EP1929068A1 - Verfahren zur herstellung von metallschäumen mit einheitlicher zellstruktur - Google Patents

Verfahren zur herstellung von metallschäumen mit einheitlicher zellstruktur

Info

Publication number
EP1929068A1
EP1929068A1 EP06790575A EP06790575A EP1929068A1 EP 1929068 A1 EP1929068 A1 EP 1929068A1 EP 06790575 A EP06790575 A EP 06790575A EP 06790575 A EP06790575 A EP 06790575A EP 1929068 A1 EP1929068 A1 EP 1929068A1
Authority
EP
European Patent Office
Prior art keywords
foam
planar
foam sheet
sheet
plated
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.)
Withdrawn
Application number
EP06790575A
Other languages
English (en)
French (fr)
Other versions
EP1929068A4 (de
Inventor
Vladimir Paserin
Jun Shu
Victor Ettel
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Vale Canada Ltd
Original Assignee
Vale Canada Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Vale Canada Ltd filed Critical Vale Canada Ltd
Publication of EP1929068A1 publication Critical patent/EP1929068A1/de
Publication of EP1929068A4 publication Critical patent/EP1929068A4/de
Withdrawn legal-status Critical Current

Links

Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00Electrodes
    • H01M4/02Electrodes composed of, or comprising, active material
    • H01M4/64Carriers or collectors
    • H01M4/70Carriers or collectors characterised by shape or form
    • H01M4/80Porous plates, e.g. sintered carriers
    • H01M4/808Foamed, spongy materials
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C28/00Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10Sintering only
    • B22F3/11Making porous workpieces or articles
    • B22F3/1121Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers
    • B22F3/1137Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers by coating porous removable preforms
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34Auxiliary operations
    • B29C44/56After-treatment of articles, e.g. for altering the shape
    • B29C44/5627After-treatment of articles, e.g. for altering the shape by mechanical deformation, e.g. crushing, embossing, stretching
    • B29C44/5654Subdividing foamed articles to obtain particular surface properties, e.g. on multiple modules
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C1/00Making non-ferrous alloys
    • C22C1/08Alloys with open or closed pores
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/04Coating on selected surface areas, e.g. using masks
    • C23C14/046Coating cavities or hollow spaces, e.g. interior of tubes; Infiltration of porous substrates
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/06Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
    • C23C14/14Metallic material, boron or silicon
    • C23C14/20Metallic material, boron or silicon on organic substrates
    • C23C14/205Metallic material, boron or silicon on organic substrates by cathodic sputtering
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C16/00Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/04Coating on selected surface areas, e.g. using masks
    • C23C16/045Coating cavities or hollow spaces, e.g. interior of tubes; Infiltration of porous substrates
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C16/00Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/44Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
    • C23C16/4418Methods for making free-standing articles
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C18/00Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
    • C23C18/16Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by reduction or substitution, e.g. electroless plating
    • C23C18/1601Process or apparatus
    • C23C18/1633Process of electroless plating
    • C23C18/1635Composition of the substrate
    • C23C18/1644Composition of the substrate porous substrates
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C18/00Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
    • C23C18/16Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by reduction or substitution, e.g. electroless plating
    • C23C18/31Coating with metals
    • CCHEMISTRY; METALLURGY
    • C25ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25DPROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D1/00Electroforming
    • C25D1/08Perforated or foraminous objects, e.g. sieves
    • CCHEMISTRY; METALLURGY
    • C25ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25DPROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/54Electroplating of non-metallic surfaces
    • C25D5/56Electroplating of non-metallic surfaces of plastics
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00Electrodes
    • H01M4/02Electrodes composed of, or comprising, active material
    • H01M4/64Carriers or collectors
    • H01M4/66Selection of materials
    • H01M4/665Composites
    • H01M4/667Composites in the form of layers, e.g. coatings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00Supplementary information concerning processes or compositions relating to powder metallurgy
    • YGENERAL 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
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10Energy storage using batteries

