CA2149129A1

CA2149129A1 - Battery electrode substrates and methods of making the same

Info

Publication number: CA2149129A1
Application number: CA002149129A
Authority: CA
Inventors: Robert J. Edgington; James A. Stepro; Harold J. Wissell; Scott A. Lundberg
Original assignee: Individual
Current assignee: National Standard Co
Priority date: 1992-11-20
Filing date: 1992-11-20
Publication date: 1994-06-09
Also published as: EP0674810B1; EP0674810A1; EP0674810A4; AU3221193A; WO1994013025A1

Abstract

A three-dimensional substrate material (28) for use in constructing battery electrodes comprises a sintered matrix material (12, 14) selected from the group consisting of reticulated metal foams, conductive fibers and metal powder compacts, and a porous covering layer of a polymeric mesh material, flexible metal screen or metal fibers (20), bonded to at least one surface of the matrix material (12, 14) to retain the sintered matrix material (12, 14) substantially within the planar surface of the surface of matrix material (12, 14) during spiral-wounding of the chemically loaded matrix material (12, 14).

Description

bl WO ~4/1302~ 912 9 ~T~S92/10055 ~ T~RY E~e~O~ ~B8~T~8 ~D
~=_ Th~ pr~nt inv~rition rol~ to i~pro~r~d thr~-di~nl~lo~al b~t~ry ol~ctrod~ ~ub~trat~ ~aS~rials and, ~or~
~p~ci~ic~lly, to a niak~ ctroda~ trat~ which provido-~nhan~ tiv~ su~stratQ ~illirJg ~nd r~t~ntion wit~in th~
~ ctrod~l m~rix and wh~c~ por~lt~ Q~nc~ ch~ni~l strQngth and int~ity du~n~ ll con~'cruetion and r6~1uc~d ~horti~g b~t~s-n ~ tro~ Iay~s in tho ¢~ll art~r ~bric~ation ~ thu~ rloing c~ nu~ nq y~old .
At pr~ nt, r~charq~--bl- b~tt0ry olo~:trodo sl trat~s ~r~ ~nu~-c~ur~d r~O~ ~ wid~ vari~ty o~ rlat~cula~-d ~
~oa~ or 9pOng- t~11 ~ot~l ~t~ri~al~, ~1 ~ib~r~ ~nd ~s~al powdQr c:o~pact~, ~p~ci~lc~lly, n~ck~ anal battory ~ trod~ r~ pr~r~ly through ~ tl~ring proG~- utl1lz~ns a ~lt~typs conduGtivQ po~ou~
m~ ri~l co~ d o~ a~ad alek~l po~d~r, ~uch, a- c~rbc~ayl n1dc~ r.: m~ r--ulta~'c nl~::k~ t~ry ctr~-~ g~nor-l~y cont~æ1n b~t~ 75-gO w~g~t p~rc~nt nic~ l~r ~ 10-2~ ~lght ~r~ po~lar. ~n ~x~pl~ o~ I~U~ a b~t~ pamo~
Pat~nt Pul~l~lc~t~on 63 ~2473. Thl~ pu~11~tlo~ lo~
~-lt-typa ni~c~l bstt~ry ~ onta~g 1e~ng ni~:k~l ~ ~ nic~c~l ~O ~r. 9u~h an ~ i~r and powd~r pr~vid~ ou~ orl~l h~v~ c~ri~i~s or voi~ r~eln w~Lie~ on sv~ags i~r~ ~pprQ~a~ly 60 Dlicron~
, in di~ t r. Att~ ~ntlr~nq oP th~ Ant~ 151dO~ pOE'OUf~
~, ~tQr~a~ Ct~ ud~ a$ck~l~ an~l c:a~iu~
hy~lroxid~ r~ acld~d or load~ i~to ~a~ porou~ ~t~arlal to !~ , . ~ g~n~ra~ th~ n~gy :o~ tho ~tt~ rod- by : ~ : .
ch~Ric~l r~action~ cti~ ~ lo~d~lsd or ~d~od to t~ r ~u~tr~ or ~atrl~ by a n~r o~ t~chniqu~, including: ch~ica~ or ~-ctroch~ical con~rsion ~rld ~: :

WO 9~13025 2 1 ~ 9 1 2 9 ~/US92/10055 ~echanical injaction o~ high vi~cosity aqu~ou~3 pa~t~3 of tb ~!
.~!
.~ ac:tive materials or cha~icals.
A~ t~e d~m~nd ~or highsr c~pacity al~ctrod~ ha~
:~ incr~a~ed, the prior ~rt thr~e-di~ensional battery ma~eri 1B
'~ or Aubstrate~3 and, in p2lrticular, the prior art porous matri~s or Bt~lCtUr~E!LI~ compri~ins7 ~int~rQd long nickel fibQr~ ~nd nic:kel powdar~ h~v~ n found to bQ only 3 pnrtially e~f~ctive in ~at thQ nickel powd~r contalned within the f ibrous E~ub~tr~te t~nd to bloc}; the entry of active chemicals into the pos~ible loading ar~as within the fiber laatrix. Ac~ordinqly, I:hQ reticulatQd mQtal foa~ns, m~tal f ib~r ~nd powder co~pzct~, in acGord~nc:~ with the prior ~rt, app~ar to exhibit ~ porosity o~ a l~vel which ~trict~ the p~netratio~a of~ th~ ac'cive chemical or ¦ I chemicnls to th~ centar o:E the m~trix, and whic:h li~its the ~ount v~ 8Ct iVe! ch~ic~l~ that ~ay be loaded into the .
matrix, thu~ ra~ulting in reduced el~ctrod~ ~f f ic:i~ncy .
A furth~r di~;advantags of ~uch prior art thr~e-dim0n~l0nal Qlectrod~ Elub~trat~ 5trUctur~ 8 il!3 ~at the metal fiber ~trix i~ co~po~d o~ ~iber l~ngt:h~ eacc~Qding about a I quart~r ~nd a hal~ in~h in length~ It is bslielved that thi~
length of long fik~r wa~ d~irabl~ to facilitat@
distribution c: f the activa ch~Jnical ~pac~ throu~hout the fi~er m~trix to providQ an overall fiber D~trix contairling a predetermin~ :I weight of ~iber ~t~rial . A~o, it ha~ b~en found th~t th~ subs~ nt procca~ing of such ~aàtal fib~r oatrices, m~t2~1 foam~ and ~Qtal powdered co~p~ct~ and layering of the electrodQ m~terial re~ult~ in ~n electrode material which po~s~ e~ ad~uAte t~n6ile ~tr~ngth an~
ductility, which ~ub~tantially reduc~s the pr~duction yield - of materi l which ~y be ~pir~l-wound into cells for in~ertion into the complet~d ol~ctrodx~ zls~e~bly.

.

