Membrane for electrochemical apparatus
A membrane for use with an electrochemical apparatus is provided. The electrochemical apparatus may include a fuel cell or electrolyzer, for example, an electrolyzer adapted to produce hydrogen. The membrane comprises a fabric made from a synthetic fiber such as nylon where the nylon, in an exemplary embodiment, is woven into ripstop nylon fabric. The electrochemical apparatus is constructed with frames comprising high-density polyethylene (HDPE) which provide support and structure to the membranes as well as to internal electrodes. A method of making an electrochemical apparatus, such as an electrolyzer, containing a membrane comprising ripstop nylon is also disclosed, as is a method for producing hydrogen gas with an electrolyzer containing a membrane comprising ripstop nylon.
1. An apparatus, comprising:
a first compression plate, the first compression plate having a first side and a second side;
a first insulator plate, a first side of the first insulator plate facing and abutting the second side of the first compression plate;
a first electrode, a first side of the first electrode facing and abutting a second side of the first insulator plate;
a first end frame, the first end frame defining an aperture, and comprising;
a first side, the first side facing and abutting a second side of the first electrode;
a second side;
a liquid inlet forming a hole between the first side and the second side;
a channel formed on the first side between the aperture and the liquid inlet;
a gas outlet forming a hole between the first side and the second side; and
a channel formed on the first side between the aperture and the gas outlet;
at least one membrane-electrode assembly, a membrane side of the membrane-electrode assembly facing and abutting the second side of the first end frame, the at least one membrane-electrode assembly comprising:
a membrane assembly, the membrane assembly comprising:
a ripstop nylon membrane;
a gasket affixed to a border of a first side of the membrane; and
a gasket affixed to a border of a second side of the membrane, the first electrode, the first end frame, and the membrane assembly defining a first end frame chamber, the first end frame chamber substantially void of solid material;
a first interior frame, the first interior frame defining an aperture, and comprising:
a first side, the first side facing and abutting a second side of the membrane assembly;
a second side;
a liquid inlet forming a hole between the first side and the second side;
a channel formed on the second side between the aperture and the liquid inlet;
a gas outlet forming a hole between the first side and the second side; and
a channel formed on the second side between the aperture and the gas outlet;
an interior electrode, a first side of the interior electrode facing and abutting the second side of the first interior frame, the membrane assembly, the first interior frame, and the interior electrode defining a first interior frame chamber, the first interior frame chamber substantially void of solid material; and
a second interior frame, the second interior frame defining an aperture, and comprising:
a first side, the first side facing and abutting a second side of the electrode;
a second side;
a liquid inlet forming a hole between the first side and the second side;
a channel formed on the first side between the aperture and the liquid inlet;
a gas outlet forming a hole between the first side and the second side; and
a channel formed on the first side between the aperture and the gas outlet;
a further membrane assembly, the further membrane assembly comprising:
a ripstop nylon membrane;
a gasket affixed to a border of a first side of the further membrane; and
a gasket affixed to a border of a second side of the further membrane, a first side of the further membrane facing and abutting the second side of the second interior frame, the interior electrode, the second interior frame, and the further membrane assembly defining a second interior frame chamber, the second interior frame chamber substantially void of solid material;
a second end frame, the second end frame defining an aperture, and comprising:
a first side, the first side facing and abutting a second side of the further membrane;
a second side;
a liquid inlet forming a hole between the first side and the second side;
a channel formed on the second side between the aperture and the liquid inlet;
a gas outlet forming a hole between the first side and the second side; and
a channel formed on the second side between the aperture and the gas outlet;
a further electrode, a first side of the further electrode facing and abutting the second side of the second end frame, the further membrane assembly, the second end frame, and the further electrode defining a second end frame chamber, the second end frame chamber substantially void of solid material;
a second insulator plate, a first side of the second insulator plate facing and abutting a second side of the further electrode; and
a second compression plate, a first side of the second compression plate facing and abutting a second side of the second insulator plate.