Definitions

  • the present invention relates to the production of foams in general, and in particular, to the production of porous metal plated foams having substantially isotropic characteristics.
  • Porous metal plated foams are used in many industrial and commercial applications: battery electrodes, fuel cell components, filters, pollution control equipment, catalyst supports, audio components, etc.
  • the underlying cell structure is often key to the characteristics of the foam.
  • the three dimensional shape of the repeating cell matrix affects the performance of the foam.
  • Foams typically come in either open cell or closed cell variants.
  • NiMH nickel metal hydride
  • NiCd nickel cadmium
  • HEV hybrid electrical vehicles
  • the cell structure of nickel foams affects battery performance; in particular in HEV battery applications. Non-uniform size, shape and orientation of foam cells lead to non-uniform thickness of nickel, foam conductivity, active mass loading and electrochemical performance of individual battery cells. This in turn will give some of the battery cells different performance characteristics (capacity, impedance, rate of aging) and will eventually cause a premature failure of a large battery pack that often contains as many as 200 battery cells.
  • Nickel foam is produced through adopting cell structures of polyurethane ("PU") foam substrates as templates by means of electroplating or chemical vapor deposition.
  • PU polyurethane
  • electroplating a suitable pretreatment of PU foam substrate is required to make the foam conductive.
  • sintering is performed to remove the polyurethane substrate, leaving nickel struts arranged in the original three-dimensional framework. Accordingly, a uniform cell structure of the polymeric substrate is key in producing superior nickel foam with a uniform cell structure.
  • the structure of precursor open cell polyurethane foam is generally described as a pentagonal dodecahedron, which has twelve 5-sided faces with occasional 4- and 6-sided cells found in polyurethane foam structures.
  • a geometric anisotropy in the polyurethane cell structure parallel and perpendicular to the foam rise direction during foaming. Due to gravity, the cells near the bottom of the block of foam (also called a bun or slab) are smaller and more spherical, whereas the cells in the upper part of the block are vertically elongated and larger.
  • Figures I and 2 show images of the prior art foam geometric anisotropy, parallel and perpendicular to the foam rise direction respectively. See also U.S. patent 6,383,687.
  • the resultant foam sheet has circular cell structures from the "parallel" direction (i.e. parallel with the foam rise direction or horizontal position at the time of foaming), and elliptical cell structures from the "perpendicular" direction (perpendicular to the foam rise direction or vertical position at the time of foaming) exhibiting undesirable periodic cell structure variations.
  • these inconsistencies are sometimes visible as light and dark bands containing cells of different size, shape and orientation.
  • periodic density perturbation patterns are created, adversely affecting the application performance of the material when used as battery electrodes. See Figures 8 and 9 of V. Paserin.
  • Other important properties of metal foam produced from the rotary peeled polymeric foam are affected as well: periodic variations in electrical conductivity, tensile strength and elongation.
  • FIG. 4 A schematic representation of loop slitting is shown in Figure 4.
  • a large foam loop 24 is formed at joint 26 by gluing the two ends of a long (typically 60m) polyurethane slab 28 together.
  • the loop 24 is then rotated in direction 34 by drive belts 44 and is slit by knife 30 in a loop slitting machine as schematically represented in Figure 4 along the slab's surface to continuously form planar sheets 46 which are then rolled into spools 32 of desired thickness.
  • Loop slit foam substrates have more uniform cell structures than rotary peeled foams. This is because the foam is cut only in the "perpendicular" direction (the horizontal direction at the time of foaming) so that all cells are essentially circular and their size changes only slowly and over many hundreds of meters of produced foam sheet.
  • Figure 8 of V. Paserin shows the longitudinal density profile of loop slit foam. It is more consistent than rotary peeled foam. See also Japanese patent JP 9153365. However, the slitting of a large loop 24 requires sophisticated control machinery.
  • foams are reticulated either chemically or thermally to eliminate localized internal obstructions. Residual internal membranes are removed and the edges of the struts of the cells are rounded to create larger and smoother openings in the cell walls.
  • the openings (windows) between adjacent cells are much smaller than the cell diameters and their size and uniformity is critical in many demanding applications, particularly batteries.
  • Well reticulated foams with narrow struts and large openings between cells will improve pasting with active mass and produce higher capacity and higher power batteries than poorly reticulated foams with smaller windows.
  • Thermal reticulation involves placing the foam into an autoclave, evacuating the autoclave and filling it with an explosive oxygen/hydrogen mixture. After ignition of the mixture, the explosive flame front rapidly travels through the foam while simultaneously melting the residual membranes and the thin edges of the struts.
  • the flame front rounds off the edges of the struts and enlarges the pores. Openings between the struts are favorably increased.
  • Figure 5A shows typical unreticulated pore struts 36 and 38 separated by opening A.
  • Figure 5B shows typical thermally reticulated pore struts 40 and 42 that are more rounded and are separated by larger opening B.