~, WO ~4/1302~ 9 1 2 9 ~IUS921~005~
y `) Ad :litionally, ~uch prior ~rt thr~-dimQnE~ional ~piral-wound el~ctrod~ ma~erial~ pog~ ubstant:ial f iber ends , rising from th~ ~piral--&round surf~ce or surfaces of the completed electrode 2a~8~11~ y, a prc~bl~ which results in a brittle~nQ~fi in bandirlg which auk~st~ntially incrQa~se~ the a~ount of breaking during proce~s~ing of the electrode.
Furthennore, the 100B~ r snd~ and broken ~i~Qrs ~ttentling froD~ the surfac~ of ths spiral-wound alectrode, which ~nds o~ten ti~E~ p~n~tr~t~ the ~p~rator ~n~terial thereby re~ulting in a E~horting out betw~en electrodex of the f ini~hed battery a~ bly .
: : ~
It is one ob~ect o~ th~ pr~ent inv~ntion to provide an i~provQd three-diDl~n~ion~l ~lectrode ~ tr~te po~Qs~ing i:
3ub~t ntially i~proved 1Oading ~nd ret~ntion of ~ e electrod2 active ~tsr$al.
; It is still nothQr obj~ct of th~ pr~nt inv~ntion to provide an i~proved thr~-d~m~n-iona1 b~tt~ry ~l~ctrade ~uh3træte pv~ s1ng inar~a-~d surface ~rea, pliability, ductility, ~1exibility and t~nsile ~trQng*h ~o pro~ide no~inal el~ctr~d~ ~ub~tr~t- ~aterial partlcular1y u~eful in c~ll con3truction.
Still another ob~ct o~tbe pr~-nt inv~ntion i~ to provide an~ i~prov~d b~tt~ry~lectrode sub~trate which `: po~e~E~es sup~rior mQdlanical strength ~qnd integrity and haYing a sur~aoe rQ~ tant:Q to Dlech~nic~l brQa~age ~nd:
~; ~ : damage during c:ell con~truction ~nd u~e~
`~ Another object o the pr~ ent invention i to provid~ ~
: an i~,proved~ high o~p~city i~tt-ry lectrode ubstrate ha~ing a~synthetic materia1 adh~red eo the~sur~ce of the electrode sub~trate which~provid~ enh~nGed activ~ che~ical substra~e .~, : ~ :
3 ~ :

~, ~
~ ~ :

~:t WO 94lL30~$ PCT/US92/10055 matsrial filling and rQt~ntion within the electrodq ~natrix ij . or sub~tralte.
Still another obj~ct of the prQsant invention iB to ~;~ provide an improved lc~ad~d battery ~lectrode having a ,'1 . ~ ~7 surrace condi~ion c:onducive to the utilization of reduced t.. , ~
e~2 separator thickne~3s thereby ~nabling battery de~i~ns that maxi~ize cell c~p~city.
It i~ still anot:her ob~ct of t~ç~ pr2~ent invention to provid~ an i~aproved thr~-di~n~ional electrode ~ubs~rate ha~ring a porouE~ cover~ ng layer or ~a~n~ ~onded 3nd in intimate phy~ical contac:t with th~ el~ctrode ~ub~trate to permit c:h~ically loading of th~ zlctive ~aterial into the ~ubstr~te and to preve~t Dlac~anical breakage zl~d d2lmAge during spiral-winding ~nd cell conBtrucrtion by retaining the ~etal foala or Dl~tal fibar~3 ~rithin the ~lectrode ~ub~tr3te from sub~tantially p~netrating the pl~ne or ~urf~ce o~ ~he el~ctrode sub~trate6.
It i~ yet another ob~t of the pr~,~ent inv~ntion to provid~ an incr~a3ed yi~1d of ui~Qful el~ctrcde ~ateri~l when ~uch material i~ ~piral-wound to compl~te the el~tr~de a,~sembly .
It i~ till a further obj~ct of the pr~nk i~vention to provide improv~d methods of ~anufacturing the batt~ry ~l~ctrode substratc ~aterial~ po~e6,~ing enhanaed loading and retention characteristies o~ the actiYe c~ical sub~ate ~at~ri~l within thQ ,~ub~tr~te.
In accordanc~ with th~ pr~sent invention a three-dimQnslo~al el~ctrod~ ~ub~trat~ or ~atrix ~aterial, such a~, a nickel prior art battery el~ctro~, pro~ide~ a ~onducting, porous nickel fiber m~trix which a~c~pt~ ~h~ a~tive che~ical materials which are lo~d~d within the void ~rea~ o~ the fiber matrix. The~e prior art lnng nickel fiber ~atri¢es WO 9411302~ PCT/VS92tlO055 .i _ ~re compri~ed of nickel f ib~ars that ex~nded one quArter to one half inch in l~ngth, with ~e long nickel fib~r~
praferably compriRing b~tw~sn 70-90% o~ the ~o~al weis~ht percent of material in the nickel batt~ry electrode. .
It ha~ an Pound ~at by ~pplying ~ synthetic or polymerio ~esh ~aterial or r~a~inou~ coating or WRb, or porous resinous fi~er onto thQ nickel fiber nickel pc~wder matrix, ~de in ~c:cord~nc~ with the prior art, a mor~ po~ou~-electrode structur~ ormed whlch posE~e~es incrQ~ed active ohemica1 material }o~din~ and retention. The direct applic2~tion of the synth-tic ~esh, porous reE~inous coating, or porou6 re~inous :~barE~ onto th~ slnt~red prior ~rt nickel f iber-~ickel p~wder E~ trats m tariaI may b~ ac~oDIplish~d in a number of way~ including applyinq a s~thetic ~e~h material by pr~a~ing the mat~rial in heated c:ontact with the .
nickel electrode ~atrix atnacture. The synth~tic meE~h or :: web fabric is a re~inou~ ~bri¢ which is pref~rably ~elec:t~d ~ :
: ~ ~ to provide a porous che~ical:ly rQ~i~;t~nt ~ which i~
co~patible with t~- e1~otro1yt- ~yatem u~ed in th- co~plotad elsctrde b~t:t~ry. The porou~3 r~Esin coating ~y ~ appl~ed to the al~ctrod8 Bu~8tra5 te Dlat~rial by utilizang ~ hot ~elt ~pray, an 21qUe~OU8 ~31urr y, conv~sntional al~ and wet l~yering, fluid1zed bed,~ ol-¢tro~tatic~ st-l~m calendering of a :~ :
pre~or~Qd fabric, :~nd a hot calender 1~D~ination ~of the preformed fabric. The rQsin fzl~ric, web, or c:oa~ing ~ay be bonded to onë:or~both ~urf~c~ o~ th~ ~tallic ~b~tr~te trix uaed as th~ el~ctro~ or carrier for th~ active materials in the electro~he~ic~l oell.
.
n s~iIl anot~or ~bDdim~nt of:the pr~ent inv~ntion, a layer of fine dia~ter m~t~1lic f~ber~ ~ay be~onded to one or:more of~the:outer urfacQ- of the~prior art three-i~enslD~al ~attery el-ctrod- ub~trat~. After the direct ',!~ WO 94113025 P~:T/US92/100~5 aEsplication of the multi-l~y~r~d f ine f i~sr~ to the three-dimQn ional electrode ~ub~trate, tha r~sultant layered substrate is ~int~red, th~n c~ilendered a3~d sintered again '~r~
.~ ~ prior to loading with thQ chQmically active material by the e~ electrode cel1 ~nainufactur~r. The ~ddition of the surfa:e 'l ''~
network of lay~r~ of f in~i diame'cer f ibars provide~ a lattice of increa~d iur~ace ar~a ~ind prt~vidas a ~int~robonded surface lay~r tc the undQrlying ~l~ctrc~de sub~trate. The 6mall di ameter ~ur~ac~ fibar layer ~aay b~ appl~ Qd to the ,.,~
surace o the thrse-di~3n~ional baktery E~ub~tr~e by conventional air and wet layering, aqueou spray and rs~, coating tach~iques, techniqu~ kno~ in the art. Th~
re~ultant multi-layarsd batt~ ctrod~ ~ub~tr2lte provid~-an el~ctrod~ ~tructure whic~ po~ aE~e~ increa~ed lo~dinq and ., retention of the electrodQ active material. Additionally, .. th8 enhanc~d ~lec:trod~ ~ub3trate, co~ted with ~hultiple 1ayer~ of f ine dia~tOE f iW~rs, providQ~ a ~ub~trate ~;urf ace ~,i e~fQck which ~ub~tantially reduce~ battQry ¢~ horting and ~ pro~riâes ext~nded rech~rg~blQ b~tt~ry cell l~fe cyc:ling ,, per~ormaJ~ce by aub~tslntiaIly reducing the nu~ber of ~ne~allic ~iber ~nds s~ nding frola ~8 ~urface o~ the ~l~ctrode a~ter th~ Qlectrod~ is c:hemic~11y loa31ed and then rolled or ~pirally--wound to co~npl~te the electrode cell ax~3~bly.
In 3till a further ~mbodi~nt of th~ pre~nt in~r~ntion a f lexible f ine m~h ~etal scr~en ~ay be ~onded to Zlt least ': ` 1 one ~urfac~ o~ th~ long nickel fiber-nil:kel powder !Rubstrate to substantia1ly r~duc:e the n~er of metallic nic:kel ~iber end~ extending fro~ th~ pl~n~r ~urf~Ge o~ 3le~:trode a~ter the electrode iB chemically loaded and ther~ rolled or spirally-wound to complete the electrode cell a~e~ly.
The t~rm three-di~n~ional batt~ lectrode ~ub~3trate generally ref ~rs to an electrode having a ~or~ exten~ive ;~ .
-'I

