Patent Description:
Three-chamber electrolysis and the like are used in salt separation processes, lithium hydroxide production processes, organic electrolysis processes, hypochlorous acid production processes and the like. A three-chamber electrolyzer has, as a basic structure, a unit cell including an anode chamber, an intermediate chamber and a cathode chamber, in which an anode is housed in the anode chamber, a cathode is housed in the cathode chamber, the anode chamber and the intermediate chamber are separated by an anion exchange membrane in an anion-permeable manner, and the cathode chamber and the intermediate chamber are separated by a cation exchange membrane in a cation-permeable manner (Patent Document <NUM>).

A conventional intermediate chamber of such a three-chamber electrolyzer is an element which generally includes a metal-made frame, and in which a liquid inlet and a liquid outlet are arranged on this frame and an electrolyte solution can be circulated inside the frame through the inlet and the outlet.

In addition to the three-chamber electrolyzers, there are two-chamber electrolyzers that include an anode chamber in which an anode is arranged, a cathode chamber in which a cathode is arranged, and an ion exchange membrane arranged as a diaphragm between the anode chamber and the cathode chamber. As one of such two-chamber electrolyzers, a two-chamber electrolyzer in which unit cells, each of which is constituted by: a bipolar electrode having an anode arranged on one side of a membrane and a cathode arranged on the other side of the membrane; an anode chamber arranged on the anode side of the bipolar electrode; and a cathode chamber arranged on the cathode side of the bipolar electrode, are sequentially disposed with an ion exchange membrane being arranged as a diaphragm between each anode chamber and cathode chamber is used in some cases. Alternatively, depending on the electrolysis process, a single-chamber electrolyzer having no diaphragm (diaphragm-free single-chamber electrolyzer), in which an electrolysis chamber is arranged on the anode side of the above-described bipolar electrode and another electrolysis chamber is arranged on the cathode side of the bipolar electrode, may be used. A metal-made frame is also used in the electrolysis chambers (the general term "electrolysis chamber" used herein encompasses an anode chamber, a cathode chamber, and an intermediate chamber) of these single-chamber and two-chamber electrolyzers.

Further, there are some electrolysis chambers that include an element constituted by a frame made of a resin rather than a metal.

Moreover, a metal-made frame is also used in electrodialysis cells that perform electrodialysis.

Patent Document <NUM> discloses an electrode chamber having an anode and a cation exchange membrane installed on a frame, characterised in that the exchange membrane is open at the top and has a bag-like structure whose shape and size are matched with the frame and the outside of the frame is sheathed with the exchange membrane.

In an electrolysis chamber of a conventional electrolyzer, for example, for connecting a manifold to the inlet and the outlet that are arranged on the frame, the frame is required to have a certain thickness, i.e. a certain dimension in the respective directions toward the electrodes of the anode chamber and the cathode chamber in the case of an intermediate chamber of a three-chamber electrolyzer. During an electrolysis treatment, the frame thickness of this electrolysis chamber causes a drop in the voltage that is applied between the anode of the anode chamber adjacent to the electrolysis chamber and the cathode of the cathode chamber adjacent to the electrolysis chamber. The amount of this voltage drop directly relates to the power consumption during electrolysis. Further, since the voltage drop induces heating of an electrolyte solution in the electrolysis chamber, a greater amount of voltage drop leads to an increase in the consumption of energy for cooling. Accordingly, it is desired to inhibit such a voltage drop as much as possible; however, the inhibition of a voltage drop is limited due to the above-described frame thickness.

Further, since the frame of an electrolysis chamber of a conventional electrolyzer is made of a metal, a leakage current occurs between the frame and a ground during electrolysis, and this causes corrosion of the metal. Accordingly, as a countermeasure against the metal corrosion, a sacrificial electrode is arranged in the electrolyzer in such a manner that it is electrically connected to the frame of the electrolysis chamber or a metal casing welded to the frame. However, despite that the sacrificial electrode needs to be replaced regularly, the sacrificial electrode is welded to an equipment of the electrolyzer and thus not easily replaceable, which requires a work cost for the replacement and a material cost of the sacrificial electrode itself.

In the case of an electrolysis chamber constituted by a resin element, metal corrosion of the electrolysis chamber caused by a leakage current is not an issue; however, an electrolyte solution is circulated between the electrolysis chamber and the outside through a manifold arranged inside the electrolysis chamber. Accordingly, for the formation of the manifold, a flow path that penetrates all elements is required in an electrolyzer in which plural unit cells are arranged. In addition, in an element having a structure in which a manifold is arranged inside an electrolysis chamber, the distance with its adjacent element is generally close; therefore, the consumption of reactive power increases due to a larger bypass current.

