Electrophoretic deposition of asbestos diaphragms

Claim 2

In a method of assemblying a chlor-alkali diaphragm cell wherein an electrolyte permeable first electrode having an aqueous sodium chloride brine permeable asbestos diaphragm thereon and a second electrode are inserted in a cell body, the improvement wherein the aqueous sodium chloride brine permeable diaphragm is deposited by the method comprising: A. placing the first electrode in an aqueous liquid composition comprising (1) chrysotile asbestos at a concentration below 1.0 weight percent to avoid formation of asbestos fiber agglomerates and high enough to allow electrophoretic deposition and having a nominal fiber length short enough to remain in suspension and long enough to form a porous deposited diaphragm, and (2) sufficient surfactant to transport the asbestos and reduce the surface tension of the liquid composition while maintaining the pH thereof above the isoelectric point of asbestos; B. maintaining said liquid composition basic; and C. maintaining an electrical potential above about 150 volts between the first electrode and a second electrode in said liquid composition to provide an electrophoretic current density.

Claim 3

The method of claim 1 wherein said first electrode is maintained anodic with respect to said second electrode during the deposition of asbestos.

Claim 4

The method of claim 2 wherein said first electrode is maintained at an anodic potential of at least 150 volts with respect to said second electrode.

Claim 5

The method of claim 2 wherein said liquid composition includes an anionic surfactant and a non-ionic surfactant whereby to maintain said liquid composition basic.

Claim 6

The method of claim 2 wherein said surfactant is an anionic surfactant.

Claim 7

The method of claim 5 wherein said anionic surfactant is an anionic fluorocarbon-sulfonic acid resin.

Claim 8

The method of claim 5 wherein said anionic surfactant is chosen from the group consisting of carboxylic acids, carboxylic acid amides, and phosphates.

Claim 9

The method of claim 1 wherein said first electrode is maintained cathodic with respect to said second electrode during the deposition of asbestos.

Claim 10

The method of claim 8 wherein said first electrode is maintained at a cathodic potential of at least 150 volts with respect to said second electrode.

Claim 11

The method of claim 8 wherein said surfactant is a cationic surfactant.

Claim 12

The method of claim 1 comprising maintaining the pH of the liquid composition below about 11.3.

Claim 13

The method of claim 11 comprising maintaining the pH of the liquid composition between 9 and 10.

Claim 14

The method of claim 1 wherein the asbestos concentration is from about 0.1 to about 1.0 weight percent.

Claim 15

The method of claim 1 wherein the asbestos has a nominal fiber length of from 4 mesh, Q.A.P.A., to 10 mesh, Q.A.P.A.

Claim 16

The method of claim 1 wherein the surfactant concentration is from about 0.01 to about 0.10 weight percent.

Claim 17

In a method of assemblying a chlor-alkali diaphragm cell wherein an electrolyte permeable first electrode having an aqueous sodium chloride brine permeable asbestos diaphragm thereon and a second electrode are inserted in a cell body, the improvement wherein the aqueous sodium chloride brine permeable diaphragm is deposited by the method comprising: A. placing the first electrode in an aqueous liquid composition comprising (1) chrysotile asbestos at a concentration of from about 0.1 weight percent to about 1.0 weight percent thereby avoiding formation of asbestos fiber agglomerates while allowing electrophoretic deposition and having a nominal fiber length of from about 4 mesh Q.A.P.A., to about 10 mesh, Q.A.P.A., whereby to remain in suspension without settling and to form a porous deposited diaphragm, and (2) sufficient surfactant to transport the asbestos and reduce the surface tension of the liquid composition while maintaining the pH above the isoelectric point of asbestos; B. maintaining said liquid composition basic; and C. maintaining an electrical potential above about 150 volts between the first electrode and a second electrode in said liquid composition to provide an electrophoretic current density.

Claim 18

In a method of assemblying a chlor-alkali diaphragm cell wherein an electrolyte permeable first electrode having an aqueous sodium chloride brine permeable asbestos diaphragm thereon and a second electrode are inserted in a cell body, the improvement wherein the aqueous sodium chloride brine permeable diaphragm is deposited by the method comprising: A. placing the first electrode in an aqueous liquid composition comprising (1) chrysotile asbestos at a concentration of from about 0.1 weight percent to about 1.0 weight percent thereby avoiding formation of asbestos fiber agglomerates while allowing electrophoretic deposition and having a nominal fiber length of from about 4 mesh Q.A.P.A., to about 10 mesh, Q.A.P.A., whereby to remain in suspension without settling and to form a porous deposited diaphragm, and (2) sufficient surfactant to transport the asbestos and reduce the surface tension of the liquid composition while maintaining the pH above the isoelectric point of asbestos; B. maintaining said liquid composition basic; and C. maintaining an electrical potential above about 150 volts between the first electrode and a second electrode in said liquid composition to provide an electrophoretic current density.