  • Flame fronted reticulated foams are more amenable for metalizing and plating with nickel or any other metal inside the foam structure. Accordingly, the plated foams have enhanced mechanical strengths and preferred geometric framework for battery applications.
  • loop peeling is used for producing thin sheets of polyurethane foam for laminated fabrics and other non-battery applications.
  • rotary peeled foam Because of the inability to properly reticulate the typical 60 meter long foam blocks destined for loop peeling, almost all of the nickel foam produced for battery applications today is rotary peeled foam. However, as noted, rotary peeled foam suffers from disabilities: unavoidable cyclic variations in foam density, conductivity, strength and plating density across the thickness of the foam.
  • polymeric foam slabs of desired length are slit with a horizontal slitting knife along the longitudinal bun surface to a desired thickness in a horizontal slitting apparatus.
  • the resulting sheets may be attached to one another end to end to increase their effective length and in any event are typically spooled.
  • the horizontal slitting can be done in a loop slitting apparatus, producing a spooled long sheet similar to the long sheet produced by the joining shorter sheets made by the horizontal slitting apparatus.
  • the rolled or spooled sheets are subject to thermal reticulation and then plated by chemical vapor deposition, by electrodeposition (preceded by a suitable treatment to make the foam sufficiently conductive) or by other metal deposition process.
  • the resulting metal foam is substantially uniform having consistent and desirable characteristics.
  • Figure 1 is a photomicrograph of conventional metal foam parallel to foam rise direction.
  • Figure 2 is a photomicrograph of conventional metal foam perpendicular to foam rise direction.
  • Figure 3 is a perspective schematic representation of a horizontal slitting apparatus.
  • Figure 4 is a schematic representation of a prior art loop slitting apparatus in plain view.
  • Figure 5A is a schematic representation of unreticulated foam struts.
  • Figure 5B is a schematic representation of reticulated foam struts.
  • Figure 6 is a graph depicting an embodiment of the present invention.
  • An object of the present invention is for the production of porous metal plated foam having a uniform cell structure.
  • the metal foam has a consistent distribution of area density, controlled metal strut thickness, and uniform mechanical and electrical properties such as tensile strength, elongation and electrical conductivity.
  • (slabs) 10 of desired length, width and height are slit by a horizontal slitting apparatus 12 along the upper longitudinal bun surface 14.
  • the foam bun 10 is repeatedly reciprocated over the slitter bed 16 to cut and raise a planar foam sheet 20 of predetermined thickness from the horizontal longitudinal bun surface 14. Knife 18 slits the bun 10 to generate the foam sheet 20.
  • the foam sheet 20 is transported to a storage section 22 of the apparatus 12. Side trimmer 46 maintains the correct foam slab 10 width. If desired, the foam sheet 20 may be shortened by a blade, heated surface, or similar device (not shown) known to those skilled in the art.
  • the horizontally slit foam sheet 20 is subsequently spooled. Individual foam sheets 20 may be joined at their ends by hot compression or by an adhesive to create longer foam sheets 20 prior to spooling. The horizontally slit foam spools are then subject to reticulation — to generate fully open cell foam structures and substrates.
  • thermal (flame) reticulation when treating the spools. See Figure 5B.
  • the opposing ends of one or more foam sheets 20 may be affixed to one another to form a loop 24.
  • the loop 24 may be then subjected to conventional loop slitting as shown in Figure 4.
  • the resultant planar foam sheet made initially either by horizontal slitting (20) and joining or by loop peeling (46) may be then subjected to spooling, thermal reticulation, unwinding, metal plating and sizing to predetermined dimensions.
  • Horizontal slitting is not limited to the upper longitudinal bun surface
  • the reticulated foam sheets 20 are then nickel plated by chemical vapor deposition, electroplating, or electroless plating techniques to produce plated nickel foam with uniform cell structures.
  • Deposition techniques include, but are not limited to metal carbonyl decomposition, sputtering, thermal evaporation, etc. Other metals such as copper, chromium, cobalt, platinum, palladium, rhodium, silver, gold, iron, etc. may be plated on to the foam sheets as well.
  • the plated foam sheets 20 can be used as-produced, or can be heat- treated, typically by sintering, to remove the internal polymer structure and to stabilize the metal plating. As noted previously, these plated foams may be utilized in a variety of applications. In the case of batteries, the plated foams are impregnated with battery active mass pastes to provide suitable electrodes.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • General Chemical & Material Sciences (AREA)
  • Electrochemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Composite Materials (AREA)
  • Cell Electrode Carriers And Collectors (AREA)
  • Electroplating Methods And Accessories (AREA)
  • Physical Vapour Deposition (AREA)
  • Chemical Vapour Deposition (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
EP06790575A 2005-09-07 2006-08-25 Verfahren zur herstellung von metallschäumen mit einheitlicher zellstruktur Withdrawn EP1929068A4 (de)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US71494305P 2005-09-07 2005-09-07
PCT/CA2006/001394 WO2007028234A1 (en) 2005-09-07 2006-08-25 Process for producing metal foams having uniform cell structure

