CA2405351C - Conductive sheet material - Google Patents
Conductive sheet material Download PDFInfo
- Publication number
- CA2405351C CA2405351C CA2405351A CA2405351A CA2405351C CA 2405351 C CA2405351 C CA 2405351C CA 2405351 A CA2405351 A CA 2405351A CA 2405351 A CA2405351 A CA 2405351A CA 2405351 C CA2405351 C CA 2405351C
- Authority
- CA
- Canada
- Prior art keywords
- sheet material
- material according
- sheet
- fibres
- binding agent
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 239000000463 material Substances 0.000 title claims abstract description 53
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 34
- 229910052799 carbon Inorganic materials 0.000 claims abstract description 34
- 239000011230 binding agent Substances 0.000 claims abstract description 24
- 238000000034 method Methods 0.000 claims abstract description 15
- 239000011148 porous material Substances 0.000 claims description 9
- 239000000835 fiber Substances 0.000 claims description 8
- 239000002002 slurry Substances 0.000 claims description 5
- 229920005989 resin Polymers 0.000 claims description 4
- 239000011347 resin Substances 0.000 claims description 4
- 238000003763 carbonization Methods 0.000 claims description 3
- 238000010438 heat treatment Methods 0.000 claims description 3
- 230000035699 permeability Effects 0.000 claims description 3
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 claims description 2
- 229920001187 thermosetting polymer Polymers 0.000 claims description 2
- 239000004034 viscosity adjusting agent Substances 0.000 claims description 2
- 238000001035 drying Methods 0.000 claims 2
- 229920005992 thermoplastic resin Polymers 0.000 claims 1
- 238000009792 diffusion process Methods 0.000 abstract description 3
- 239000007772 electrode material Substances 0.000 abstract description 3
- 239000000446 fuel Substances 0.000 abstract description 3
- 238000004519 manufacturing process Methods 0.000 description 6
- 239000002121 nanofiber Substances 0.000 description 5
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 239000005011 phenolic resin Substances 0.000 description 4
- 229920001568 phenolic resin Polymers 0.000 description 4
- 238000007602 hot air drying Methods 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 238000006243 chemical reaction Methods 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 238000001291 vacuum drying Methods 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M8/00—Fuel cells; Manufacture thereof
- H01M8/02—Details
- H01M8/0202—Collectors; Separators, e.g. bipolar separators; Interconnectors
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
- H01M4/8605—Porous electrodes
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M4/00—Electrodes
- H01M4/86—Inert electrodes with catalytic activity, e.g. for fuel cells
- H01M4/96—Carbon-based electrodes
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- H01M8/00—Fuel cells; Manufacture thereof
- H01M8/10—Fuel cells with solid electrolytes
- H01M8/1004—Fuel cells with solid electrolytes characterised by membrane-electrode assemblies [MEA]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/10—Energy storage using batteries
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E60/00—Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
- Y02E60/30—Hydrogen technology
- Y02E60/50—Fuel cells
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
- Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
- Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
- Y10T428/249942—Fibers are aligned substantially parallel
- Y10T428/249945—Carbon or carbonaceous fiber
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/30—Self-sustaining carbon mass or layer with impregnant or other layer
Landscapes
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Electrochemistry (AREA)
- General Chemical & Material Sciences (AREA)
- Manufacturing & Machinery (AREA)
- Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Sustainable Development (AREA)
- Sustainable Energy (AREA)
- Paper (AREA)
- Inert Electrodes (AREA)
- Separation Using Semi-Permeable Membranes (AREA)
- Conductive Materials (AREA)
- Cell Electrode Carriers And Collectors (AREA)
Abstract
A conductive microporous sheet material comprises primary carbon fibres having a cross-sectional dimension of at least 1 µm, secondary carbon fibres in the form of carbon nanofibres and a binding agent for binding said primary and secondary fibres. The material may be produced by a wet-laid non-woven (paper-making) process. The sheet material may be used as a gas diffusion layer for a fuel cell or an electrode material for a battery.