WO~/13~5 PCT~S92/100~5 loctrochemical ~tructur~ or activity in a dim-~n~ion normal to the elec~rodes front~l sur~ace than does a plan~r .,~ .
electrode. Such ~intere~ three-dimensional batte~y electrodes sub~rate~ are, preferably, a conductive fiber or m~al fiber fflatrix mat~rial. However, it i~ within the scope o~ the pre~ent inv-ntion that th~ sintered metal ~atrix material ~y be r~ticul~t~d ~etal fo~s or ~etal powder compact~.
The matrix of plan&r stat~-of-the~rt ~lQctrodes, being construct-d from ~etallic scr~-n or m~-h co~po~d of wrought wirQ or filament~, i8 ganerally guite ductil2 and capable of being rolled or b~nt int~ a ~mall dia~Qter spiral cylinder without br~a~ge o~ the fila~Qntary ela~ent~ of the ~atrix.
The ~atrix of three-di~Qnsional electrod~ ~tructure~
gen~rally are constructed fro`m non-wrought ~etallic fila~ents from:a Eintering nr Rl~ctrodepo8it typo of proces~. Such ele~trode ~tru~ture tend to be rel~tively : le6~ ductile in rollinfg or ~endin~ into a ff~all dia~ter spiral cylinder and tend to ~xhibit a d~gr~e of ~rittlen~ss wlth br~akage of somQ ~atrix ~ nts~up~n b~nding. The~e : le~s ductile alfa~nt~ o~ th~ thr~-dim~nf~ional olectrode ~: mztrix are:~he~primary cau~e of shorting ~hen they protrude ~` from the surra~ of ~he oomplQted electrode oell.
It is al~o~within the ~copa of the prev-nt~ inv~ntion ;~ that the porous covering layer bonded to at l~a~t sne i ;surfac~iof the three-di~noional:l~lectrode provides'a loaded cell electrode tructure khat po~es~es increased conductivity and lower~d rffe~istivity over non-coated three-imeneional electrod~s. This pe~its the elff~ctrode ~aterial of~the pre~en~ lnvention ~o b- us~d in spiral-wff~d electrode~cells a~ well:a~ be u~d in pl&nar or plaque cells which:may:be stack~d in the completed ~ell af~e~

: 7 : : :

,~ WO 94/13025 PCT/US92/1005 Althc>ugh ~uch pl21n~r or but~on cells may b~ conf ig~red or tackad in a f inal ::ell ~ nbly ~E~ a non-planar arc, in ,, ~
c~ thi~ sense, th~y ~re considered ~ub3tantially planar for il3 ~
. ~ purpo~es of this di~clo~ur~.
t:`2 In the pra~ant invantiorl it i~ pref erred that ths porous covering layer be applied and bonded 1:o both ~he upper and lower ~urfac~E~ of thQ ~hr~a2-di~ ngiOnal QleCtrode to providt3 a l~inat~ or s~ndwich ~tructure. Accordirlgly, it i~ within th~ ~cop~ of the pr~sent invention that the proper orienta~ion and handling o~ the spiral-wound che~ically lQhded ma~r~x ~ateri2l1 will rQguir~ that only the o~tside periph~ral 5ur~Q o~ th~ wsund c:ell r~quir~ a~ , bonded porou~ covering lay~r to sub~tantially r~duce the nu~er oi~ conductive or ~etallic f iber end~ ~xtending fro~
the p~ripheral or pl~n~r ~ur~ e of the c~Mpl~t~ el~ctrode.

The foregoirag da~cription and other ~h~racteristics /
ob; et:t~, f eatur~ and ad~ nt~g~s o~ th~ pre~nt invention will bQcome moro appar~nt upon con~id~rzltion of the : following d~tailQd dQscription, having refer~nce to ~he acco~p2my drawing~, wharoin:
FIG. 1 i~ a 3~:h~matic vi~w ~howinq the 3t~p~3 o~

manu~acturing a niskel batt~ry ~atrix or ~ trate in :
acc:ordance with the prior art;
FIG. 2 i~ the ~chamatic Vi@W showing the ~stQpE; of m~nuf ac~uring the ~ynthetic: Dss~h bonded to the nic3cel battery ~Datrix or ~ubstra~e in accordance ~ith one ` e~bodiment of th- prQ-~nt in~entiorl;
FIG. 3 is an enlarg~d ~ch~atic top p~an vi~w of the ynthetic mesh bonded to the nic:kel b~tt~ry substr~te manufactured in a~cord~nc~ with FIG. 2;
FïG. 4 is a sectional view taJc~n along line~ 4-4 in .