Publications (2)

Publication Number Publication Date
EP1929068A1 true EP1929068A1 (de) 2008-06-11
EP1929068A4 EP1929068A4 (de) 2012-10-03

Family

ID=37835331

Family Applications (1)

Application Number Title Priority Date Filing Date
EP06790575A Withdrawn EP1929068A4 (de) 2005-09-07 2006-08-25 Verfahren zur herstellung von metallschäumen mit einheitlicher zellstruktur

Country Status (9)

Country Link
US (1) US20070051636A1 (de)
EP (1) EP1929068A4 (de)
JP (1) JP2009509033A (de)
KR (1) KR20080030095A (de)
CN (1) CN101287859A (de)
CA (1) CA2619013A1 (de)
RU (1) RU2008113164A (de)
TW (1) TW200714446A (de)
WO (1) WO2007028234A1 (de)

Families Citing this family (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1943890A4 (de) * 2005-11-01 2009-12-16 Laird Technologies Inc Emi-lüftungstafeln mit elektrisch leitenden porösen substraten und netzen
BRPI1008746A2 (pt) 2009-02-05 2017-05-16 Evt Power Inc multiplicar a matriz condutora para correntes coletoras de bateria
US20110262813A1 (en) * 2010-04-21 2011-10-27 Evt Power Inc. Method of producing current collectors for electrochemical devices
CN103339701A (zh) * 2011-02-18 2013-10-02 住友电气工业株式会社 集电体用三维网状铝多孔体、使用该铝多孔体的集电体、使用该集电体的电极、以及均使用该电极的非水电解质电池、电容器和锂离子电容器
CN103572270B (zh) * 2013-11-12 2016-04-13 无锡英普林纳米科技有限公司 金属-聚合物复合滤网的制备方法
CN105509522A (zh) * 2014-09-26 2016-04-20 江苏格业新材料科技有限公司 一种铜粉烧结和高孔隙泡沫铜复合热管的制造方法
KR102166464B1 (ko) * 2016-11-30 2020-10-16 주식회사 엘지화학 금속폼의 제조 방법
DE102018203829A1 (de) * 2018-03-14 2019-09-19 Robert Bosch Gmbh Verfahren zum Herstellen einer porösen Verteilerstruktur
JP7444590B2 (ja) * 2019-12-03 2024-03-06 倉敷紡績株式会社 軟質ポリウレタンフォームシートおよびそれを用いた多層シート
TWI825470B (zh) * 2021-08-26 2023-12-11 達運精密工業股份有限公司 形成金屬遮罩的方法
CN114959347B (zh) * 2022-06-20 2023-09-22 上海电力大学 一种制备泡沫镍复合材料的装置
CN117070913B (zh) * 2023-10-12 2024-01-26 广州航海学院 一种多孔金属的表面包覆装置及其使用方法和应用

