 B2
• Filed: 03/26/2019
• Issued: 11/19/2019
• Est. Priority Date: 03/16/2015
• Status: Active Grant

• Current Assignee: Calera Corporation
• Original Assignee: Calera Corporation
• Inventors: Gilliam, Ryan J, Kostowskyj, Michael, McWaid, Thomas H, Mohanta, Samaresh, Zhao, Hong
• Primary Examiner(s): Bernshteyn, Michael
• Application Number:
  US16/364,383
• Publication Number:
  US 20190218673A1
• Time in Patent Office: 238 Days
• Field of Search: 205770
• CPC Class Codes: C25B 11/036 Bipolar electrodes
• CPC Class Codes: C25B 13/02 characterised by shape or form
• CPC Class Codes: C25B 13/04 characterised by the material
• CPC Class Codes: C25B 9/00 Cells or assemblies of cells; Constructional parts of cells; Assemblies of constructional parts, e.g. electrode-diaphragm assemblies; Process-related cell features
• CPC Class Codes: C25B 9/19 with diaphragms

Abstract

Disclosed herein are ion exchange membranes, electrochemical systems, and methods that relate to various configurations of the ion exchange membranes and other components of the electrochemical cell.

Claims

1. An ion exchange membrane (IEM), comprising:

an ionomer membrane with a built-in separator wherein one or more sections of the built-in separator protrude out from front and back surfaces of the ionomer membrane, wherein the built-in separator is a mesh and wherein the built-in separator is made of polyethylene.

2. The ion exchange membrane of claim 1, wherein amplitude of the protrusion is from 0.01 mm to 1 mm.

3. The ion exchange membrane of claim 2, wherein wavelength of the amplitude of the protrusion is from 0.5 mm to 50 mm.

4. The ion exchange membrane of claim 1, wherein an average thickness of the ionomer membrane is from 10 μ

m to 250 μ

m.

5. The ion exchange membrane of claim 1, wherein ratio of cross-sectional area of the built-in separator to nominal cross-sectional area of the IEM is between about 5-70%.

6. The ion exchange membrane of claim 1, wherein the built-in separator is configured to separate the IEM from an anode;

separate the IEM from a cathode;

separate the IEM from another IEM;

or combinations thereof.

7. The ion exchange membrane of claim 1, further comprising a gasket material integrated with the IEM.

8. The ion exchange membrane of claim 7, wherein the gasket material is integrated to the edges of the IEM.

9. The ion exchange membrane of claim 7, wherein the gasket material is integrated on front, back, or both sides of the IEM.

10. The ion exchange membrane of claim 7, wherein the gasket material is of thickness between about 0.01 mm to 5 mm.

11. The ion exchange membrane of claim 7, wherein the gasket material is made of silicone, viton, rubber, cork, felt, foam, plastic, fiber glass, flexible graphite, mica, or polymer.