The present invention was made in view of the above-described problems, and an object of the present invention is to provide: a chamber frame element having a smaller amount of voltage drop and less consumption of reactive power than the prior art; and an electrolyzer and an electrodialysis cell including the chamber frame element.

A first aspect of the present invention is a chamber frame element for an electrolyzer or an electrodialysis cell according to claim <NUM>.

In the first aspect of the present invention, it is preferred that the chamber frame element be made of a resin.

Further, in the first aspect of the present invention, the chamber frame element is preferably a chamber frame element for a three-chamber electrolyzer.

A second aspect of the present invention is an electrolyzer including the chamber frame element of the first aspect.

A third aspect of the present invention is an electrodialysis cell including the chamber frame element of the first aspect.

According to the present invention, an intermediate chamber can be reduced in thickness, and the amount of voltage drop during electrolysis can be reduced. In addition, since a manifold is not arranged inside an electrolysis chamber, a bypass current is small, and the consumption of reactive power is limited.

Embodiments of the chamber frame element, the electrolyzer, and the electrodialysis cell according to the present invention will now be described referring to the drawings. In the following descriptions, a chamber frame element used for an intermediate chamber of a three-chamber electrolyzer is described as a representative example of the chamber frame element of the present invention, and a three-chamber electrolyzer is described as a representative example of the electrolyzer of the present invention; however, the chamber frame element of the present invention is not limited to be used for an intermediate chamber of a three-chamber electrolyzer, and can be used in the same manner also for an anode chamber and a cathode chamber of a two-chamber electrolyzer, as well as an electrolysis chamber of a single-chamber electrolyzer. Further, the electrolyzer of the present invention is not limited to be a three-chamber electrolyzer, and can be a two-chamber or single-chamber electrolyzer in which the chamber frame element of the present invention is used. Moreover, the chamber frame element of the present invention is not limited to be used in an electrolyzer, and can be used in an electrodialysis cell.

<FIG> is a schematic cross-sectional view of a three-chamber electrolyzer <NUM> in which a chamber frame element according to one embodiment of the present invention is used. In <FIG>, the three-chamber electrolyzer <NUM> includes: an anode chamber <NUM> in which an anode <NUM> is housed; an intermediate chamber <NUM>; and a cathode chamber <NUM> in which a cathode <NUM> is housed. The anode chamber <NUM> and the intermediate chamber <NUM> are separated by an anion exchange membrane <NUM> in an anion-permeable manner. The intermediate chamber <NUM> and the cathode chamber <NUM> are separated by a cation exchange membrane <NUM> in a cation-permeable manner.

Describing one example of electrolysis using the three-chamber electrolyzer <NUM> for the case of sodium sulfate, when an aqueous sodium sulfate solution as an electrolyte solution is introduced to the intermediate chamber <NUM> and electric power is supplied between the anode <NUM> and the cathode <NUM> to perform electrolysis, sulfate ions pass through the anion exchange membrane <NUM> and move to the anode chamber <NUM>, while sodium ions pass through the cation exchange membrane <NUM> and move to the cathode chamber <NUM>. The thus diluted aqueous solution is discharged from the intermediate chamber <NUM>.

<FIG> shows a perspective view of main parts of the chamber frame element <NUM> that constitute an intermediate chamber for such a three-chamber electrolyzer as shown in <FIG>. The chamber frame element <NUM> of <FIG> has a frame shape with an opening in the central part. As for the thickness of the chamber frame element <NUM>, the chamber frame element <NUM> has a thickness that is required for attachment of piping used for connecting the chamber frame element <NUM> with a manifold. It is noted here that the piping to be attached and the manifold are omitted in <FIG>. The chamber frame element <NUM> is made of a resin, whereby corrosion caused by a leakage current, which is problematic for conventional metal-made chamber frame elements, can be inhibited.

Nevertheless, with the chamber frame element <NUM> in which the material of a conventional metal-made chamber frame element is simply changed to a resin without changing the shape, the thickness of an intermediate chamber stays the same, and a voltage drop during electrolysis is thus not inhibited relative to the prior art. In this respect, a chamber frame element <NUM> according to one embodiment of the present invention, with which the thickness of an intermediate chamber can be reduced, is shown in <FIG> as a plane view (<FIG>) and a side view (<FIG>).

The chamber frame element <NUM> of <FIG> includes: a bag body <NUM> having an interior space; a frame <NUM> housed in the bag body <NUM>; and an inlet <NUM> and an outlet <NUM> formed on the bag body <NUM>.