Family Cites Families (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CH398069A (de) * 1961-07-04 1965-08-31 Heberlein & Co Ag Verfahren zur Nachbehandlung von Schaumstoffbahnen aus Polyurethanen
US3475525A (en) * 1966-09-22 1969-10-28 Timothy V Peters Process of reticulating polyurethane foams
US3946039A (en) * 1967-10-30 1976-03-23 Energy Research & Generation, Inc. Reticulated foam structure
BE758991A (fr) * 1969-11-18 1971-05-17 Reeves Bros Inc Procede de reticulation hydrodynamique d'une mousse de polyurethanne
ZA717378B (en) * 1970-12-01 1972-07-26 Tenneco Chem Increasing the degree of openness of a foamed polymer
SE361844B (de) * 1972-09-20 1973-11-19 R T Wirstroem
US4246057A (en) * 1977-02-16 1981-01-20 Uop Inc. Heat transfer surface and method for producing such surface
US4244789A (en) * 1979-01-24 1981-01-13 Stauffer Chemical Company Method of metallizing materials
JPS62243245A (ja) * 1986-04-15 1987-10-23 Shin Kobe Electric Mach Co Ltd アルカリ蓄電池用極板
JPS6319235A (ja) * 1986-07-14 1988-01-27 Sanpuku Kogyo Kk 発泡体シ−トの製造方法
US4957543A (en) * 1989-06-16 1990-09-18 Inco Limited Method of forming nickel foam
US5738907A (en) * 1995-08-04 1998-04-14 Eltech Systems Corporation Conductive metal porous sheet production
JP3515652B2 (ja) * 1995-11-30 2004-04-05 住友電気工業株式会社 金属多孔体の製造方法
US5723510A (en) * 1996-06-11 1998-03-03 The Furukawa Electric Co., Ltd. Method of manufacturing thermoplastic polyester foam sheet
JPH11176450A (ja) * 1997-12-11 1999-07-02 Sumitomo Electric Ind Ltd 金属多孔体とその製造方法及びそれを用いた電池用基板
ES2237924T3 (es) * 1998-06-29 2005-08-01 Stork Screens Bv Fabricacion de un producto esponjoso, poroso, para electrodos de bateria.
US6309742B1 (en) * 2000-01-28 2001-10-30 Gore Enterprise Holdings, Inc. EMI/RFI shielding gasket
KR100466614B1 (ko) * 2002-03-08 2005-01-15 삼성전자주식회사 개방셀 경질 폴리우레탄 폼의 제조방법 및 진공단열패널

Also Published As

Publication number Publication date
CA2619013A1 (en) 2007-03-15
RU2008113164A (ru) 2009-10-20
US20070051636A1 (en) 2007-03-08
WO2007028234A1 (en) 2007-03-15
CN101287859A (zh) 2008-10-15
EP1929068A4 (de) 2012-10-03
KR20080030095A (ko) 2008-04-03
JP2009509033A (ja) 2009-03-05
TW200714446A (en) 2007-04-16

