JPH10134824A - Manufacture of metal porous body and battery using it - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enhance productivity and reduce the cost by fixing fiber-like metal onto a metal base material plate in a vertical state as transferring the same, and integrating the same with the base material plate through sintering. SOLUTION: A metal base material plate 4 is continuously transferred at a constant speed, and adhesive 8 is sprayed on its top face so as to form an adhesion layer 11. Fiber-like metal 3 is vertically implanted onto the base material plate 4. The fiber-like metal 3 not vertically implanted is further oriented in a vertical state by an orientation magnet portion 18. Thereafter, the metal base material plate 4 and the fiber-like metal 3 are integrated by sintering. Thereby, the same is manufactured with high productivity comparing with a conventional method manufacturing piece by piece. Further, without using a plating method or the like, the fiber-like metal 3 is vertically implanted onto the metal base material plate 4 by flocking, and is sintered after fixing temporarily by the adhesive 8 so that the same is easily manufactured by an inexpensive facility.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for manufacturing a porous metal body which can be suitably used as a core material of an electrode plate in a secondary battery such as a lithium ion secondary battery, a nickel hydrogen storage battery or a nickel cadmium battery. The present invention relates to a battery using the porous metal body as an electrode core material.

[0002]

2. Description of the Related Art Porous metal bodies are widely used in mechanical parts and various other industrial fields, and have been produced by various methods. In the past, there has been a manufacturing method in which a metal powder is formed and sintered by a raw material powder filling sintering method or a powder compression sintering method. In recent years, electroless plating is performed on the skeleton surface of a three-dimensional mesh-shaped sponge-like foam such as urethane. Generally, a manufacturing method in which a metal is adhered by a plating method such as electrolytic plating or vapor phase plating, and a manufacturing method in which a foam is immersed in a slurry in which metal powder is dispersed are generally adopted. Further, a method of forming a felt-like nonwoven fabric in which fibrous metal is entangled irregularly (see Japanese Patent Application Laid-Open No. 56-88266), and a method of sintering and rolling a stainless steel fine-wire aggregate (Japanese Patent Application Laid-Open No. 4-165006)
And the like are being studied.

In general, an electrode plate of a battery has a structure in which the above porous metal body is used as a core material and the porous metal body is filled with a positive or negative active material. As the metal porous body for the core material of the electrode plate in a battery in which a chemical reaction occurs, among various kinds as described above, a metal foamed porous body having a three-dimensional network structure has been generally adopted in recent years. ing. This metal foam porous body is obtained by electroplating a sponge-like foam body. For example, as a core material for an electrode plate in a secondary battery such as a nickel cadmium battery or a nickel metal hydride battery, as shown in FIG.
A metal foam porous body which is a sponge-like metal in which many holes 2 are formed by nickel 1 is used. Compared with a conventional porous metal body, the porous metal body has a maximum porosity of 98% because of a spongy three-dimensional network structure of the metal skeleton, a high specific surface area, and a high airflow resistance. It has excellent characteristics such as low pressure loss, small pressure loss and free shape.

[0004] The metal foamed porous body is manufactured by a manufacturing method as described in Japanese Patent Publication No. 57-39317. That is, a sponge-like foam such as a polyurethane sheet having a three-dimensional mesh shape is impregnated with a conductive paint such as carbon, or after imparting conductivity by means such as electroless plating, the foaming is performed. By attaching a metal to the skeletal surface of the body by plating, heating it, and firing and removing only the sponge-like foam,
A porous metal foam is obtained.

[0005]

However, a battery using the above-mentioned metal foamed porous body as a core material for an electrode plate,
When the hole 2 in FIG. 7 is enlarged in order to increase the amount of the active material to be formed into a slurry having a relatively high viscosity per unit volume, the central portion of the hole 2 is not directly in contact with the mesh nickel 1. Since the active material filled in the battery is not used for charging and discharging, the utilization efficiency of the active material is reduced, and the discharge characteristics per unit volume of the battery cannot be improved. Conversely, if the shape is such that the porosity is increased while reducing the size of the hole 2, it is difficult to fill the hole 2 with the active material, so that the filling amount is reduced, and the nickel 1 is thinned to increase the electric resistance. Sufficient current does not flow. Therefore, a battery using an electrode plate having the porous metal body as a core material cannot be used for an application that requires a large current to flow, such as an electric vehicle, an electric tool, or an electric lawn mower. .