Description
Conductive Sheet Material The present invention relates to a conductive microporous sheet material for use in electrical devices, particularly but not exclusively for batteries and related devices.
There is an increasing demand fox sheet materials which have a microporous structure combined with electrical conductivity and a high level of chemical resistance. Such materials fmd application as gas diffusion layers for fuel cells and as electrode materials for batteries. The present invention seeks to provide materials which meet these requirements as well as a method for the manufacture of such materials.
According to the present invention there is provided a conductive microporous sheet material comprising primary carbon fibres having a cross-sectional dimension of at least 1 ~.m, secondary carbon fibres in the form of carbon nanofibres and a binding agent for binding said primary and secondary fibres.
The sheet of the invention has a microporous structure determined primarily by the relative proportions of the first and second fibres. The variation in pore structure with the secondary (nanofibre) content may readily be determined experimentally by a person skilled in the art. Thus, for example, the sheet may be produced by a wet-laying technique (see below) and the experimental determination may be effected by producing and testing laboratory produced single sheets (hard sheets). This information may then be used to select the appropriate blend of primary and secondary fibres for a given microporous structure.
The sheet of the invention may be a thin, flexible material.
The primary fibres preferably have a cross-section of 1 to 15 ~.m, more preferably 4 to 12 ~.m, even more preferably 5 to 10 pm. Typically the primary fibres will have a length of a few millimetres, e.g. 3 to 8 mm (about 6 mm). A
preferred example of primary carbon fibxe is SGL C25 (available from Technical Fibre Products Ltd.).
The primary fibres may be obtained from acryloriitrile or pitch.
The secondary fibres (nanofibres) preferably have a cross section of between I00 and 500 nanometres, more preferably between 100 and 250 nanometres. The nanofibres may be produced by vapour deposition. A preferred example of a carbon nanofibre is Pyrograf III (available from ASI).
Preferably the primary carbon fibre constitutes between 10 and 90wt% of the total weight of fibres and secondary fibres constitute between 10 and 90wt°lo on the same basis: Preferably the fibres together provide at least 90°!o by weight of the sheet material.
The binding agent is required for adequate bonding strength of the material.
The binding agent will generally constitute less than 10% by weight of the sheet material, and more typically less than 5% on the same basis.
The binding agent may for example be a thermoplastic or thermosetting resin, a suitable example of which is a phenolic resin such as GP5520. Whilst the use of xesin binding agent is perfectly satisfactory, improved conductivity ~ can generally be achieved by use of carbon as the binding agent. Sheets utilising carbon as the binding agent may be produced by heat treatment in an inert atmosphere of a sheet material incorporating a resin binding agent, said conversion of the resin binding agent to carbon serving to increase conductivity whilst retaining the controlled microporous structure.
A sheet according to the present invention may have any one or any combination of the following properties: -A. A weight of between 10 and 200g/m2, more preferably about SOg/mz.
B. A thickness of between 0:1 and 2mm, more preferably about 0.3mm.
C. A Gurley air permeability of between 8 and 50 seconds / 300cm3.
D. A maximum pore sire of less than 22p,m, more preferably less than l6p.m and most preferably less than l2pm.
E. A through plane resistance of less than 1505~/cm, more preferably less than SOSZIcm.
F. A tensile strength of between 0.7 and I .3kN/m.
Conductive sheet material in accordance with the invention has a variety Qf end uses, including: -(1) Gas diffusion layers for fuel cells (2) Electrode materials for batteries.
The conductive sheet material, according to the invention is preferably produced using a wet-laid non-woven (papermaking) process. The use of a wet-laid production process allows a -wide range of proportions of carbon fibres and carbon nanofibres to be used and thus lends itself to production of materials with highly specific pore structures The preferred method of manufacture is to form a slurry of the two fibre types with bindex by mixing the materials in water at a concentration of up to 1 %
by weight (e.g. between 0.02 and O.Swt%). Mixing is preferably carried out using a high speed agitator and the resulting slurry is formed into a suitable sheet material by passing through a papermaking former.
