EP1929068A1 - Procede de fabrication de mousses metalliques presentant une structure cellulaire uniforme - Google Patents

Procede de fabrication de mousses metalliques presentant une structure cellulaire uniforme

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Withdrawn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
German (de)
English (en)
Other versions
EP1929068A4 (fr
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/fr
Publication of EP1929068A4 publication Critical patent/EP1929068A4/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • 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
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/64—Carriers or collectors
    • H01M4/70—Carriers or collectors characterised by shape or form
    • H01M4/80—Porous plates, e.g. sintered carriers
    • H01M4/808—Foamed, spongy materials
    • C—CHEMISTRY; METALLURGY
    • C23—COATING 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
    • C23C—COATING 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
    • C23C28/00—Coating 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/11—Making porous workpieces or articles
    • B22F3/1121—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers
    • B22F3/1137—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers by coating porous removable preforms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
    • B29C44/34—Auxiliary operations
    • B29C44/56—After-treatment of articles, e.g. for altering the shape
    • B29C44/5627—After-treatment of articles, e.g. for altering the shape by mechanical deformation, e.g. crushing, embossing, stretching
    • B29C44/5654—Subdividing foamed articles to obtain particular surface properties, e.g. on multiple modules
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C1/00—Making non-ferrous alloys
    • C22C1/08—Alloys with open or closed pores
    • C—CHEMISTRY; METALLURGY
    • C23—COATING 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
    • C23C—COATING 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
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/04—Coating on selected surface areas, e.g. using masks
    • C23C14/046—Coating cavities or hollow spaces, e.g. interior of tubes; Infiltration of porous substrates
    • C—CHEMISTRY; METALLURGY
    • C23—COATING 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
    • C23C—COATING 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
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
    • C23C14/14—Metallic material, boron or silicon
    • C23C14/20—Metallic material, boron or silicon on organic substrates
    • C23C14/205—Metallic material, boron or silicon on organic substrates by cathodic sputtering
    • C—CHEMISTRY; METALLURGY
    • C23—COATING 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
    • C23C—COATING 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
    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/04—Coating on selected surface areas, e.g. using masks
    • C23C16/045—Coating cavities or hollow spaces, e.g. interior of tubes; Infiltration of porous substrates
    • C—CHEMISTRY; METALLURGY
    • C23—COATING 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
    • C23C—COATING 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
    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/44—Chemical 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
    • C23C16/4418—Methods for making free-standing articles
    • C—CHEMISTRY; METALLURGY
    • C23—COATING 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
    • C23C—COATING 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
    • C23C18/00—Chemical 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
    • C23C18/16—Chemical 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
    • C23C18/1601—Process or apparatus
    • C23C18/1633—Process of electroless plating
    • C23C18/1635—Composition of the substrate
    • C23C18/1644—Composition of the substrate porous substrates
    • C—CHEMISTRY; METALLURGY
    • C23—COATING 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
    • C23C—COATING 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
    • C23C18/00—Chemical 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
    • C23C18/16—Chemical 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
    • C23C18/31—Coating with metals
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D1/00—Electroforming
    • C25D1/08—Perforated or foraminous objects, e.g. sieves
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/54—Electroplating of non-metallic surfaces
    • C25D5/56—Electroplating of non-metallic surfaces of plastics
    • 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
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/64—Carriers or collectors
    • H01M4/66—Selection of materials
    • H01M4/665—Composites
    • H01M4/667—Composites in the form of layers, e.g. coatings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
    • 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

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)

Abstract

L'invention concerne un procédé de fabrication d'une mousse polymère poreuse à revêtement métallique dont les pores possèdent des propriétés uniformes. Des pains de mousse polymère sont découpés horizontalement le long d'une surface longitudinale pour former une feuille de mousse. La feuille est enroulée puis réticulée pour supprimer toutes les parois cellulaires résiduelles et arrondir les liaisons des pores internes de manière à élargir les ouvertures entre les cellules adjacentes. La feuille de mousse réticulée est déroulée puis revêtue de métal. Des panneaux peuvent être attachés bout à bout, fendus en boucle et réticulés. La mousse uniforme à revêtement métallique ainsi obtenue constitue un substrat de qualité supérieure pour les plaques de batteries et d'autres applications.
EP06790575A 2005-09-07 2006-08-25 Procede de fabrication de mousses metalliques presentant une structure cellulaire uniforme Withdrawn EP1929068A4 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US71494305P 2005-09-07 2005-09-07
PCT/CA2006/001394 WO2007028234A1 (fr) 2005-09-07 2006-08-25 Procede de fabrication de mousses metalliques presentant une structure cellulaire uniforme

Publications (2)

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

Family

ID=37835331

Family Applications (1)

Application Number Title Priority Date Filing Date
EP06790575A Withdrawn EP1929068A4 (fr) 2005-09-07 2006-08-25 Procede de fabrication de mousses metalliques presentant une structure cellulaire uniforme

Country Status (9)

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

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EP1943890A4 (fr) * 2005-11-01 2009-12-16 Laird Technologies Inc Panneaux d'event iem avec grilles et substrats poreux conducteurs de l'electricite
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
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CN101287859A (zh) 2008-10-15
EP1929068A4 (fr) 2012-10-03
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JP2009509033A (ja) 2009-03-05
TW200714446A (en) 2007-04-16

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