~`1 WO ~4/13025 PCT~S92/1005~
21~9129 FIG. 3;
FIG. 5 l~ a ~ch~matic view showing the ~teps of manufacturing multiple 13y~r~ o~ fine diameter fibers bonded to a surf ace of a nickel b~ttery ubstrate in accordance with a further embodimQnt of the pre~ent invention;
FIG. 6 is an enl~rgQd sche~atic top plan view of multiple layers o~ fine diamQter fiber~ bonded to a surface of a nickel battÆry ~ubstr~te ~a~ufactured in accordance with FIG. 5;
FIG. 7 is a -~ectional view taken along line~ 7-7 in FIG. 6;
F~G. 8 i~ an ~nlargsd ~che~atic top plan view of the wire screen bo~ded to at lea~t one ~rface of a nickel battery substrate in accord~nce with a further a~bodiment of the present invention; and FIG. 9 is a ~ctional view taken along lines ~-9 in FIG. 8.
~_ Referri~g now to the dr~wings whQrein like numerals have been used throu~hout th~ ~everal vi~ws to designate the same or similar parts; a fibrous nickel baktery matrix, substrat~ or ~t~rial lO ha b-en manufactur~d u ing con~ntional appar~tu~ and tec~nique ~ ~s is known in the art. In the past, ~uch nickel~ er matrix materials have been utilized ~s the fiber matrix material for u~e in preparing nickel battery electrode~ when the matrix material is cal~ndered and pressed to size to r~ceive nickel powder a~ ~ pa~te or filler material to i~pregnate ~h~ fiber matrice~ with the nickel pow~er.
In accordance with ~uch prior art teachings, the prior art techni~ues have utillzed b~tween 70-gO percent by weight nickel fiber ~aterial and 30-lO percent by wai~ht nickel !~ .

!~
WO94113~25 PCT~S92/10055 powder as the pa~te or ~iller m~t2rial to provide a, -~
~ C~ conventional fiber ~atrix or ~ubstrat~ matQrial that is d c~
sintered in a reducing a~mo~phere. A preferr~d material containing 80 percent by w~ight long nickel fiber and 20 percent by weight nickel powd~r, norm lly provid~s, ~or axample, an end weight of O.45 gram~ per s~uare inch. This material results when the fiber matrix of 0.36 grams per squarP inch wou}d be coat~d with o.os gram~ per ~qu~re inch o~ nickel powder, a~ i~ known in the ~rt. The nickel fib~rs ~re long fibQrs having a lQngt~ in ~xces of O.25 inch to O.5 inch in lengt~, with the nic~el fibers ha~ing a nominal 25 micron diaDet~r.
1 Ref~rring now to FIG. 1, there i6 ~hown a ~he~a~ic j view illustrating the ~p5 ~ of m nufacturing a nickel fiber-¦ nickel powder matrix or ~ubstrate lO in accordance with the ¦ prior art. Long nickel ~ibrous material 12 i8 introduced into a calendering appar~tus 13 and pressed to receive the filler materi~l, nickel powder and/or nickel oxide powder 14, which is appliod by a roller coating ~ppar~tus 15, including hopper 16 and rolIQr~ 17. T~e ~iller ~aterial l~
is deposited on~o th~ c~}endered and pr~s~ed ~ibrou~
material and rolled by roll~r~ 17 to a unifar~ed thickne~, pr~sing the filler materia1 14 into the ~i~er ~rix to i~pregnate the fibrou~ ~trix with the fill~r ~aterial. The nickel battery matrix or ~ub~trate lO thu~ for~ed is then pas~ed through a sintering oven 18 and then wound on a ~ake up reel l9, for example, for storage prior to its u~e and th~ manufacture of the battery electrodes substrate in accordance with the pre~ent invention.
In accordance with the present inv~ntion t a synthetic or polymeric m~sh material or porous covering layer means 20 may be bonded to at least one of the surfaces of th~ niokel .

WO 94/1302S 214 9 12 9 PCTtUS92/10055 fiber~rlickel powder matrix l0 to proviàs a porous electrode s~ru ~ ure which pOBB~E18~ incr~a~ed active chQ~ical m~tQrial loading and retention a~ well a~ providing a ~ubstantial reduction in the number of metallic f iber end~ which extend fro~ the surface of th~ ctrode after the electrode i~
chemically loaded zlnd then rolled or spirally-wound to 50~apl1~te the oell ~ an~bly. A EsuitAbl~ poly~Qric or nylon mesh ~aaterial u~eful in pr~cticing the preE~ent invention may be a polyester, polyole~in, polya~ide, or other ~ynthetic material. One co~oercial ~aterial uE~ful in the pr~ ent invention is Inarketed under the trademark SH~RNET~ which is an adhe~iv~ web ~anu~ tur~d and sold by AppliQd Extrusion Technology, Inc.
FI :; . 2 illustrates the ~ proc~ or applying a resinous or polymeric coating onto the surfaces o~ a ~intered nickel f iber-nidcel powder s~ub~trate materi~ l ~, A~ sl~own in FIG . 2, the silltered wound nickel f iber-nickel powder ~ub~r2lte l0 is wound on a take up reel l9 which ic mounted on a let o~f stand 21 for fe~ding in~o ~ la~in~tor ~t~tion 22. The laminator statiorl 22 is compri~d o an upper pcl~eric . coatad belt apparatu is 23 3nd a lower polyDlaric: bel~
. ~ . apparatus 24 which guida~ inta~ed nicJcel ~iberonit:kel powder substrate lO bQtw~en ~eated preE~ure roll~rs 2S to :
bond the re5in or polym&ric web or meE;h Diaterial 20 onto the nickel fiberl nickel po~der substrate lO, as will hereinafter be described. ~ ~
Pref era~}y, the poly~exic or synthetic mesh or web material 20 is applie~d to both ~rfac:es of the nickel fiber-nickel powder sub~trat~ l0. Accordingly, reel~i containing the resin netting, ~e~h or w~b 20 are 3nounted on the let off stand 21 to fac:ilitate f~eding of the resin netting or mesh 20 onto the upper and lower surfaces o the substra~e lO.

~ ........ . . . .. .. .. ... . . . . . ... .. . . . . ... . .. . .. ... .... . . . ...... . .. . .. . .
. . . .. . . . . . . .. . . . ..

