Method of production of metal particles through electrolysis
First Claim
1. A method of producing zinc particles having low superficial density and high surface area, suitable for use in metal/air fuel cells, comprising:
- containing a solution including dissolved zinc;
maintaining the solution at a temperature between about 0 and about 100 degrees Centigrade;
immersing an anode at least partly in the solution;
immersing a cathode at least partly in the solution, the cathode having a plurality of active zones separated from each other by an insulator, each active zone having an area less than about 0.04 square mm, said active zones electrically coupled to a conductor and spaced apart by less than about 2.0 mm;
maintaining turbulent flow of the solution past one or more of the active zones;
applying an electric potential across the anode and cathode sufficient to grow a plurality of lobes of the zinc at each active zone; and
ceasing growth of the zinc lobes when the plurality of lobes at each active zone bond together to form a multi-lobed particle, wherein the particle at each active zone is grown initially from lobes.
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Abstract
A method of producing metal particles through electrolysis. A cathode having a plurality of active zones on a surface thereof is at least partially immersed in a reaction solution. 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. In order to promote the formation of good quality particles, a turbulent flow of the solution is maintained past one or more the active zones, and the current density in the active zones is maintained greater than about 5 kA/m2. The particles may be dislodged from the cathode after they have achieved a desired size.
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Citations
26 Claims
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1. A method of producing zinc particles having low superficial density and high surface area, suitable for use in metal/air fuel cells, comprising:
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containing a solution including dissolved zinc; maintaining the solution at a temperature between about 0 and about 100 degrees Centigrade; immersing an anode at least partly in the solution; immersing a cathode at least partly in the solution, the cathode having a plurality of active zones separated from each other by an insulator, each active zone having an area less than about 0.04 square mm, said active zones electrically coupled to a conductor and spaced apart by less than about 2.0 mm; maintaining turbulent flow of the solution past one or more of the active zones; applying an electric potential across the anode and cathode sufficient to grow a plurality of lobes of the zinc at each active zone; and ceasing growth of the zinc lobes when the plurality of lobes at each active zone bond together to form a multi-lobed particle, wherein the particle at each active zone is grown initially from lobes. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A process for producing coherent, mechanically strong zinc particles suitable for use in metal/air fuel cells, comprising:
- a step for containing a solution including dissolved zinc, the solution having a molarity between about 0.55M and about 1.25M;
a step for maintaining the solution at a temperature between about 20 and about 40 degrees Centigrade; a step for immersing an anode at least partly in the solution; a step for immersing a cathode at least partly in the solution, the cathode having a plurality of active zones separated from each other by an insulator, each active zone having an area less than about 0.04 square mm, said active zones electrically coupled to a conductor and spaced apart by less than about 2.0 mm; a step for maintaining a turbulent flow of the solution past one or more of the active zones; a step for applying an electric potential across the anode and cathode sufficient to grow a plurality of lobes of the zinc at each active zone; and a step for ceasing growth of the zinc lobes when the plurality of lobes at each active zone bond together to form a multi-lobed particle, wherein the particle at each active zone is grown initially from lobes. - View Dependent Claims (16, 17, 18, 19, 20, 21, 22, 23, 25, 26)
- a step for containing a solution including dissolved zinc, the solution having a molarity between about 0.55M and about 1.25M;
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24. The method of 23 wherein the bismuth is added as Bi2O3 in a proportion equivalent to about 400 ppm Bi2O3 to about 40 liters of the solution.
Specification