Similar Documents

Publication Publication Date Title
EP1091841B1 (de) Produktion eines porösen schaumproduktes für batterieelektroden
US20070051636A1 (en) Process for producing metal foams having uniform cell structure
EP0710995B1 (de) Batterieelektrodeplatte und Verfahren zu ihrer Herstellung
EP2666890B1 (de) Poröses metall mit hoher korrosionsbeständigkeit und verfahren zu seiner herstellung
CN1192290A (zh) 导电金属多孔板产品
EP3130432B1 (de) Verfahren und vorrichtung zur herstellung einer mikroporösen metallfolie
KR102032265B1 (ko) 리튬이차전지 음극 집전체용 다공성 구리의 제조 방법 및 이에 따라 제조된 다공성 구리 및 리튬이차전지 음극 집전체
JPS6381767A (ja) 電池用電極とその製造方法
US20080085453A1 (en) Battery electrode substrate, and electrode employing the same
JP3515652B2 (ja) 金属多孔体の製造方法
JP7616536B2 (ja) 金属多孔体および金属多孔体の製造方法
JP5294809B2 (ja) ニッケル焼結基板の製造方法
JPH08329953A (ja) ニッケルめっき不織布電極基板の製造方法
CN1275457A (zh) 金属带敷泡沫镍材料及其制造方法
RU2015855C1 (ru) Способ получения пористого ячеистого материала
JP3408047B2 (ja) アルカリ蓄電池
JP2006505917A (ja) 電極、電極の製造方法及びバイポーラ電池
CN112735771B (zh) 用于变压器绕组的铜带及其制作方法、变压器绕组
JPH09204919A (ja) アルカリ電池用電極基板およびその製造方法
JPH01292754A (ja) アルカリ蓄電池用電極及びその製造方法
CA2232697A1 (en) Method of manufacturing metal sheet and metal sheet manufactured by manufacturing method
JP2001234207A (ja) 金属シートの製造方法及びその装置
CN1725531A (zh) 一种制作泡沫镍电极基体的方法
JPH08337895A (ja) 金属多孔体の製造方法とその装置
JPH08138680A (ja) 電池用電極基板及びその製造方法

Legal Events

Date Code Title Description
PUAI Public reference made under article 153(3) epc to a published international application that has entered the european phase

Free format text: ORIGINAL CODE: 0009012

17P Request for examination filed

Effective date: 20080318

AK Designated contracting states

Kind code of ref document: A1

Designated state(s): DE GB PL RO SK

DAX Request for extension of the european patent (deleted)
RBV Designated contracting states (corrected)

Designated state(s): DE GB PL RO SK

A4 Supplementary search report drawn up and despatched

Effective date: 20120905

RIC1 Information provided on ipc code assigned before grant

Ipc: C23C 16/04 20060101ALI20120830BHEP

Ipc: C23C 14/20 20060101ALI20120830BHEP

Ipc: C23C 18/20 20060101ALI20120830BHEP

Ipc: B22F 3/11 20060101ALI20120830BHEP

Ipc: C23C 18/31 20060101ALI20120830BHEP

Ipc: C25D 1/08 20060101ALI20120830BHEP

Ipc: C22C 1/08 20060101ALI20120830BHEP

Ipc: C25D 5/56 20060101ALI20120830BHEP

Ipc: B29C 44/56 20060101AFI20120830BHEP

Ipc: C23C 14/04 20060101ALI20120830BHEP

Ipc: H01M 4/66 20060101ALI20120830BHEP

Ipc: C23C 18/16 20060101ALI20120830BHEP

Ipc: C23C 16/44 20060101ALI20120830BHEP

Ipc: H01M 4/80 20060101ALI20120830BHEP

STAA Information on the status of an ep patent application or granted ep patent

Free format text: STATUS: THE APPLICATION IS DEEMED TO BE WITHDRAWN

18D Application deemed to be withdrawn

Effective date: 20130405