Discrete particle electrolyzer cathode and method of making same

A scraper for removing metal particles from a plurality of active zones on a planar cathode surface, comprising:

• a housing;
• a cathode having a plurality of active zones, the cathode fixed within the housing;
• a rotatable blade having an edge, the blade mounted within the housing such that the edge of the blade is in proximity to active zones of the cathode;
• a shaft coupled to the blade, and
• a means for rotating the shaft, whereby the edge of the blade dislodges particles from the cathode surface.

An electrode comprising:

• a conductor having a surface;
• a plurality of electrically coupled active zones separated from each other at the electrode surface by an insulator providing a separation distance between any two active zones from about 0.1 mm to about 10 mm, each active zone having a surface area no less than about 0.02 square mm and being formed of an electrically conductive material;
• and
• a terminal for coupling electrical energy to the conductor.

A method of manufacturing an electrode comprising a plurality of active zones separated from each other by an insulator, the method comprising the following steps:

• forming a metal plate having a plurality of pins, each pin protruding from the plate and separated from adjacent pins by a separation distance between about 0.1 mm and about 10 mm, each pin having an end forming an active zone having a surface area no less than about 0.02 square mm;
• coating the formed metal plate with a curable insulating material;
• curing the insulating material;
• and
• machining the cured insulating material and the active zones.

A method of manufacturing an electrode comprising a plurality of active zones separated from each other by an insulator, the method comprising the following steps:

• forming a bundle of two or more parallel wires, each wire separated by a separation distance between about 0.1 mm and about 10 mm, each wire having a diameter no less than about 0.02 square mm;
• electrically insulating each wire by surrounding the wires with a curable insulating material;
• curing the insulating material;
• and
• slicing the insulated bundle to form a planar cross-section having generally smooth surfaces whereon the wires form active zones substantially coplanar with the insulating material;
• and
• attaching a support plate to one surface, thereby electrically coupling the active zones to the plate.