The bag body <NUM> is made of, for example, resin films, and has a substantially rectangular planar shape in the illustrated example. The bag body <NUM> is formed by superimposing two resin films and sealing the circumference of these films in a bag shape with an adhesive or a heat seal. Instead of preparing two resin films, a single resin film may be folded and overlaid, and the circumference of this film except the folded part may be sealed to form a bag. As the resin film, any resin film that is not corroded by an electrolyte solution can be selected and, for example, a film of a polyethylene, a polyester (e.g., PET), a polypropylene, or a common plastic such as PTFE, PFA, or PVC, can be used.

In the central part of each of the two resin films constituting the bag body <NUM>, an opening 141a for allowing ion exchange membranes to face each other as diaphragms is formed. In the illustrated present embodiment, on the outer side of the portion of the bag body <NUM> in which the above-described frame is housed, the inlet <NUM> is formed in the vicinity of one longitudinal end of the bag body <NUM>, and the outlet <NUM> is formed in the vicinity of the other end.

More specifically, in the present embodiment shown in <FIG>, the bag body <NUM> has a protruding part 141b and a protruding part 141c, which have a substantially triangular planar shape, on the respective longitudinal ends, and thus has a hexagonal planar shape rather than a substantially rectangular planar shape as a whole. The inlet <NUM> is formed on the protruding part 141b, while the outlet <NUM> is formed on the protruding part 141c. As a result, an electrolyte solution introduced into the bag body <NUM> via the inlet <NUM> flows in such a manner to spread in the width direction toward the base of the triangular protruding part 141b at one longitudinal end of the bag body <NUM>, so that good fluidity is attained and the electrolyte solution can smoothly flow in the frame <NUM>. In addition, the electrolyte solution directed from the frame <NUM> toward the outlet <NUM> in the bag body <NUM> flows from the base of the triangular protruding part 141c to the outlet <NUM> in a converging manner, so that good fluidity is attained and the electrolyte solution can smoothly flow to the outlet <NUM>. It is noted here that the protruding parts 141b and 141c of the bag body <NUM> are not indispensable, and the shape of each longitudinal end of the bag body <NUM> is not restricted as long as an electrolyte solution can smoothly flow in the bag body <NUM>. Embodiments without the protruding parts 141b and 141c will be described later.

The inlet <NUM> has a structure through which an electrolyte solution can be introduced into the bag body <NUM>. The outlet <NUM> has a structure through which the electrolyte solution in the bag body <NUM> can be discharged. In the example shown in <FIG>, the inlet <NUM> and the outlet <NUM> are formed by making holes on a single resin film. A nozzle <NUM> is attached to each of the inlet <NUM> and the outlet <NUM>, and resin-made piping is connected to the nozzle <NUM>. In the example shown in <FIG>, the inlet <NUM> and the outlet <NUM> are each arranged singly; however, the inlet <NUM> or the outlet <NUM> may be arranged in a plural number.

The electrolyte solution introduced via the inlet <NUM> into the bag body <NUM> flows toward the opening 141a. In the case of the three-chamber electrolyzer shown in <FIG>, the electrolyte solution is ion-exchanged in the opening 141a by the anion exchange membrane <NUM> and the cation exchange membrane <NUM>, and the thus ion-exchanged electrolyte solution flows toward the outlet <NUM>.

In order to ensure a flow rate necessary for such a series of electrolysis processes, the chamber frame element <NUM> is required to have an electrolyte solution flow path formed in the bag body <NUM>. Accordingly, in the chamber frame element <NUM> of the present embodiment, the frame <NUM> is arranged in the interior space of the bag body <NUM>. The frame <NUM> is made of a resin. As the resin of the frame <NUM>, any resin that is not corroded by an electrolyte solution can be selected and, for example, a polyethylene, a polyester (e.g., PET), a polypropylene, a polyvinyl chloride, a polystyrene, a polyurethane, or a common plastic such as PTFE, PFA, or PVC, can be used.

The planar shape and the size of the opening of the frame <NUM> are substantially the same as those of the opening 141a of the bag body <NUM>. The opening of the frame <NUM> and the opening 141a of the bag body <NUM> are aligned at the same position and adhered with each other using an adhesive or the like. The frame <NUM> is provided with a groove or a channel communicating from the outside to the inside of the frame, allowing an electrolyte solution to flow from the inside to the outside of the frame <NUM> and vice versa. In the chamber frame element of the present embodiment that is shown in <FIG>, grooves 142a communicating to both the outside and the inside of the frame <NUM> are formed on the surface of the frame <NUM>. In the illustrated present embodiment, the grooves 142a are formed on each of a total of two sides among the four sides of the frame <NUM>, which are the side facing the inlet <NUM> and the side facing the outlet <NUM>. The positions, the size, and the number of the grooves are not limited to the ones shown in <FIG>.