Fibre distribution and sheet forming may be aided by the use of viscosity modifiers andJor drainage aids.
After forming liquid may be removed from the sheet by vacuum and/or hot air drying. Where both liquid removal methods are used it is preferred that hot air drying is applied ultimately as it may be used to melt or cure the binder. It is preferred that the final stage of the production process is the carbonisation of the binding agent.
Following the carbonisation stage the sheet material is preferably formed into a continuous roll in order to facilitate further automated processing.
Bath continuous of batch processing of the sheet material are envisaged.
Preferably in the production process the binder is initially the form of a powder although the use of a binder in any other physical form is not precluded.
The invention will now be described further with reference to the following non-limiting Examples.
Example 1 A sheet was formed by mixing the following elements in water using a high speed agitator at a combined concentration of O.Swt%.
Carbon fibre (SGL C25), 6mm chopped length 24wt%
Carbon nanofibre (Pyrograf - III, ex ASI) 73wt%
Phenolic resin (GP 5520) 2wt%
The resulting material was converted into sheet form using a papermaking former. The sheet was dried using a combination of vacuum and hot air and then carbonised by heating in an inert atmosphere until the phenolic binder was completely converted to carbon.
Sheets formed from the above mixture had the following characteristics :-Weight S Og/m2 Thickness 0.3mm Tensile strength 0.7kN/m Gurley air permeability SOseconds / 300cm3 Maximum pore size 12~.m Through plane xesistance 150S21cm Example 2 A sheet was formed by mixing the following elements using the same technique as in Example 1.
Carbon fibre (SGL C25) , 6mm chopped length 49wt%
Carbon nanofibre (Pyrograf - III, ex ASI) 49wt%
Phenolic resin (GP 5520) 2wt%
Sheets formed from the above mixture had the following characteristics :-Weight S Og/m2 Thickness 0.3mm Tensile strength I.OkN/m Gurley air permeability20 seconds /
300 cm3 Maximum pore size16p,m Through plane 150 S2/cm resistance Example 3 A sheet was formed by mixing the following elements using the same technique as in Example 1.
Carbon fibre (SGL C25), 6mm chopped length 74wt%
Carbon nanofibre (Pyrograf-III, ex ASI) 24wt%
Phenolic resin (GP 5520) 2wt%
Sheets formed from the above mixture had the following characteristics :-Weight SOg/m2 Thickness 0.3mm Tensile strength l.3kNlm Gurley air permeability8 seconds /
300 cm3 Maximum pore size22 ~.m Through plane 150 S2lcm resistance
There is an increasing demand fox sheet materials which have a microporous structure combined with electrical conductivity and a high level of chemical resistance. Such materials fmd application as gas diffusion layers for fuel cells and as electrode materials for batteries. The present invention seeks to provide materials which meet these requirements as well as a method for the manufacture of such materials.
According to the present invention there is provided a conductive microporous sheet material comprising primary carbon fibres having a cross-sectional dimension of at least 1 ~.m, secondary carbon fibres in the form of carbon nanofibres and a binding agent for binding said primary and secondary fibres.
The sheet of the invention has a microporous structure determined primarily by the relative proportions of the first and second fibres. The variation in pore structure with the secondary (nanofibre) content may readily be determined experimentally by a person skilled in the art. Thus, for example, the sheet may be produced by a wet-laying technique (see below) and the experimental determination may be effected by producing and testing laboratory produced single sheets (hard sheets). This information may then be used to select the appropriate blend of primary and secondary fibres for a given microporous structure.
The sheet of the invention may be a thin, flexible material.
The primary fibres preferably have a cross-section of 1 to 15 ~.m, more preferably 4 to 12 ~.m, even more preferably 5 to 10 pm. Typically the primary fibres will have a length of a few millimetres, e.g. 3 to 8 mm (about 6 mm). A
preferred example of primary carbon fibxe is SGL C25 (available from Technical Fibre Products Ltd.).
The primary fibres may be obtained from acryloriitrile or pitch.