2. The apparatus of claim 1 , wherein the further electrode further comprises:
a liquid inlet forming a hole between the first side and the second side; and
a gas outlet forming a hole between the first side and the second side.
3. The apparatus of claim 1 , wherein the second insulator plate further comprises:
a liquid inlet forming a hole between the first side and the second side; and
a gas outlet forming a hole between the first side and the second side.
4. The apparatus of claim 1 , wherein the second compression plate further comprises:
a second side;
a liquid inlet forming a hole between the first side and the second side; and
a gas outlet forming a hole between the first side and the second side.
5. An electrolyzer, the electrolyzer comprising:
an anode;
a cathode; and
an ion transfer membrane, the ion transfer membrane interposed between the anode and the cathode, the ion transfer membrane comprising ripstop nylon.
6. The membrane of claim 5 , wherein the ripstop nylon has a weight of about two ounces per square yard.
7. The membrane of claim 5 , wherein the ripstop nylon has a thread count of about 118×92.
8. A membrane-electrode assembly comprising:
a membrane assembly, the membrane assembly comprising;
an ion transfer membrane, the membrane comprising ripstop nylon;
a gasket affixed to a border of at least one side of the membrane;
a membrane assembly first side; and
a membrane assembly second side;
a first interior frame the first interior frame defining an aperture and comprising:
a first interior frame first side, the first interior frame first side facing and abutting the membrane assembly second side;
a first interior frame second side;
a liquid inlet forming a hole between the first interior frame first side and the first interior frame second side;
a channel formed on the first interior frame second side between the aperture and the liquid inlet;
a gas outlet forming a hole between the first interior frame first side and the first interior frame second side; and
a channel formed on the first interior frame second side between the aperture and the gas outlet;
an interior electrode, a first side of the interior electrode facing and abutting the first interior frame second side; and
a second interior frame the second interior frame defining an aperture and comprising:
a second interior frame first side, the second interior frame first side facing and abutting a second side of the interior electrode;
a second interior frame second side;
a liquid inlet forming a hole between the second interior frame first side and the second interior frame second side;
a channel formed on the second interior frame first side between the aperture and the liquid inlet;
a gas outlet forming a hole between the second interior frame first side and the second interior frame second side; and
a channel formed on the second interior frame first side between the aperture and the gas outlet.
9. The membrane assembly of claim 8 , wherein the gasket comprises a plastisol.
10. An apparatus, the apparatus comprising:
a first compression plate, the first compression plate having a first side and a second side;
a first insulator plate, a first side of the first insulator plate facing and abutting the second side of the first compression plate;
a first electrode, a first side of the first electrode facing and abutting a second side of the first insulator plate;
a first end frame, the first end frame defining an aperture, and comprising;
a first side, the first side facing and abutting a second side of the first electrode;
a second side;
a liquid inlet forming a hole between the first side and the second side;
a channel formed on the first side between the aperture and the liquid inlet;
a gas outlet forming a hole between the first side and the second side; and
a channel formed on the first side between the aperture and the gas outlet;
at least one membrane-electrode assembly according to claim 8 , the first side of at least one of the at least one membrane-electrode assemblies facing and abutting the second side of the first end frame;
a further membrane assembly, the further membrane assembly comprising:
ripstop nylon fabric; and
a gasket affixed to a border of at least one side of the ripstop nylon fabric, a first side of the further membrane assembly facing and abutting the second side of the second interior frame;
a second end frame, the second end frame defining an aperture, and comprising:
a first side, the first side facing and abutting a second side of the further membrane assembly;
a second side;
a liquid inlet forming a hole between the first side and the second side;
a channel formed on the second side between the aperture and the liquid inlet;
a gas outlet forming a hole between the first side and the second side; and
a channel formed on the second side between the aperture and the gas outlet;
a further electrode a first side of the further electrode facing and abutting the second side of the second end frame;
a second insulator plate, a first side of the second insulator plate facing and abutting a second side of the further electrode; and
a second compression plate, a first side of the second compression plate facing and abutting a second side of the second insulator plate.