W094/1302~ PCT~S92t10055 Prefer~bly, it i~ desired to utilize a rPlaase liner 29 `
betw~en the mash material 20 ~nd the lower teflon coated C~ belt 24 and heated pressure rollers 2~ a~ well as utilizing a relea~e liner 29 po~itioned between the ~esh material 20 and the upper teflon belt 23 and the heated pre~ure rollers 25 to prevent accumulation o~ the poly~eri~ material ont~
the h~ated pres~ure roll~rs and bel~.
The r~ultant poly~eric cont~d nickel ~iber-nickel powder substrate ~aterial 28 i~ ~che~atic&lly 3hown in FIG.
` . 3. In such a view, the outer covering or surface of the polymeric coated nickel ~iber-nickel powder subs~rate includes a poly~eric or ~sh ~aterial 20 on the outer ur~ace of the sub~tratQ 10 with the inner portio~ o~ the substrate being co~pri~ed o~.lonq nickel fibers 12 and nickel powder 14. The polymeric or mesh ~aterial 20 when heated and applied to the bonded surface of the ~ubs~rate lO
yields a non-uniform open spaced covering tha~ permits the battery manu~acturer to load th~ poly~eric coated nickel ~iber-nickel powder aubstrate with the active chemical m~terizls ~or co~pl~ting the a~bly o~ a cell.
Additionally, it has b2en found that the nickel fiber-nickel . powder ~ub tr~te when coat~d with a poly~ric ~esh coating, as d2scribed above, provide~ a substrate surface effec~
which ~ub tantially r~duce~ batt~ry cell ~horting and provides extended rechargQable baktery cell life cycling ;~ I per~ormance by sub~tantially reducing th~ nu~ber ofimetailic iber ends extending ~rom the surface of the ~le~trode when the alectrode is c~emically load~d and rolled or spirally-il wound to~comple~e the cell as~e~bly.
,~ The s~nth~tic m~h, netting or web fabric 20 is a ~ polymeric fabric which i~ pr~ferably ~elected to pro~ide a3 ;~ porous chemically resistant surface which is co~patible with i;! , ,, :. :
`.i the sl~3ctrolyte ~yet~m u~d in the co~pl~ted Qlectrode ba~tery. Although no~ Elho~dn in the drawings, the ~3yn~hetic mesh or web fabric 20 may be applied ~o the nickel fiber- .
nickel powder sub~;trate lO by utilizing a hot ~lt spray, an a~au~ous slurry, conven~ional air and wet layering, steam calendering of pref or~ed f ~brics and hot calsnder lamination of the pref or~d f ~Ibric: .
A further embodimQnt of th~ preserl~ invention is shown sche~atically in FIGS. 5, 6 and 7 which g~n~rally illus~rate l:he utilization o~ a pc3rou~ cc-verinq layer ~ne~n~ compri~d of fine diameter metallic nickel fiber~ 30 which ar~ appli~d to and bonded to at l~aE~t one or ~ore of ~l~e outer surf ace~
o~ the three-dimensional ~intered ~ickel f iber-nickel powder sub~trate lO.. As ~hown ~nd~illu~trated in FIG. 5, the process include~ the uncoiling of the sintered nickel ~iber-nick~l powder ~ub trate lO from the take-up r~el l9 and directing this subE~trate to receive ~ ine dias~eter nickel fibers 30 which are appli~d by ~n upper 3urfac2 coating apparatus 31 including a spr~y ~:oating appar~tu~; 32 and including re!3ervoir 33. ~he firle dia~eter nickel fib~rs 30 may have a rang2 o~ diz~ters o~ betwe2n 5-1~ microns and pre~erably s~ill have a no~inal dia~eter of approximately 10 microns.: The diamet~r o~ the fine nickel covering fibers is ~o be co~pared ~ with the nickal ~iber contained in the nic~kel powder substrate 10 wherein the nominal diameter of ~;uch nickel ~ibers is approxi~at~ly 25 ~icron~. 'rh~ application of the surface coating of one or more layer~ oî ~:ine diameter nickel ~ibers 30 provid~ a ~ultiple layered f ib~r cover or surf ace 3 0A on t2~e nickel f iber-nickel powder sub~trate lO which is then pa3E~çd through 8rying oven 34 and thPn passed throu~h sintering oven 35 which bonds ~he multiple layered ~urface of ~ine diametQr nic:kel ~ibers on~o : `-"lj WO94/13025 PCTrUS92/10055 the lar~er diameter nick~l ~iber-nickel powder ~ubTtrate lO
C~ to provide a coated 3ubstrat~ 28A' h ving a multi-layered fine fiber surfa~e 30A on the upper surface of the three-dimensional elec~rode sub~trate prior to th~ }o~ding of the active che~ical b~ ths ~}~tro~ manufacture. In the embodi~ent of the proc~3~ illu~tr~ted in FIG. 5, a multi-,~lay~r~d fib~r cover or ~urf~a i~ appliad both to the upper and the lower ~urfacQ~ o~ the ~ub~trate lO. To thi~ end, ~,~the upper surface coated sub-tr te 28A' provid~d at the output of sintering ov~n 35 i unloaded to a sui~able web inversion apparatus 36, which Invert~ the sub~trate 28A' top to botto~, and p~B~S ths inverted ~ub~tr~te ~8~' "lower ~urface-up" to a lower surf~ce coating app~ratu~ 31' which includes a r~ervoir 33', drying oven 34', ~intering oven 35', calendering ro1lers 37 and sintering oven 38 which :pro~ide a multiple layered ~iber cover or surface 30A and the lower surface of the nickel fiber-nickel ~owder 3ub~trate lO, ther~by pro~iding the coated ~ub~tr~te 28A
which is wound on a take-up r~e} l9~ For ~pplic~tions where :~ only the upper ~urf~cQ o~ th~ subst~te lO i~ ~oated wlt~

,!`,. ~: fine diamet~r nickel fib~r- 30, the coated sub~trats 28A' . provided at the o~tput Or the sintering oven 35 of ~h~ upper , ~urface ~oating appar~tN~ 3l can be direct~d to calender . :
.' rolls 37, sintering o~en 38 and wound on a take-up reel.
:;
For example, it hae been found that a wa~er ba~ed ~ slurry containing 25 percent by wei~ht no~inal lO ~i~ro~
.~ .
diameter nickel ~iber~ WaB ~prayed through the coating apparatus 32 onto the~ ub trate lO, i.e., both on the top , : ~su~face of the substrat~ and on the lower surface of the top , coated ubstrate~, the porou~ layer of fine diameter nickel fibers yielded a surface coating of containing 25 grams per m~terZ on each surface. The w~iight p~rcent of finar : 14 ?/~ W0 94/l31)25 214 9 12 9 PCTNS9~/lO0SS
;j ! diam~ter nickel f iber in the E~urfac~ cs:~ating may ~ange between 10 to 6 0 qr~m~ per meter2 .
`, As sllown in FIG. 6, a ~ch~matic top view o~ the coated substrate 2 8A shows ~he overlying upper and lower surf aces-`~`
3 OA containing f ine dia~tQr nickel f ibers 3 0 overlyin~ the inner portion o~ the nickel :Ciber-nickel powder Rub~trate 10 t:ontaining the larger di~ter long nickel f ibers 12 .
Al~o, FIG. 7 i~ a crons su3ctional vi~w tak~n throllgh lines 7-7 of FIG. 6, ~3howinq l:hQ daposi~ or co21ting 30A o~
multiple layers o~ ~ine ~iber6 30 bondad to the ~urface of the nickel ~iber-nickel powdQr sub~tra~e 10. ~gain, ~he re~ultant multi-lay~r~d balttQry el~ctrode ~trix provides an electrode structur~ which pQs~e~es inc:r~e ~ ding and retention of the electrode active material. Additionally, the multiple layers 30A of $ine diam~ter fibers 30 provides a sub~trata surfaca af~e::t which ~ub~;tantially r~ducec batt~ry c:ell shorting and provides extended rechargeable battery cell life cyclirlg by rQduc:ing the number of metallic fib~r endEi whi~::h would ~xt~nd from thQ ~urface of the ~!lectrode! after the ~lactrode i~ chemically load~d and tllen rolled or ~;pirally-wound to c:omplete th~ cell a~ nbly. The layering of the ~ine diaR~ er nickel fibæ!r~ 30 e3nto the nickel f i~er-nickel powder ~ub~tr~te lO ~ tog~ther with the sub~equ~nt calend~ring and ~intering op~ration forms the electrode sub~trate into a non-woven ~etallic fahric: of a speci~ied density, thickne~s, poro~ity and weight, a~
de~ired by th~ el~c~rode ~anufa~turer. The layered ~netallic sur~ace coating incr~zlses t:he conductivity and owers the resistivity o~ the re6ultant loaded cell el~trode and provldes that about 2~-5 perc:erlt increase in electrical capacity of re~ultant recharg~able batteries utilizing the multiple layer of f ine f ibers bonded to the three-.9 . ,., . " .~ ., , ,, . , ~, . . . . . . . . . . .. ... . . . . . . . . . . . . . . . . .

