Patent attributes
A system for producing metal particles using a discrete particle electrolyzer cathode, a discrete particle electrolyzer cathode, and methods for manufacturing the cathode. The cathode has a plurality of active zones on a surface thereof at least partially immersed in a reaction solution. The active zones are spaced from one another by between about 0.1 mm and about 10 mm, and each has a surface area no less than about 0.02 square mm. The cathode is spaced from an anode also at least partially immersed in the reaction solution. A voltage potential is applied between the anode and cathode. Metal particles form on the active zones of the cathode. The particles may be dislodged from the cathode after they have achieved a desired size. The geometry and composition of the active zones are specified to promote the growth of high quality particles suitable for use in metal/air fuel cells. Cathodes may be formed from bundled wire, machined metal, chemical etching, or chemical vapor deposition techniques.