11. The apparatus of claim 10 , wherein the further electrode further comprises:
a liquid inlet forming a hole between the first side and the second side; and
a gas outlet forming a hole between the first side and the second side.
12. The apparatus of claim 10 , wherein the second insulator plate further comprises:
a liquid inlet forming a hole between the first side and the second side; and
a gas outlet forming a hole between the first side and the second side.
13. The apparatus of claim 10 , wherein the second compression plate further comprises:
a second side;
a liquid inlet forming a hole between the first side and the second side; and
a gas outlet forming a hole between the first side and the second side.
14. A method, comprising impressing a DC electric current across the membrane of claim 5 .
15. The method of claim 14 , wherein the membrane is at least partially immersed in an aqueous environment.
16. A method, comprising:
(a) applying a plastisol to a border of a first side of the membrane of claim 5 ;
(b) curing the plastisol.
17. The method of claim 16 , wherein step (b) further comprises curing the plastisol at a temperature of between about 140 deg. C and about 180 deg. C.
18. The method of claim 17 , wherein step (b) further comprises curing the plastisol for between about 45 and about 120 seconds.
19. The method of claim 16 , wherein step (b) further comprises curing the plastisol at a temperature of about 175 deg. C. for about 90 seconds.
20. The method of claim 16 , wherein step (a) comprises a silkscreen process.
21. A method, comprising:
(a) placing a first side of a first insulator plate against a second side of a first compression plate;
(b) placing a first side of a first electrode against a second side of the first insulator plate;
(c) placing a first side of a first end frame against a second side of the first electrode, the first end frame defining an aperture, the first end frame comprising:
a second side;
a liquid inlet forming a hole between the first side and the second side;
a channel formed on the first side between the aperture and the liquid inlet;
a gas outlet forming a hole between the first side and the second side; and
a channel formed on the first side between the aperture and the gas outlet;
(d) placing a first membrane assembly side of at least one membrane-electrode assembly against the second side of the first end frame, the at least one membrane-electrode assembly comprising:
a membrane assembly, the membrane assembly comprising:
an ion transfer membrane, the ion transfer membrane comprising ripstop nylon; and
a gasket affixed to a border of at least one side of the membrane;
a first interior frame, the first interior frame defining an aperture, and comprising:
a first side, the first side facing and abutting a second side of the membrane assembly;
a second side;
a liquid inlet forming a hole between the first side and the second side;
a channel formed on the second side between the aperture and the liquid inlet;
a gas outlet forming a hole between the first side and the second side; and
a channel formed on the second side between the aperture and the gas outlet;
an interior electrode, a first side of the interior electrode facing and abutting the second side of the first interior frame; and
a second interior frame, the second interior frame defining an aperture, and comprising:
a first side, the first side facing and abutting a second side of the interior electrode;
a second side;
a liquid inlet forming a hole between the first side and the second side;
a channel formed on the first side between the aperture and the liquid inlet;
a gas outlet forming a hole between the first side and the second side; and
a channel formed on the first side between the aperture and the gas outlet;
(e) placing a first side of a further membrane assembly against the second side of the second interior frame of the membrane-electrode assembly;
(f) placing a first side of a second end frame against a second side of the further membrane assembly;
(g) placing a first side of a further electrode against a second side of the second end frame;
(h) placing the first side of a second insulator plate against a second side of the further electrode; and
(i) placing a first side of a second compression plate against a second side of the second insulator plate.
22. The method of claim 21 , wherein the further electrode of step (g) further comprises:
a liquid inlet forming a hole between the first side and the second side; and
a gas outlet forming a hole between the first side and the second side.
23. The method of claim 21 , wherein the second insulator plate of step (h) further comprises:
a liquid inlet forming a hole between the first side and the second side; and
a gas outlet forming a hole between the first side and the second side.
24. The method of claim 21 , wherein the second compression plate of step (i) further comprises:
a second side;
a liquid inlet forming a hole between the first side and the second side; and
a gas outlet forming a hole between the first side and the second side.