W~ 9~/13025 PCrrUS92110~5 dimensional nickel f'iber~ kel powder subs~rate. 1 In still a further smbodi~nant of the present invention ~2 il lus~rated in FIGS . 8 and 9, a f lexible f ine mesh metal ~ screen ~O may be directly bonded to at lexst s~ne surface of C~ th~ nickel ~iber-nicicel powder subfitrate lO to fonn an el~ctrode structure 28B. ~he ~tal screen 40 i~ preferably Qf approximately 4 O ~l3sh in 1~i21~ and n~ay be compo~ed of `,,~,, nickel, nickel co2t~d steel or ~tainless steel. The screen i~ bonded to 2t: }~aast on~ ~urf~ce of the nickel fiber-nid~el powd~r ~ub6trate by brazing, or ~pot welding or sintering to ~provide a substrate ~andwich-like structure that ~ay ~e chemically loa~ed and ~pir,~l~y-wou~d to co~pl~te the electrod~ as~embly. Th~ ~creen 40 prev~nt3 and substantially.reduces the number o~ ~etallic ~iber ends extending from the surface of the electrode after the electrode is chemically loaded a~d wound to complete the electrode cell a~e~bly.
It is al~o within th~ ~cope of the prevent inv~ntion that the porous covering l~yer bond~d to at lQast one ~urface nf the three di~en ion~l electr~de provide~ a loaded cell el~ctrode structure that pO8~ S incr~a~ed conductivity and lowered r~ tivity ov~r non- oated thr~e-dimensional ~lectrodes. Thi~ permit~ the ~l~ctrode ~aterial of the pre*ent invention to be u~ed in ~piral-wound electrode ce11s as well a~ be uaed in pl~nar or pl~que cells which ~ay be stacked in the completedicell a~se~bly.
Although such planar or button cells ~ay bei ~onigursd or ~tacked in a ~inal cell a~embly as a non-planar arc, in this s~inse, they are con id~red substantially planar ~or purposes of this disclo6ure.

~ .

2 1 ~ 9 1 2 9 PCT/11592/10055 .'~^c~ ? ~L~
~,!,.,, Prior Ar~ Fine Ni Fiber Resin Bonded .`~"~,~ lJI Fiber Bonded to Ni to Ni Fiber ~a~ Fiber Substra~:e 5U~str~a~e LO~DING 1 g~/ i2 2 1 . 1gm/ i2 1 . 1 gm/ in Pa~te 1550 gmt~1700 gm/m 1700 g~n/m2 LOADING1240 gm~m21360 gm/m 1360 gm/m Ni (OH) 2 Utilization ~0% 83% 80%
Of Ni (OH) 2 Use~ulO . 8 g~/ in2o . 91 gm/ in2o . 8 8 gm/ in Ni ( OH) 2 Amp/Hourtm2 286 326 314 capac:lty 1~ As shown in Table I, the resin mesh bonded to the .:~
',~ surfaces of a ~hree-~i~e~sional ~intered nickel fiber-nickel powder substrate yields an amp per hour capacity of 314.
l~ The three-dimensional sub~trate material when coated with a multiple layer of ~ine nickel fibers po~s~e~ amp per hour ~ capacity of 326. In compari~vn, the a~p per hour capacity

3~ of a ~intared nickel fiber-nickel powder sub~trate as an ; electrode material posses~e~ an a~p per hour capacity of :l~ 286. This should be co~par~d to an a~p per hour capacity of s~ 210 for a pla~ar ele~trod~ which is compri~ed of nickel powder sintered onto a ~@tal m~h s~ructure.
Additionally, when comp~r~d with a nickel-cadmium AA
c~ll which po se~es 550 ~illia~ps per hour output, the output of the sintered nickel fiber-nickel powd~r substrate i5 700, the output of the resin-mesh coated nlck~l fiber-nick~l powder substrate i5 770, and the ou~put of ~he multiple-layered fine fiber bonded to the ~hree-dimen~ional nickel fiber-nickel powder suh~trate is 790. Al~o, when a si~ilar comparison is made to a nickel metal hy~rid AA
battery having an output of 1,000 mi~liamps per hour, the thre~-diménsional nickel fiber-nickel powder substrate ;l rh3 ,~s~ 1 7 .., W094/13025 PCT~S92110055 po~se~es an output of 1272, milli~mp~, the resin bonded three-dimensional substrat~ posae~e~ an output of 1400, C~ millia~p~, and the multi-layer~d fi~er bond~d thrse-dimen-sional nickel fiber-nick~l powder substrate pc~ses~es an .y ~ output of 1436. ~ccordingly, a porous covering layer means ~I positioned on at lea~t one ~urface of the three di~ensional nickel ~iber-nickel powder sub~trate provides for signi~ioant improv~d output ~B w~ll as for ~ignificant improved loading o~ thQ ~ctiYe che~ical ~eri~l into the :`;
~ substrate.
'~ Additionally, ~uch treated and layered structures made in accordance with the pre~ent invention reBult in a manufacturing loss of 1Q~3 than one h~lf of one parcen~ due ;, to shorting problem~. This,is compared to a manufacturing lo~s of approximately 10 percent due to shoxting when the three-dimQnsional nickel fiber-nickel powder substrate in ~ accordance with the prior art is spirally-wound intQ an :~ electrode cell. Thus, becau~ th~ novel structurQs in accordance with the pre~ent inYention re~ain ~ore active material by utilizing and retaining more of the active material or nickel hydroxide there exist approxiffl~tely a lO-percnt improve~ent in ~he utilization of the active material in the rei~iultant ~lectrode cell a~iembly, ~hereby sub~itantially increa~ing th~ output of the ~lectrode cell.

!' ' I j , I ! `

~' ` , ' ::

Claims

19 PCT/US9?/10055 We Claim:

1. A three-dimensional substrate material for use in constructing battery electrodes comprising:
a sintered matrix material selected from the group consisting of reticulated metal foams, conductive fibers and metal powder compacts said matrix material having at least one flexible bonded open surface structure, and a flexible open surface retaining means bonded to at least on surface of said sintered matrix material to retain said sintered matrix material, with said retaining means structurally arranged to permit loading of active chemical material through said retaining means into said sintered matrix material and to retain said sintered matrix material substan-tially within the formed surface of said at least one surface of said matrix material during subsequent spiral-winding of the sintered matrix material.

