# US 11,078,584 B2 · Systems and methods of electrolytic production of aluminum > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,078,584 B2 - Document ID: US11078584B2 - Status: Granted - Kind: B2 - Application number: 15/943,171 - Filed: 2018-04-02 - Published: 2018-10-04 - Granted: 2021-08-03 - Earliest claimed: 2017-03-31 - Assignees: Alcoa USA Corp. - Applicants: Alcoa USA Corp. - Inventors: Xinghua Liu - Web page: https://patentgrep.com/patent/US11078584B2 ## CPC - C25C 3/08: Cell construction, e.g. bottoms, walls, cathodes - C25C 3/12: Anodes - C25C 7/02: Electrodes (consumable anodes for the refining the metals C25C1/00 - C25C5/00); Connections thereof - C25C 7/025: {used in cells for the electrolysis of melts} - Y02P 10/20: Recycling - C25C: PROCESSES FOR THE ELECTROLYTIC PRODUCTION, RECOVERY OR REFINING OF METALS; APPARATUS THEREFOR - Y02P: CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS ## Abstract In some embodiments, an exemplary electrolytic cell includes: a cathode structure disposed within an electrolysis cell, wherein the electrolysis cell is configured to produce metal on a surface of the cathode structure, wherein the cathode structure is configured to fit along a floor of the electrolysis cell, wherein the cathode structure has a sloped surface when compared to a generally horizontal plane, and wherein via the sloped surface, the cathode structure is configured to drain a metal product from the sloped surface towards a lower end of the cathode structure. ## Claims ### Claim 1 An apparatus, comprising: a cathode structure disposed within an electrolysis cell, wherein the electrolysis cell is configured to produce metal on a surface of the cathode structure; wherein the cathode structure is configured to fit along a floor of the electrolysis cell; wherein the cathode structure comprises (a) a support member having a first wall and an opposing second wall, and (b) at least two cathode plates attached to a support member; wherein a first cathode plate is attached to the first wall of the support member; wherein a second cathode plate is attached to the second wall of the support member; wherein the at least two cathode plates are configured to be at least partially submerged in a molten electrolyte bath; wherein the cathode structure has a sloped surface when compared to a generally horizontal plane; wherein, via the sloped surface, the cathode structure is configured to drain a metal product from the sloped surface towards a carbon floor of the electrolysis cell. ### Claim 2 (depends on 1) The apparatus of claim 1, wherein the cathode structure has a triangular geometry. ### Claim 3 (depends on 1) The apparatus of claim 1, wherein the sloped surface of the cathode structure has a wall angle of from 15 degrees to not greater than 89 degrees. ### Claim 4 (depends on 1) The apparatus of claim 1, wherein a height of the cathode structure is from 5% to 95% of a height of the molten electrolyte bath. ### Claim 5 (depends on 1) The apparatus of claim 1, wherein the cathode structure is one of a plurality of cathode structures, wherein a cathode assembly comprises the plurality of cathode structures, and wherein the plurality of cathode structures are disposed in a generally parallel, interspaced configuration along the floor of the electrolysis cell. ### Claim 6 (depends on 1) The apparatus of claim 1, wherein the support member comprises a carbon block, wherein the first wall is a first carbon block wall, wherein the second wall is a second carbon block wall, wherein the first cathode plate is attached to the first carbon block wall, and wherein the second cathode plate is attached to the second carbon block wall. ### Claim 7 (depends on 1) The apparatus of claim 1, wherein the floor comprises a cathode drain angle. ### Claim 8 (depends on 7) The apparatus of claim 7, comprising a collection area adjacent the floor, wherein the cathode drain angle of the floor is sufficient to direct the metal product to the collection area. ### Claim 9 (depends on 7) The apparatus of claim 7, wherein the cathode drain angle is from 0 degrees to 15 degrees. ### Claim 10 (depends on 9) The apparatus of claim 9, wherein the cathode drain angle is from 0.1 degrees to 15 degrees. ### Claim 11 (depends on 10) The apparatus of claim 10, wherein the cathode drain angle is from 1 degree to 5 degrees. ### Claim 12 (depends on 1) The apparatus of claim 1, wherein the cathode plates are fully submerged in the molten electrolyte bath. ### Claim 13 (depends on 1) The apparatus of claim 1, wherein the cathode support comprises a male member extending from a bottom portion of the cathode support member; wherein the cathode floor comprises a female portion configured to receive the male member of the cathode support; wherein the cathode support is connected to the cathode floor via engagement of the male member of the cathode support with the female portion of the cathode floor. ### Claim 14 (depends on 1) The apparatus of claim 1, wherein the cathode floor comprises a first slot and a second slot, wherein the first cathode plate sits in the first slot, and wherein the second cathode plate sits in the second slot. ### Claim 15 (depends on 1) The apparatus of claim 1, wherein the support member is constructed of a first material, and wherein the first cathode plate is constructed of a second material, wherein the first material is different than the second material. ### Claim 16 (depends on 15) The apparatus of claim 15, wherein the first material is non-aluminum wettable and wherein the second material is aluminum wettable. ### Claim 17 (depends on 16) The apparatus of claim 16, wherein the second material is a metal boride. ### Claim 18 (depends on 17) The apparatus of claim 17, wherein the metal boride comprises a titanium boride. ### Claim 19 (depends on 15) The apparatus of claim 15, wherein the first material is selected from the group consisting of a refractory material, a non-aluminum wettable ceramic material, a carbonaceous material, a composite carbon-ceramic material, and combinations thereof. ### Claim 20 (depends on 1) The apparatus of claim 1, wherein the first plate and the second plate connect near an apex of the support member. ### Claim 21 A cathode for an aluminum electrolysis cell, the cathode comprising: a supporting block having at least a first wall, wherein the first wall comprises a wall angle (beta) of from 15 degrees to not greater than 89 degrees relative to vertical; a plurality of tiles attached to the first wall, wherein at least some of the plurality of tiles are constructed from an aluminum wettable material. ### Claim 22 (depends on 21) The cathode of claim 21, wherein the aluminum wettable material is a metal boride. ### Claim 23 (depends on 22) The cathode of claim 22, wherein the metal boride is a titanium boride.