A sheet having anion exchange functionality and a sheet having cation
exchange functionality are juxtaposed and joined by current bonding into
a unitary bipolar membrane. This may be done without added reactants or
bonding agents by placing the two-layer assembly between opposed
electrodes in a fluid cell, preferably at pressure, and applying power
across the cell to split water in a junction region of the membrane
assembly. Preferably the anion exchange sheet is treated with an iron
salt solution so as to incorporate or immobilize the metal in the polymer
during the current bonding process, and enhance operating characteristics
of the bipolar junction. Membrane peel strength is comparable to or
greater than that of an underlying sheet of ion exchange material, but
the bonding is fully reversible, e.g., by soaking in a concentrated
solution. Preferably both sheets include an aromatic backbone or
cross-linker component. One membrane may be a self supporting membrane,
such as a conventional electrodialysis exchange membrane of 5-50 mil
(0.12-1.2 mm) thickness, while the other may also be a commercial
membrane of opposite exchange type and of similar strength or thickness,
or may be specially manufactured to tailor its performance in the
completed membrane. For example, one or both starting sheets may be
manufactured with a pore former or may otherwise have its porosity,
cross-linking, strength, ion rejection characteristics or thickness
tailored for more effective bipolar operation--for example, to enhance
transport or diffusion, resist shear or mechanical forces, improve
chemical resistance to splitting products or species in the intended
feed, or the like. Preferably, prior to contacting and bonding, the anion
exchange membrane is treated with a group VIII metal salt. The
current-bonded unitary bilayer construction remains contact bonded over
its surface and resists degradation in normal use.