2. The three-dimensional substrate material in accordance with claim 1 wherein said retaining means is as polymeric mesh material.

3. The three-dimensional substrate material in accordance with claim 2 wherein said polymeric mesh material is selected from the group consisting of polyesters, polyolefins and polyamides.

4. The three-dimensional substrate material in accordance with claim 2 wherein said polymeric mesh material is nylon.

5. The three-dimensional substrate material in accordance with claim 1 wherein said retaining means is comprised of nickel fibers having a diameter between about 5-18 microns.

6. The three-dimensional substrate material in accordance with claim 5 wherein said nickel fibers have a diameter of about 10 microns.

7. The three-dimensional substrate material in accordance with claim 1 wherein said sintered matrix material is comprised of conductive metal fibers.

8. The three-dimensional substrate material in accor-dance with claim 7 wherein said conductive metal fibers are comprised of 70-90 weight percent nickel fibers and 30-10 weight percent nickel powder.

9. The three-dimensional substrate material in accor-dance claim 7 wherein said conductive metal fibers are com-prised of 80 weight percent nickel fiber and 20 weight percent nickel powder.

10. The three-dimensional substrate material in accor-dance claim 8 wherein said retaining means is a polymeric mesh material.

11. The three-dimensional substrate material in accor-dance with claim 10 wherein said polymeric mesh material is selected from the group consisting of polyesters, polyolefins and polyamides.

12. The three-dimensional substrate material in accor-dance with claim 10 wherein said polymeric mesh material is nylon.

13. The three-dimensional substrate material in accor-dance with claim 8 wherein said retaining means is comprised of nickel fibers having a diameter between about 5-18 microns.

14. The three-dimensional substrate material in accor-dance with claim 13 wherein said retaining means bonded to at least one surface is comprised of a coating weight of nickel fibers of between 10-100 grams per meter2.

15. The three-dimensional substrate material in accor-dance with claim 14 wherein said coating weight of nickel fibers is about 25 grams per meter2.

16. The three-dimensional substrate material in accor-dance with claim 1 wherein said retaining means is a flexible metal screen.

17. The three-dimensional substrate material in accor-dance with claim 16 wherein said flexible metal screen is a 40 mesh screen.

18. The three-dimensional substrate material in accor-dance with claim 16 wherein said flexible metal screen is selected from a group consisting of nickel, nickel coated steel and stainless steel.

19. A three-dimensional substrate material for use in constructing battery electrodes comprising:
a sintered matrix material selected from the group consisting of reticulated metal foams, conductive fibers and metal powder compacts said matrix material having at least one flexible bonded open surface structure, and an open surface matrix retaining means bonded to at least one surface of said sintered matrix material, with said retaining means structurally arranged to permit loading of active chemical material through said retaining means into said sintered matrix material and to retain said sintered matrix material substantially within the planar surface of said at least one surface of said sintered matrix material when said sintered matrix material when said sintered material plaques are assembled into the substantially planar battery electrode cell.

20. The three-dimensional substrate material in accor-dance with claim 19 wherein said retaining means is a polymeric mesh material.

21. The three dimensional substrate material in accor-dance with claim 20 wherein said polymeric mesh material is selected from the group consisting of polyesters, polyolefins and polyamides.

22. The three-dimensional substrate material in accor-dance with claim 20 wherein said polymeric mesh material is nylon.

23. The three-dimensional substrate material in accor-dance with claim 19 wherein said retaining means is comprised of nickel fibers having a diameter between about 5-18 microns.

24. The three-dimensional substrate material in accordance claim 23 wherein said nickel fibers have a diameter of about 10 microns.

25. The three-dimensional substrate material in accor-dance with claim 19 wherein said sintered matrix material is comprised of conductive metal fibers.

26. The three-dimensional substrate material in accor-dance with claim 25 wherein said conductive metal fibers are comprised of 70-90 weight percent nickel fibers and 30-10 weight percent nickel powder.

27. The three-dimensional substrate material in accor-dance with claim 25 wherein said conductive metal fibers are comprised of 80 weight percent nickel fiber and 20 weight percent nickel powder.

28. The three-dimensional substrate material in accor-dance claim 26 wherein said retaining means is a polymeric mesh material.

29. The three-dimensional substrate material in accor-dance with claim 28 wherein said polymeric mesh material is selected from the group of polyesters, polyolefins and polyamides.

30. The three-dimensional substrate material in accor-dance with claim 28 wherein said polymeric mesh material is nylon.

31. The three-dimensional substrate material in accor-dance with claim 26 wherein said retaining means is comprised of nickel fibers having a diameter between about 5-18 microns.

32. The three-dimensional substrate material in accordance with claim 31 wherein said retaining means bonded to at least one surface is comprised of coating weight of nickel fibers of between 10-60 grams per meter2.

33. The three-dimensional substrate material in accor-dance with claim 32 wherein said coating weight of nickel fibers is about 25 grams per meter2.

34. The three-dimensional substrate material in accor-dance with claim 19 wherein said retaining means is a flexible metal screen.

35. The three-dimensional substrate material in accor-dance with claim 34 wherein said flexible metal screen is a 40 mesh screen.

36. The three dimensional substrate material in accor-dance with claim 34 wherein said flexible metal screen is selected from a group consisting of nickel, nickel coated steel and stainless steel.

37. A method of making a three-dimensional substrate material for use in constructing battery electrodes comprising the steps of:
providing a sintered matrix material selected from the group consisting of reticulated metal foams, conductive fibers and metal powder compacts, said matrix material having at least an upper surface and a lower surface, with a least one surface providing a flexible bonded open structure, and applying a flexible open surface retaining means to at least one surface of said sintered matrix material permit loading of active chemical material through said retaining means into said sintered matrix material to retain said sintered matrix material substantially within the planar surface of said at least one surface of said matrix material.

38. The method according to claim 37 wherein said retaining means is a polymeric mesh material.

39. The method according to claim 38 which includes the step of subjecting the coated matrix material to heat and pressure to bond said covering layer to said at least one surface of matrix material by advancing said coated matrix material through heated pressure rollers.

24.

40. The method according to claim 38 wherein said polymeric mesh material is selected from the group consisting of polyesters, polyolefins and polyamides.

41. The method according to claim 38 wherein said polymeric mesh material is nylon.

42. The method according to claim 37 wherein said retaining means is comprised of nickel fibers having a diameter between about 5-18 microns.

43. The method according to claim 42 wherein applying said retaining means to said sintered matrix material includes spraying a fluid mixture containing said nickel fibers onto said at least one surface of said matrix material.

44. The method according to claim 42 which includes sizing said coated matrix material by advancing said coated matrix material through sizing rollers to pressure and thereafter sintering said coated matrix material.

45. The method according to claim 37 wherein said retaining means comprises a flexible mesh metal screen, and including bonding said metal screen to at least one surface of said matrix material.

46. The method according to claim 45 wherein said metal screen is bonded to said surface of said matrix material by brazing.