The secondary fibres (nanofibres) preferably have a cross section of between I00 and 500 nanometres, more preferably between 100 and 250 nanometres. The nanofibres may be produced by vapour deposition. A preferred example of a carbon nanofibre is Pyrograf III (available from ASI).
Preferably the primary carbon fibre constitutes between 10 and 90wt% of the total weight of fibres and secondary fibres constitute between 10 and 90wt°lo on the same basis: Preferably the fibres together provide at least 90°!o by weight of the sheet material.
The binding agent is required for adequate bonding strength of the material.
The binding agent will generally constitute less than 10% by weight of the sheet material, and more typically less than 5% on the same basis.
The binding agent may for example be a thermoplastic or thermosetting resin, a suitable example of which is a phenolic resin such as GP5520. Whilst the use of xesin binding agent is perfectly satisfactory, improved conductivity ~ can generally be achieved by use of carbon as the binding agent. Sheets utilising carbon as the binding agent may be produced by heat treatment in an inert atmosphere of a sheet material incorporating a resin binding agent, said conversion of the resin binding agent to carbon serving to increase conductivity whilst retaining the controlled microporous structure.
A sheet according to the present invention may have any one or any combination of the following properties: -A. A weight of between 10 and 200g/m2, more preferably about SOg/mz.
B. A thickness of between 0:1 and 2mm, more preferably about 0.3mm.
C. A Gurley air permeability of between 8 and 50 seconds / 300cm3.
D. A maximum pore sire of less than 22p,m, more preferably less than l6p.m and most preferably less than l2pm.
E. A through plane resistance of less than 1505~/cm, more preferably less than SOSZIcm.
F. A tensile strength of between 0.7 and I .3kN/m.
Conductive sheet material in accordance with the invention has a variety Qf end uses, including: -(1) Gas diffusion layers for fuel cells (2) Electrode materials for batteries.
The conductive sheet material, according to the invention is preferably produced using a wet-laid non-woven (papermaking) process. The use of a wet-laid production process allows a -wide range of proportions of carbon fibres and carbon nanofibres to be used and thus lends itself to production of materials with highly specific pore structures The preferred method of manufacture is to form a slurry of the two fibre types with bindex by mixing the materials in water at a concentration of up to 1 %
by weight (e.g. between 0.02 and O.Swt%). Mixing is preferably carried out using a high speed agitator and the resulting slurry is formed into a suitable sheet material by passing through a papermaking former.
Fibre distribution and sheet forming may be aided by the use of viscosity modifiers andJor drainage aids.
After forming liquid may be removed from the sheet by vacuum and/or hot air drying. Where both liquid removal methods are used it is preferred that hot air drying is applied ultimately as it may be used to melt or cure the binder. It is preferred that the final stage of the production process is the carbonisation of the binding agent.
Following the carbonisation stage the sheet material is preferably formed into a continuous roll in order to facilitate further automated processing.
Bath continuous of batch processing of the sheet material are envisaged.
Preferably in the production process the binder is initially the form of a powder although the use of a binder in any other physical form is not precluded.
The invention will now be described further with reference to the following non-limiting Examples.
Example 1 A sheet was formed by mixing the following elements in water using a high speed agitator at a combined concentration of O.Swt%.
Carbon fibre (SGL C25), 6mm chopped length 24wt%
Carbon nanofibre (Pyrograf - III, ex ASI) 73wt%
Phenolic resin (GP 5520) 2wt%
The resulting material was converted into sheet form using a papermaking former. The sheet was dried using a combination of vacuum and hot air and then carbonised by heating in an inert atmosphere until the phenolic binder was completely converted to carbon.
Sheets formed from the above mixture had the following characteristics :-Weight S Og/m2 Thickness 0.3mm Tensile strength 0.7kN/m Gurley air permeability SOseconds / 300cm3 Maximum pore size 12~.m Through plane xesistance 150S21cm Example 2 A sheet was formed by mixing the following elements using the same technique as in Example 1.