In addition, the above-mentioned metal foamed porous body is expensive due to the use of a plating method in its manufacturing process, in addition to the cost of related equipment and waste liquid treatment, and the large power consumption. Further, it is difficult to control the plating conditions, so that the plating rate cannot be increased, and the productivity cannot be improved. For this reason, the porous metal foam is expensive, and cannot be used as a core material for an electrode plate in an electric vehicle battery in which the number of electrode plates used is large, from the viewpoint of cost.

Therefore, the present inventor has proposed a quasi-porous metal porous body which can be easily manufactured at low cost and can further increase the utilization of an active material when used as a core material for an electrode plate of a battery. (Japanese Patent Application No. 8-73528). This porous metal body is formed by arranging a large number of fibrous metals such as nickel fibers on a metal base plate serving as a main current collector in an arrangement perpendicular to the metal base plate. Are combined by sintering. If this porous metal body is used as a core material for an electrode plate of a battery, since the porous metal body is shaped like a sword, many active materials can be smoothly filled, and a large number of fibrous metals are formed. Since it functions as a current collector for the active material, the usage of the active material is significantly higher than that of the metal foam porous body. Therefore, a battery using the porous metal body as a core material for an electrode plate is suitable for an application requiring a large current, such as an electric vehicle.
However, a problem that remains in the above-described porous metal body is the establishment of a manufacturing method capable of obtaining a high-quality porous metal body while mass-producing the above-described porous metal body at a low cost by a continuous production process. The development of such a manufacturing method has been long-awaited.

Accordingly, the present invention is to produce a metal porous body having a pseudo-porous structure in which a large number of fibrous metals are fixed in a vertical arrangement on a metal base plate at high productivity and at low cost. It is an object of the present invention to provide a method for producing a porous metal body capable of obtaining a high-quality porous metal.

[0009]

In order to achieve the above-mentioned object, the present invention provides a three-dimensional pseudo-porous material formed by vertically arranging and joining a large number of fibrous metals on one or both sides of a metal base plate. Forming a pressure-sensitive adhesive layer by applying an adhesive to the metal base plate while continuously transporting the strip-shaped metal base plate; A step of flocking the fibrous metal formed by the metal powder and the binder resin on the adhesive layer formed on the material plate, and the metal substrate on which the fibrous metal is planted by the flocking. Applying a perpendicular magnetic field to the plate to orient the fibrous metal in a direction perpendicular to the metal base plate, and decomposing the organic components in the binder resin and the adhesive in the fibrous metal by firing. Removed and said fibrous And a step of integrating said metal substrate sheet metal powder in the genus by sintering.

In this method for producing a porous metal body, a large number of fibrous metals can be fixed to the metal base plate being transferred in a vertical arrangement while the metal base plate in the form of a strip is continuously transferred. Mass production with high productivity. In addition, the manufacturing cost can be reduced because the manufacturing can be performed by an inexpensive and easy process such as application of an adhesive, flocking and generation of a vertical magnetic field without using a plating method or the like. Further, the fibrous metal is implanted by flocking so as to pierce the adhesive layer on the metal base plate in the vertical direction, and then, by applying a vertical magnetic field, the fibrous metal that is not implanted vertically is metal-based. Since it is oriented perpendicular to the material plate, almost all fibrous metal can be surely opposed perpendicularly to the metal base plate, and this oriented fibrous metal is integrated into the metal base plate by sintering. Therefore, a high quality porous metal body having a required shape can be obtained.

Further, in the flocking according to the present invention, it is preferable that a fibrous metal having a double structure covered with a resin film is implanted on the adhesive layer of the metal base plate, and the resin coating is removed by firing.

Accordingly, if the resin film is decomposed and removed,
The remaining fibrous metal is arranged at substantially equal intervals corresponding to the thickness of the resin film, and there is no portion where the fibrous metal is intertwined with each other, so that a very high quality porous metal body can be obtained.