47. The method according to claim 45 wherein said metal screen is bonded to said surface of said matrix material by spot welding.

48. The method according to claim 45 wherein said metal screen is bonded to said surface of said matrix material by sintering.

49. A method for making a three-dimensional substrate material for use in constructing battery electrodes comprising the steps of:

25.

providing a sintered matrix material selected from the group consisting of reticulated metal foams, conductive fibers and metal powder compacts, said matrix material having at least an upper surface and a lower surface, with at least one surface thereof providing a flexible bonded open surface structure, applying a flexible open surface retaining means to at least one surface of said sintered matrix material to provide a coated matrix material which permits loading of active chemical therethrough, and subjecting said coated matrix material to heat and pressure to bond said retaining means to said matrix material in intimate physical contact, said retaining means permitting chemical loading of active material onto said matrix material and retaining said sintered matrix material substantially within the formed surface of said one surface of said matrix material during spiral-winding of the chemically loaded matrix material.

50. The method according to claim 49 wherein said retaining means is a polymeric mesh material selected from the group consisting of polyesters, polyolefins and polyamides.

51. The method according to claim 49 wherein said retaining means is comprised of nickel fibers having a diameter between about 5-18 microns.

52. The method according to claim 49 wherein said retaining means is comprised of a flexible mesh metal screen, and includes bonding said metal screen to at least one surface of said matrix material.

53. A three-dimensional electrode material for use in constructing battery electrodes comprising:
a sintered matrix material selected from the group consisting of reticulated metal foams, conductive fibers and metal powder compacts, with said matrix material having at least one flexible bonded open surface structure, a flexible open surface retaining means bonded to at least one surface of said sintered matrix material, and an active chemical material loaded through said retaining means into said sintered matrix material, with said retaining means permitting loading of said active chemical material into said sintered matrix material and retaining said chemically loaded matrix material within the planar surface of said at least one surface of said matrix material.

54. The three-dimensional electrode material in accordance with claim 53 wherein said retaining means retains said chemically loaded said matrix material substantially within the planar surface of at least one surface of said matrix material during spiral-winding of the chemically loaded matrix material for constructing a spirally wound battery electrode.

55. The three-dimensional substrate material in accor-dance with claim 54 wherein said retaining means is a polymeric mesh material.

56. The three-dimensional substrate material in accor-dance with claim 55 wherein said polymeric mesh material is selected from the group consisting of polyesters, polyolefins and polyamides.

57. The three-dimensional substrate material in accor-dance with claim 55 wherein said polymeric mesh material is nylon.

58. The three-dimensional substrate material in accor-dance with claim 54 wherein said retaining means is comprised of nickel fibers having a diameter between about 5-18 microns.

59. The three-dimensional substrate material in accordance claim 58 wherein said nickel fibers have a diameter of about 10 microns.

60. The three-dimensional substrate material in accor-dance with claim 53 wherein said sintered matrix material is comprised of conductive metal fibers.

61. The three-dimensional substrate material in accor-dance with claim 60 wherein said conductive metal fibers are comprised of 70-90 weight percent nickel fibers and 30-10 weight percent nickel powder.

62. The three-dimensional substrate material in accor-dance claim 60 wherein said conductive metal fibers are com-prised of 80 weight percent nickel fiber and 20 weight percent nickel powder.

63. The three dimensional substrate material in accor-dance claim 61 wherein said retaining means is a polymeric mesh material.

64. The three dimensional substrate material in accor-dance with claim 63 wherein said polymeric mesh material is selected from the group consisting of polyesters, polyolefins and polyamides.

65. The three-dimensional substrate material in accor-dance with claim 63 wherein said polymeric mesh material is nylon.

66. The three-dimensional substrate material in accor-dance with claim 61 wherein said retaining means is comprised of nickel fibers having a diameter between about 5-18 microns.

67. The three dimensional substrate material in accor-dance with claim 66 wherein said retaining means bonded to at least one surface is comprised of a coating weight of nickel fibers of between 10-100 grams per meter2.

68. The three-dimensional substrate material in accor-dance with claim 67 wherein said coating weight of nickel fibers is about 25 grams per meter2.

69. The three-dimensional substrate material in accor-dance with claim 54 wherein said retaining is a flexible metal screen.

70. The three-dimensional substrate material in accor-dance with claim 69 wherein said flexible metal screen is a 40 mesh screen.

71. The three-dimensional substrate material in accor-dance with claim 69 wherein said flexible metal screen is selected from a group consisting of nickel, nickel coated steel and stainless steel.

72. The three-dimensional electrode material in accordance with claim 53 wherein said retaining means retains said chemically loaded matrix material substantially within the planar surface of said at least one surface of said matrix material when said chemical loaded matrix material plates are assembled into a substantially planar battery electrode.

73. The three-dimensional substrate material in accor-dance with claim 72 wherein said retaining means is a polymeric mesh material.

74. The three-dimensional substrate material in accor-dance with claim 73 wherein said polymeric mesh material is selected from the group consisting of polyesters, polyolefins and polyamides.

75. The three-dimensional substrate material in accor-dance with claim 73 wherein said polymeric mesh material is nylon.

76. The three-dimensional substrate material in accor-dance with claim 73 wherein said retaining means is comprised of nickel fiber having a diameter between about 5-18 microns.

77. The three-dimensional substrate material in accordance claim 76 wherein said nickel fibers have a diameter of about 10 micros.

78. The three-dimensional substrate material in accor-dance with claim 72 wherein said sintered matrix material is comprised of conductive metal fibers.

79. The three-dimensional substrate material in accor-dance with claim 78 wherein said conductive metal fibers are comprised of 70-90 weight percent nickel fibers and 30-10 weight percent nickel powder.

80. The three-dimensional substrate material in accor-dance with claim 78 wherein said conductive metal fibers are comprised of 80 weight percent nickel fiber and 20 weight percent nickel powder.

81. The three-dimensional substrate material in accor-dance claim 79 wherein said retaining means is a polymeric mesh material.

82. The three-dimensional substrate material in accor-dance with claim 81 wherein said polymeric mesh material is selected from the group of polyesters, polyolefins and polyamides.

83. The three-dimensional substrate material in accor-dance with claim 81 wherein said polymeric mesh material is nylon.

84. The three-dimensional substrate material in accor-dance with claim 82 wherein said retaining means is comprised of nickel fibers having a diameter between about 5-18 microns.

85. The three-dimensional substrate material in accor-dance claim 84 wherein said retaining means bonded to at least one surface is comprised of coating weight of nickel fibers of between 10-100 grams per meter2.

86. The three dimensional substrate material in accor-dance with claim 85 wherein said coating weight of nickel fibers is about 25 grams per meter2.

87. The three dimensional substrate material in accor-dance with claim 72 wherein said retaining means is a flexible metal screen.

88. The three-dimensional substrate material in accor-dance with claim 87 wherein said flexible metal screen is a 40 mesh screen.

89. The three-dimensional substrate material in accor-dance with claim 87 wherein said flexible metal screen is selected from a group consisting of nickel, nickel coated steel and stainless steel.