Carbon fibre (SGL C25) , 6mm chopped length 49wt%
Carbon nanofibre (Pyrograf - III, ex ASI) 49wt%
Phenolic resin (GP 5520) 2wt%
Sheets formed from the above mixture had the following characteristics :-Weight S Og/m2 Thickness 0.3mm Tensile strength I.OkN/m Gurley air permeability20 seconds /
300 cm3 Maximum pore size16p,m Through plane 150 S2/cm resistance Example 3 A sheet was formed by mixing the following elements using the same technique as in Example 1.
Carbon fibre (SGL C25), 6mm chopped length 74wt%
Carbon nanofibre (Pyrograf-III, ex ASI) 24wt%
Phenolic resin (GP 5520) 2wt%
Sheets formed from the above mixture had the following characteristics :-Weight SOg/m2 Thickness 0.3mm Tensile strength l.3kNlm Gurley air permeability8 seconds /
300 cm3 Maximum pore size22 ~.m Through plane 150 S2lcm resistance
Claims (32)
1) A conductive microporous sheet material comprising primary carbon fibres having a cross-sectional dimension of at least 1 µm, secondary carbon fibres in the form of carbon nanofibres and a binding agent for binding said primary and secondary fibres.
2) A sheet material according to claim 1, wherein the primary carbon fibres have a cross section of between 4 and 12µm.
3) A sheet material according to claim 2, wherein the primary carbon fibres have a cross section of between 5 and 10µm.
4) A sheet material according to claim 1, 2 or 3, wherein the primary carbon fibres are between 3 and 8mm in length.
5) A sheet material according to claim 4, wherein the primary carbon fibres are about 6mm in length.
6) A sheet material according to any one of claims 1 to 5, wherein the secondary carbon fibres have a cross section of between 100 and 500 nanometres.
7) A sheet material according to claim 6, wherein the secondary carbon fibres have a cross section of between 100 and 250 nanometres.
8) A sheet material according to any one of claims 1 to 7, wherein the primary carbon fibres constitute between 10 and 90wt% of the total weight of fibres.
9) A sheet material according to any one of claims 1 to 8, wherein the secondary carbon fibres constitute between 10 and 90wt% of the total weight of fibres.
10) A sheet material according to any one of claims 1 to 9, wherein the binding agent constitutes less than 10wt% of the sheet material.
11) A sheet material according to claim 10, wherein the binding agent constitutes less than 5wt% of the sheet material.
12) A sheet material according to any one of claims 1 to 11, wherein the binding agent is selected from the group comprising thermoplastic resins and thermosetting resins.
13) A sheet material according to claim 12, wherein the binding agent is a phenolic binder.
14) A sheet material according to any of the preceding claims, wherein the binding agent is carbon.
15) A sheet material according to any one of claims 1 to 14, wherein the sheet has a weight of between 10 and 200g/m2.
16) A sheet material according to claim 15, wherein the sheet has a weight of about 50g/m2.
17) A sheet material according to any one of claims 1 to 16, wherein the sheet has a thickness of between 0.1 and 2mm.
18) A sheet material according to claim 17, wherein the sheet has a thickness of about 0.3mm.
19) A sheet material according to any one of claims 1 to 18, wherein the sheet has a Gurley air permeability of between 8 and 50 seconds / 300cm3.
20) A sheet material according to any one of claims 1 to 19, wherein the sheet has a maximum pore size of less than 22µm.
21) A sheet material according to claim 20, wherein the sheet has a maximum pore size of less than 16µm.
22) A sheet material according to claim 21, wherein the sheet has a maximum pore size of less than 12µm.
23) A sheet material according to any one of claims 1 to 22, wherein the sheet has a through plane resistance of less than 150.OMEGA./cm.
24) A sheet material according to claim 23, wherein the sheet has a through plane resistance of less than 50.OMEGA./cm.
25) A sheet material according to any one of claims 1 to 24, wherein the sheet has a tensile strength of between 0.7 and 1.3kN/m.
26) A battery which includes a portion of sheet material according to any one of claims 1 to 25.