In the chamber frame element <NUM> of the present embodiment, the thickness of the frame <NUM> may be as small as possible as long as a sufficient flow rate of an electrolyte solution can be ensured. Accordingly, the thickness of the frame <NUM> can be reduced to a required minimum as much as possible. The amount of voltage drop during electrolysis is determined by a total thickness of the frame <NUM> and the resin film of the bag body <NUM>; therefore, in the chamber frame element <NUM> of the present embodiment, a voltage drop can be inhibited by the frame <NUM> whose thickness is reduced to a required minimum as much as possible.

Further, in the chamber frame element <NUM>, an electrolyte solution is introduced and discharged via the piping connected to the inlet <NUM> and the outlet <NUM>, respectively; therefore, even in an electrolyzer having a structure in which plural unit cells are arranged, the piping connected to the respective unit cells may be assembled together, so that it is not necessary to arrange a manifold inside the chamber frame element <NUM>. Accordingly, a flow path penetrating through all elements is not required as in the case of an intermediate chamber in which a manifold is arranged, and this not only simplifies the unit cell structure and makes the production cost inexpensive, but also enables to reduce the bypass current and thus reduce the consumption of reactive power.

Moreover, the chamber frame element <NUM> has a simple basic structure constituted by two members, which are the bag body <NUM> and the frame <NUM>, and can be easily produced by pasting together these members by press molding; therefore, the chamber frame element <NUM> can be easily mass-produced, and the production cost can also be reduced in this respect. The size of the chamber frame element <NUM> can be easily increased as well. Furthermore, in the chamber frame element <NUM>, since the bag body <NUM> and the frame <NUM> are made of a resin, corrosion caused by a leakage current, which is problematic for conventional metal-made chamber frame elements, can be inhibited.

<FIG> show illustrative drawings of a chamber frame element <NUM> according to another embodiment. The chamber frame element <NUM> of <FIG> includes: a bag body <NUM> having an interior space; a frame <NUM> housed in the bag body <NUM>; and an inlet <NUM> and an outlet <NUM> formed on the bag body <NUM>. A nozzle <NUM> is attached to each of the inlet <NUM> and the outlet <NUM>. An opening 241a is formed on the bag body <NUM>, and grooves 242a are formed on the frame <NUM>.

The chamber frame element <NUM> shown in <FIG> is made of a resin, and has a basic structure similar to that of the chamber frame element <NUM> shown in <FIG>. A difference is that the bag body <NUM> has a rectangular planar shape. That is, while the bag body <NUM> of the chamber frame element <NUM> shown in <FIG> has the protruding parts 141b and 141c, the bag body <NUM> of the chamber frame element <NUM> of this embodiment shown in <FIG> does not have a protruding part. The frame <NUM>, the inlet <NUM>, and the outlet <NUM> of the chamber frame element <NUM> shown in <FIG> have the same configurations as the frame <NUM>, the inlet <NUM>, and the outlet <NUM> of the chamber frame element <NUM> shown in <FIG>, respectively; therefore, descriptions redundant to the above are omitted.

The chamber frame element <NUM> shown in <FIG> has the same effects as the chamber frame element <NUM> shown in <FIG>. That is, in the chamber frame element <NUM>, a voltage drop can be inhibited by the frame <NUM> whose thickness is reduced to a required minimum, and an electrolyte solution is introduced and discharged via the piping connected to the inlet <NUM> and the outlet <NUM>, respectively; therefore, as opposed to an intermediate chamber in which a manifold is arranged, a flow path penetrating through all elements is not required, and this not only simplifies the unit cell structure and makes the production cost inexpensive, but also enables to reduce the bypass current and thus reduce the consumption of reactive power. Further, the chamber frame element <NUM> has a simple basic structure constituted by two members, which are the bag body <NUM> and the frame <NUM>, and can be easily produced by pasting together these members by press molding; therefore, the chamber frame element <NUM> can be easily mass-produced, and the production cost can also be reduced in this respect. The size of the chamber frame element <NUM> can be easily increased as well. Moreover, in the chamber frame element <NUM>, since the bag body <NUM> and the frame <NUM> are made of a resin, corrosion caused by a leakage current, which is problematic for conventional metal-made chamber frame elements, can be inhibited.

