High surface area anode and method of manufacturing

Abstract

The invention described herein shows a high surface area anode. The high surface area anode contains a flat surface on one side and a ribbed surface on the opposite side. On the ribbed surface there is a first edge-lip on its first-end and a second edge-lip on its second-end. Both the first edge-lip and the second edge-lip run parallel to each other. The high surface area anode further contains a plurality of ribs and groves between the first edge-lip and the second edge-lip also running parallel to each other. The high surface area anode is manufactured using a continuous casting method that includes the following steps; dissolving the anode metal into the holding furnace shaping the anode metal using a high surface area graphite mold; solidifying the anode metal using a liquid while extruding the anode metal through the high surface area mold; solidifying the anode metal by using a secondary cooling source; and extracting the now solidified and shaped high surface anode metal.

What we claim is: 
     
         1 . A high surface area anode comprising,
 a. At least one flat surface and at least one ribbed surface on its short end;
 i. the ribbed surface further comprising at least one edge lip on the long end. 
   
     
     
         2 . The high surface area anode, wherein
 a. the ribbed surface further comprises a plurality of ribs and groves.   
     
     
         3 . The high surface area anode, wherein
 a. the at least one edge lip is larger in height and width than one of the ribs.   
     
     
         4 . The high surface area anode, wherein
 a. the at least one edge lip contains more material by volume than one of the ribs.   
     
     
         5 . The high surface area anode, wherein
 a. the plurality of ribs and groves define the width of the high surface area anode.   
     
     
         6 . A high surface area anode comprising,
 a. a flat surface on one side and a ribbed surface on its opposite side;
 i. the ribbed surface further comprising a first edge lip on its first end and a second edge lip on its second end opposite and parallel from each other. 
   
     
     
         7 . The high surface area anode, wherein
 a. the ribbed surface further comprises a plurality of ribs and groves.   
     
     
         8 . The high surface area anode, wherein
 a. the first edge lip and second edge lip are larger in height and with than one of the ribs.   
     
     
         9 . The high surface area anode, wherein
 a. the first edge lip and second edge lip contain more material by volume than one of the ribs.   
     
     
         10 . The high surface area anode, wherein
 a. the first edge lip and second edge lip contain more material by volume than the plurality of ribs.   
     
     
         11 . The high surface area anode, wherein
 a. the plurality of ribs and groves define the width of the high surface area anode.   
     
     
         12 . A method of manufacturing a high surface area anode comprising the steps of,
 a. dissolving the anode metal into the holding furnace;   b. shaping the anode metal using a high surface area graphite mold;   c. solidifying the anode metal using a liquid while extruding the anode metal through the high surface area mold;   d. solidifying the anode metal by using a secondary cooling source, and   e. extracting the now solidified and shaped high surface anode metal,   f. wherein the shape of the high surface area anode further comprises a flat surface on one side and a ribbed surface on its opposite side;
 i. the ribbed surface further comprising a first edge lip on its first end and a second edge lip on its second end opposite and parallel from each other.