27) A method of producing a porous conductive sheet according to claim 1 comprising:-(a) forming an aqueous slurry of the primary and secondary carbon fibres with a binding agent;
(b) applying the slurry to a paper forming screen to produce a sheet thereof;
and (c) drying the sheet.
(b) applying the slurry to a paper forming screen to produce a sheet thereof;
and (c) drying the sheet.
28) A method according to claim 27, wherein in step (a) the combined weight of the primary and secondary fibres and the binding agent constitutes between 0.02 and 0.5wt% of the aqueous slurry.
29) A method according to claim 27 or 28, wherein the drying step is carried out by hot air heating or vacuum technique.
30) A method according to claim 27, 28 or 29, which also includes an additional step (d) of carbonising the sheet material.
31) A method according to claim 30 wherein the carbonisation is carried out at an elevated temperature in an inert atmosphere.
32) A method according to any one of claims 27 to 31, wherein the fibre distribution and sheet forming is aided by the use of viscosity modifiers, drainage aids or a combination of both.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GBGB0009319.5A GB0009319D0 (en) | 2000-04-17 | 2000-04-17 | Conductive sheet material |
| GB0009319.5 | 2000-04-17 | ||
| PCT/GB2001/001653 WO2001080334A2 (en) | 2000-04-17 | 2001-04-12 | Conductive sheet material |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2405351A1 CA2405351A1 (en) | 2001-10-25 |
| CA2405351C true CA2405351C (en) | 2011-02-01 |
Family
ID=9889984
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2405351A Expired - Lifetime CA2405351C (en) | 2000-04-17 | 2001-04-12 | Conductive sheet material |
Country Status (7)
| Country | Link |
|---|---|
| US (1) | US7238413B2 (en) |
| EP (1) | EP1275162A2 (en) |
| JP (1) | JP5191078B2 (en) |
| AU (1) | AU4854501A (en) |
| CA (1) | CA2405351C (en) |
| GB (1) | GB0009319D0 (en) |
| WO (1) | WO2001080334A2 (en) |
Families Citing this family (26)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7144476B2 (en) * | 2002-04-12 | 2006-12-05 | Sgl Carbon Ag | Carbon fiber electrode substrate for electrochemical cells |
| WO2004109837A2 (en) * | 2002-10-31 | 2004-12-16 | Carbon Nanotechnologies, Inc. | Fuel cell electrode comprising carbon nanotubes |
| EP1627444A2 (en) * | 2003-05-09 | 2006-02-22 | Foamex L.P. | Gas diffusion layer having carbon particle mixture |
| US20050026012A1 (en) * | 2003-07-28 | 2005-02-03 | O'hara Jeanette E. | Diffusion media tailored to account for variations in operating humidity and devices incorporating the same |
| CN1871402B (en) * | 2003-10-22 | 2010-12-08 | 纳幕尔杜邦公司 | Porous Fibrous Sheets of Nanofibers |
| CN100405641C (en) * | 2004-06-23 | 2008-07-23 | 比亚迪股份有限公司 | Preparation method of membrane electrode of proton exchange membrane fuel cell |
| US9346673B2 (en) | 2004-06-23 | 2016-05-24 | Samsung Sdi Co., Ltd. | Electrode for fuel cell, membrane-electrode assembly for fuel cell comprising the same, fuel cell system comprising the same, and method for preparing the electrode |
| KR100578981B1 (en) | 2004-09-08 | 2006-05-12 | 삼성에스디아이 주식회사 | Electrode for fuel cell, fuel cell system comprising same |
| KR100658675B1 (en) | 2004-11-26 | 2006-12-15 | 삼성에스디아이 주식회사 | Electrode for fuel cell, fuel cell comprising same and method for manufacturing electrode for fuel cell |
| KR100825196B1 (en) * | 2005-03-28 | 2008-04-24 | 산요덴키가부시키가이샤 | Fuel cell |