<FIG> shows a perspective view of a chamber frame element <NUM> according to yet another embodiment. The chamber frame element <NUM> of <FIG> includes: a bag body <NUM> having an interior space; a frame <NUM> housed in the bag body <NUM>; and an inlet <NUM> and an outlet <NUM> formed on the bag body <NUM>. A nozzle <NUM> is attached to each of the inlet <NUM> and the outlet <NUM>. An opening 341a is formed on the bag body <NUM>, and grooves 342a are formed on the frame <NUM>.

The chamber frame element <NUM> shown in <FIG> is made of a resin, and has a basic structure similar to that of the chamber frame element <NUM> shown in <FIG>. A difference is that the bag body <NUM> has a substantially cuboid box shape. The frame <NUM>, the inlet <NUM>, and the outlet <NUM> of the chamber frame element <NUM> shown in <FIG> have the same configurations as the frame <NUM>, the inlet <NUM>, and the outlet <NUM> of the chamber frame element <NUM> shown in <FIG>, respectively; therefore, descriptions redundant to the above are omitted.

The chamber frame element <NUM> is made of a resin, and has the same actions and effects as the chamber frame element <NUM> shown in <FIG>. That is, in the chamber frame element <NUM>, a voltage drop can be inhibited by the frame <NUM> whose thickness is reduced to a required minimum, and an electrolyte solution is introduced and discharged via the piping connected to the inlet <NUM> and the outlet <NUM>, respectively; therefore, as opposed to an intermediate chamber in which a manifold is arranged, a flow path penetrating through all elements is not required, and this not only simplifies the unit cell structure and makes the production cost inexpensive, but also enables to reduce the bypass current and thus reduce the consumption of reactive power. Further, the chamber frame element <NUM> has a simple basic structure constituted by two members, which are the bag body <NUM> and the frame <NUM>, and can be easily produced by pasting together these members by press molding; therefore, the chamber frame element <NUM> can be easily mass-produced, and the production cost can also be reduced in this respect. The size of the chamber frame element <NUM> can be easily increased as well. Moreover, in the chamber frame element <NUM>, since the bag body <NUM> and the frame <NUM> are made of a resin, corrosion caused by a leakage current, which is problematic for conventional metal-made chamber frame elements, can be inhibited.

As understood from <FIG>, the bag body can take various shapes.

One example of a method of producing a chamber frame element will now be described for the case of the chamber frame element <NUM> shown in <FIG>, referring to <FIG>.

As shown in <FIG>, the bag body <NUM> is produced from a resin film. As a method and an apparatus for the production of the bag body <NUM>, any known method and apparatus can be employed. At least one surface of the bag body <NUM> is made openable such that the frame <NUM> can be later inserted into the interior space of the bag body <NUM>.

Next, as shown in <FIG>, the opening 341a for application of an electric current is formed on both of the opposing surfaces of the bag body <NUM>.

Subsequently, as shown in <FIG>, the inlet <NUM> and the outlet <NUM> are formed on the bag body <NUM>, and the nozzle <NUM> is attached to each of the inlet <NUM> and the outlet <NUM>.

It is noted here that the formation of the opening 341a shown in <FIG> and the formation of the inlet <NUM> and the outlet <NUM> may be carried out in any order, and the formation of the inlet <NUM> and the outlet <NUM> may be carried out before the formation of the opening 341a.

Claim 1:
A chamber frame element (<NUM>, <NUM>, <NUM>, <NUM>) for an electrolyzer or an electrodialysis cell, the chamber frame element (<NUM>, <NUM>, <NUM>, <NUM>) comprising:
a bag body (<NUM>, <NUM>, <NUM>);
a frame (<NUM>, <NUM>, <NUM>) housed in an interior space of the bag body (<NUM>, <NUM>, <NUM>); and an inlet (<NUM>, <NUM>, <NUM>) and an outlet (<NUM>, <NUM>, <NUM>) to which piping can be attached, the inlet (<NUM>, <NUM>, <NUM>) and the outlet (<NUM>, <NUM>, <NUM>) being formed on the outside of a region where the frame (<NUM>, <NUM>, <NUM>) is housed in the bag body (<NUM>, <NUM>, <NUM>), wherein the frame (<NUM>, <NUM>, <NUM>) comprises a flow path that allows a liquid inflowing from the inlet (<NUM>, <NUM>, <NUM>) to flow inside the frame (<NUM>, <NUM>, <NUM>) and a liquid inside the frame (<NUM>, <NUM>, <NUM>) to flow to the outlet (<NUM>, <NUM>, <NUM>), and the flow path is a groove (142a, 242a, 342a) or a channel that communicates to the outside and the inside of the frame (<NUM>, <NUM>, <NUM>).