In each of the above inventions, it is preferable that the adhesive layer is formed using an adhesive obtained by mixing a metal powder of the same type as the metal powder in the fibrous metal with an organic resin.

Thus, the fibrous metal and the metal base plate can be more firmly integrated during sintering.

In the battery of the present invention, an electrode plate is formed by filling an active material between each fibrous metal with the porous metal produced by the above-mentioned production methods as a core material. The plate is configured as a positive electrode.

In this battery, the active material is smoothly filled between the sword-shaped fibrous metals to provide a sufficient amount of filling, and the fibrous metals are formed at extremely small intervals. Most of them come into contact with the fibrous metal, resulting in an extremely high utilization rate of the active material. Further, since the current flows through the metal base plate as the main current collector, the electric resistance is extremely small. Therefore, a large current can be obtained.

[0017]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be described below in detail with reference to the drawings. FIG. 1 shows a process diagram of a first step in a method for manufacturing a porous metal body according to a first embodiment of the present invention. In this first step,
Through the (a) adhesive application step, (b) flocking step, and (c) alignment step, a large number of fibrous metals 3 are attached to the metal base plate 4 in a vertical arrangement in a forested state.

First, the metal base plate 4 and the fibrous metal 3 which are components of the porous metal body of the present invention will be described.
As the metal base plate 4, a thin band-shaped metal plate made of a material such as a nonwoven fabric having air permeability without being subjected to a perforation process and having a large number of fine holes formed therein, A thin band-shaped metal flat plate or metal foil that is not perforated can be used. The metal base plate 4 may be either magnetic or non-magnetic. However, when used as a core material of a battery electrode plate, the metal base plate 4 has a conductivity because it performs a current collecting action. is necessary. In particular, when used as a core material for an electrode plate of a secondary battery having a large discharge characteristic such as a nickel-metal hydride battery or a nickel cadmium battery, nickel is used as the metal base plate 4 and the fibrous metal 3 due to a chemical reaction. It is preferably used.

On the other hand, the fibrous metal 3 is obtained by kneading a metal powder and a binder resin into an elongated shape. For example, a nickel powder having an average particle size of 1.0 μm is mixed with a butyral resin (PBV) at a weight ratio of 100: 25, isophorone is mixed as a solvent, and the mixture is sufficiently mixed with a kneading machine such as a known three-roll mill or kneader. And knead it. The above-mentioned kneaded material is applied to a film or paper that has been subjected to release treatment by screen printing or gravure printing, and is formed by applying it in the form of a long and thin fiber and then peeling or stretching by a normal spinning method. Can be

The binder resin may be an aqueous or organic solvent-based resin. In addition to the above-mentioned butyral resin, polyvinyl acetal resin (PVAC), acrylic resin, styrene resin, polyethylene resin, cellulose resin And a phenol resin.
In addition, water, alcohols, cellosolves, ketones, esters, aromatic hydrocarbons, and the like can be used as the solvent depending on the binder resin. The ratio of metal powder to binder resin can range from 50:50 to 95: 5 by weight, preferably from 65:35 to 80: 2.
It should be in the range of 0 weight ratio. This is because if the fibrous metal 3 does not have a certain electric resistance when flocking the fibrous metal 3 on the metal base plate 4 in the later described (b) flocking process, this fibrous metal 3 This is because 3 does not fly.

The diameter and length of the fibrous metal 3 and the size and thickness of the metal base plate 4 are not particularly limited, and can be appropriately selected according to the required characteristics and applications. When manufacturing a porous metal body used as a core material for a battery electrode plate, a fibrous metal 3 having a diameter of several tens μm to several hundred μm and a length of 1 mm to 3 mm is used. It is preferable to configure a porous metal body in which the fibrous metals 3 are arranged on the metal base plate 4 such that the intervals between the fibrous metals 3 are about several tens μm to several hundred μm,
It is more preferable to set the interval to 200 to 300 μm.
Specifically, the diameter is 30 to 100 μm and the length is 1 to 3 m
Preferably, m fibrous metals 3 are used. When this porous metal body is used, the fibrous metal 3 in which the active material is sword-shaped is formed.
Can be smoothly filled to the root of the battery, and an electrode plate for a battery having excellent utilization efficiency of the active material can be obtained. In the case of manufacturing a porous metal body used as a core material for an electrode plate of a battery, it is preferable to use the fibrous metal 3 made of nickel powder. Any metal can be used as long as it can be sintered.