| KR100684797B1 (en) | 2005-07-29 | 2007-02-20 | 삼성에스디아이 주식회사 | Electrode for fuel cell, membrane-electrode assembly comprising same and fuel cell system comprising same |
| CN101238249B (en) * | 2005-08-10 | 2012-09-19 | 东丽株式会社 | Sponge-like structure and powder and process for production thereof |
| US8828481B2 (en) * | 2007-04-23 | 2014-09-09 | Applied Sciences, Inc. | Method of depositing silicon on carbon materials and forming an anode for use in lithium ion batteries |
| CN101808819A (en) * | 2007-09-07 | 2010-08-18 | 无机专家公司 | Silicon modified nanofiber paper as an anode material for a lithium secondary battery |
| JP2009078091A (en) * | 2007-09-27 | 2009-04-16 | Josho Gakuen | Rf exposure protective method and its protective implement in undergoing examination by mri examination method |
| US20090294733A1 (en) * | 2008-05-29 | 2009-12-03 | Kelly Dean Branham | Process for improved electrospinning using a conductive web |
| WO2010102974A2 (en) * | 2009-03-09 | 2010-09-16 | Futurecarbon Gmbh | Networks of carbon nanomaterials and method for producing the same |
| US20110143262A1 (en) * | 2009-12-10 | 2011-06-16 | Gm Global Technology Operations, Inc. | Gas diffusion media made from electrically conductive coatings on non-conductive fibers |
| US9061902B2 (en) | 2009-12-18 | 2015-06-23 | The Board Of Trustees Of The Leland Stanford Junior University | Crystalline-amorphous nanowires for battery electrodes |
| US9666848B2 (en) | 2011-05-20 | 2017-05-30 | Dreamweaver International, Inc. | Single-layer lithium ion battery separator |
| GB201118020D0 (en) | 2011-10-19 | 2011-11-30 | Johnson Matthey Plc | Gas diffusion substrate |
| KR101484762B1 (en) * | 2012-06-29 | 2015-01-21 | 주식회사 제이앤티씨 | Carbon substrate for gas diffusion layer, gas diffusion layer using the same, and electrode for fuel cell comprising the gas diffusion layer |
| US10700326B2 (en) | 2012-11-14 | 2020-06-30 | Dreamweaver International, Inc. | Single-layer lithium ion battery separators exhibiting low shrinkage rates at high temperatures |
| US10607790B2 (en) | 2013-03-15 | 2020-03-31 | Dreamweaver International, Inc. | Direct electrolyte gelling via battery separator composition and structure |
| JP6648423B2 (en) * | 2015-06-19 | 2020-02-14 | 日本ゼオン株式会社 | Nonwoven fabric and method for producing the same |
| US20180162092A1 (en) * | 2016-12-09 | 2018-06-14 | The Boeing Company | Fiber-modified interlayer for a composite structure and method of manufacture |
Family Cites Families (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2180617B1 (en) * | 1972-04-21 | 1974-09-13 | Rhone Progil | |
| JP2584497B2 (en) * | 1988-08-08 | 1997-02-26 | 昭和電工株式会社 | Carbon fiber sheet |
| US5576162A (en) * | 1996-01-18 | 1996-11-19 | Eastman Kodak Company | Imaging element having an electrically-conductive layer |
| US5800706A (en) * | 1996-03-06 | 1998-09-01 | Hyperion Catalysis International, Inc. | Nanofiber packed beds having enhanced fluid flow characteristics |
| AU721291C (en) * | 1996-05-15 | 2003-02-27 | Hyperion Catalysis International, Inc. | Graphitic nanofibers in electrochemical capacitors |
| AU727973B2 (en) * | 1996-05-15 | 2001-01-04 | Hyperion Catalysis International Inc. | Rigid porous carbon structures, methods of making, methods of using and products containing same |
| AU771319B2 (en) * | 1998-09-28 | 2004-03-18 | Hyperion Catalysis International, Inc. | Fibril composite electrode for electrochemical capacitors |
| WO2001056103A1 (en) * | 2000-01-27 | 2001-08-02 | Mitsubishi Rayon Co., Ltd. | Porous carbon electrode material, method for manufacturing the same, and carbon fiber paper |
