Thermoplastic Vulcanizate Gasket for Use in an Electrolyzer

Abstract

An electrolyzer comprising an electrolyzer cell is disclosed. The electrolyzer cell comprises a first spacer frame, a second spacer frame, and a first gasket having a first surface contacting the first spacer frame and a second and opposing surface contacting the second spacer frame. The first gasket comprises a thermoplastic vulcanizate comprising a thermoplastic resin and an at least partially cured elastomer. The thermoplastic vulcanizate exhibits a Shore A hardness (ISO 868-85) of from 35 to 100.

What is claimed is: 
     
         1 . An electrolyzer comprising:
 an electrolyzer cell comprising a first spacer frame, a second spacer frame, and a first gasket having a first surface contacting the first spacer frame and a second and opposing surface contacting the second spacer frame,   wherein the first gasket comprises a thermoplastic vulcanizate comprising a thermoplastic resin and an at least partially cured elastomer, and   wherein the thermoplastic vulcanizate exhibits a Shore A hardness (ISO 868-85) of from 35 to 100.   
     
     
         2 . The electrolyzer of  claim 1 , wherein the thermoplastic vulcanizate exhibits a Shore A hardness (ISO 868-85) of from 40 to 70. 
     
     
         3 . The electrolyzer of  claim 1 , wherein the thermoplastic vulcanizate exhibits a 100% modulus of at least 1 MPa. 
     
     
         4 . The electrolyzer of  claim 1 , wherein the thermoplastic vulcanizate exhibits a coefficient of friction of 3 or less. 
     
     
         5 . The electrolyzer of  claim 1 , wherein the thermoplastic vulcanizate exhibits a tensile stress at break of 0.5 MPa to 20 MPa. 
     
     
         6 . The electrolyzer of  claim 1 , wherein the thermoplastic vulcanizate exhibits an elongation at break of 200% or more to 1000% or less. 
     
     
         7 . The electrolyzer of  claim 1 , wherein the thermoplastic resin comprises a polyimide, a polyester, a polyamide, a poly(phenylene ether), a polycarbonate, a styrene-acrylonitrile copolymer, a polyethylene terephthalate, a polybutylene terephthalate, a polystyrene or a derivative thereof, a polyphenylene oxide, a polyoxymethylene, a fluorine-containing thermoplastic resin, or a mixture thereof. 
     
     
         8 . The electrolyzer of  claim 1 , wherein the thermoplastic resin comprises a polyolefin. 
     
     
         9 . The electrolyzer of  claim 8 , wherein the polyolefin comprises polypropylene. 
     
     
         10 . The electrolyzer of  claim 1 , wherein the elastomer comprises natural rubber, styrene-butadiene copolymer rubber, butadiene rubber, acrylonitrile rubber, halogenated rubber, butadiene-styrene-vinyl pyridine rubber, urethane rubber, polyisoprene rubber, epichlolorohydrin terpolymer rubber, polychloroprene, or a mixture thereof. 
     
     
         11 . The electrolyzer of  claim 1 , wherein the elastomer comprises a polyolefin elastomer copolymer. 
     
     
         12 . The electrolyzer of  claim 1 , wherein the elastomer comprises an ethylene/propylene/non-conjugated diene copolymer rubber (EPDM). 
     
     
         13 . The electrolyzer of  claim 1 , wherein the elastomer comprises an ethylene acrylic copolymer. 
     
     
         14 . The electrolyzer of  claim 1 , wherein the elastomer comprises a butyl rubber. 
     
     
         15 . The electrolyzer of  claim 1 , wherein the thermoplastic vulcanizate comprises from about 10 wt. % to about 90 wt. % of the elastomer and from about 10 wt. % to about 90 wt. % of the thermoplastic resin wherein the wt. % is based on the weight of the thermoplastic vulcanizate. 
     
     
         16 . The electrolyzer of  claim 1 , wherein the gasket defines a first passage hole and a second passage hole for passage of a first gas and a second gas, respectively, and a third passage hole for passage of a liquid. 
     
     
         17 . The electrolyzer of  claim 1 , wherein the first spacer frame surrounds a first electrode and the second spacer frame surrounds a second electrode. 
     
     
         18 . The electrolyzer of  claim 1 , wherein the first spacer frame surrounds a first electrode and the second spacer frame surrounds a diaphragm. 
     
     
         19 . The electrolyzer of  claim 18 , further comprising a third spacer frame and a gasket comprising a second thermoplastic vulcanizate wherein the gasket has a first surface contacting the second spacer frame and a second and opposing surface contacting the third spacer frame. 
     
     
         20 . The electrolyzer of  claim 19 , wherein the third spacer frame surrounds a second electrode.