| EP1275165A1 (en) * | 2000-04-17 | 2003-01-15 | Johnson Matthey Public Limited Company | Gas diffusion substrate |
-
2000
- 2000-04-17 GB GBGB0009319.5A patent/GB0009319D0/en not_active Ceased
-
2001
- 2001-04-12 JP JP2001577626A patent/JP5191078B2/en not_active Expired - Fee Related
- 2001-04-12 EP EP01921571A patent/EP1275162A2/en not_active Withdrawn
- 2001-04-12 AU AU48545/01A patent/AU4854501A/en not_active Abandoned
- 2001-04-12 WO PCT/GB2001/001653 patent/WO2001080334A2/en not_active Ceased
- 2001-04-12 US US10/240,799 patent/US7238413B2/en not_active Expired - Lifetime
- 2001-04-12 CA CA2405351A patent/CA2405351C/en not_active Expired - Lifetime
Also Published As
| Publication number | Publication date |
|---|---|
| US20030165740A1 (en) | 2003-09-04 |
| JP5191078B2 (en) | 2013-04-24 |
| AU4854501A (en) | 2001-10-30 |
| WO2001080334A3 (en) | 2002-03-28 |
| WO2001080334A2 (en) | 2001-10-25 |
| GB0009319D0 (en) | 2000-05-31 |
| JP2004504688A (en) | 2004-02-12 |
| US7238413B2 (en) | 2007-07-03 |
| EP1275162A2 (en) | 2003-01-15 |
| CA2405351A1 (en) | 2001-10-25 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CA2405351C (en) | Conductive sheet material | |
| EP2089925B1 (en) | Electrode substrate for electrochemical cell from carbon and cross-linkable resin fibers | |
| JP3612518B2 (en) | Porous carbon electrode substrate, method for producing the same, and carbon fiber paper | |
| JPWO2001056103A1 (en) | Porous carbon electrode substrate, its manufacturing method, and carbon fiber paper | |
| KR101832014B1 (en) | Conductive sheet and production method for same | |
| JP5844760B2 (en) | Porous electrode substrate | |
| KR101240112B1 (en) | Carbon fiber structured body and method for manufacturing the same | |
| JP2010073699A (en) | Water transport plate and its use method | |
| KR101205145B1 (en) | Carbon fiber reinforced carbon composite and method for manufacturing the same | |
| JPS60122711A (en) | Manufacture of porous carbon board | |
| WO2004085728A1 (en) | Porous carbon base material, method for preparation thereof, gas-diffusing material, film-electrode jointed article, and fuel cell | |
| JP6855843B2 (en) | Electrodes for redox flow batteries and their manufacturing methods, and redox flow batteries | |
| JP4266699B2 (en) | Porous electrode substrate for polymer electrolyte fuel cell and method for producing the same | |
| JPH076775A (en) | Electrolyte holding plate and method for manufacturing the same | |
| JP2006040886A (en) | Porous electrode substrate and method for producing the same | |
| JP5484777B2 (en) | Porous electrode substrate and method for producing the same | |
| JP2010132515A (en) | Method for manufacturing porous electrode substrate | |
| JPS61236665A (en) | Manufacture of porous carbon sheet | |
| JPH08151461A (en) | Prepreg sheet for porous carbonaceous molded plate | |
| CA2437559A1 (en) | Gas diffusion electrode manufacturing method and fuel cell | |
| JP2009076347A (en) | Gas diffusion electrode substrate and method for producing the same | |
| JPH01266223A (en) | Production of anisotropic porous carbon formed product | |
| JP5336912B2 (en) | Porous electrode substrate manufacturing method, membrane-electrode assembly using the same, and fuel cell | |
| JPH07220732A (en) | Method for producing porous carbon plate for phosphoric acid fuel cell | |
| JPS63222078A (en) | Manufacture of carbon fiber porous body |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKEX | Expiry |
Effective date: 20210412 |