The strip-shaped metal base plate 4 is continuously transferred in the horizontal direction at a constant speed by a transfer mechanism (not shown) and a pair of guide rollers 7 and the like. (A) In the adhesive application step, the adhesive 8 contained in the adhesive container 9 is sprayed on the upper surface of the metal base plate 4 by the spray nozzle 10,
The adhesive layer 11 is formed on the metal base plate 4. As the adhesive 8, a polyvinyl acetate resin, an acrylic resin, a butyral resin, a phenol resin, or the like can be used. When the same kind of metal powder as the metal base plate 4 and the fibrous metal 3 is mixed and used in the adhesive 8, the metal base plate 4 and the fibrous metal 3 are more firmly integrated in the (e) reduction step described later. And a more desirable porous metal body can be obtained.

Next, in the (b) flocking step, the fibrous metal 3 is floc-processed on the metal base plate 4. In the present invention, various types of flocking such as an electrostatic processing method and a mechanical processing method can be applied. In this embodiment, the case where the electrostatic processing method that is most expected to improve productivity is used. Illustrated. The fibrous metal 3 formed by the metal powder and the binder resin is accommodated in a hopper 12, and the bottom surface of the hopper 12 is formed by a metal wire mesh 13. A high voltage is applied between the metal wire mesh 13 and the metal base plate 4 from the power supply unit 14 with the metal base plate 4 side as a ground electrode. As a result, the fibrous metal 3 in the hopper 12 is positively charged via the metal wire mesh 13, and when falling through the mesh of the metal wire mesh 13, the metal base plate 4, which is an earth electrode, And fly while maintaining the vertical direction with respect to the metal base plate 4, pierce the adhesive layer 11 on the surface of the metal base plate 4, and implant the hair, and
1 keeps the hair in a flocking state.

A high voltage of several thousand volts to several tens of thousands volts is applied between the metal wire mesh 13 and the metal base plate 4. Preferably, a high voltage of 9000 to 40,000 volts is applied. When a voltage lower than this range is applied, the fibrous metal 3 is not charged. Conversely, when a voltage higher than the above range is applied, the entire fibrous metal 3 is charged, and the tip is not charged much. From the fibrous metal 3
Does not fly in a direction perpendicular to the base material, and the fibrous metal 3 is implanted on the metal base plate 4 in an arbitrary direction.

Subsequently, in the alignment step (c), the fibrous metal 3 implanted on the metal base plate 4 as described above transfers the metal base plate 4 with the transfer of the metal base plate 4. It enters the orienting magnet section 18 composed of electromagnets arranged above and below the road. The two orienting magnet portions 18 are disposed on both sides of the metal base plate 4 along the transfer path, and have a uniform alignment magnetic field within a certain distance along the transfer path of the metal base plate 4. Is occurring. Accordingly, (b) the fibrous metal 3 which has not been implanted perpendicularly to the metal base plate 4 in the flocking process receives a magnetic field in a direction perpendicular to the metal base plate 4, and becomes perpendicular to the metal base plate 4. Oriented. As a result, all the fibrous metals 3 stand vertically on the metal base plate 4. As the magnetic field generated in the orientation magnet section 18, a direct current or an alternating current, or a combination thereof can be used, and a magnetic field of several hundred to several thousand gauss can be used. When using an AC magnetic field, set the frequency to several Hz.
To a range of several hundred Hz. When a frequency higher than this range is used, the magnetization of the fibrous metal 3 does not follow, and the stabilizing effect is reduced.

FIG. 2 is a process chart of a subsequent step in the method for manufacturing a porous metal body according to the above embodiment. In the latter step, a large number of fibrous metals 3 are integrated with the metal base plate 4 through the (d) drying step and the (e) reduction step, and a porous metal body is obtained. (D) In the drying step, in the drying furnace 19 at a temperature of 60 ° C. in an air atmosphere at about 3 ° C.
Dry for about 0 minutes. Thereby, the fibrous metal 3
By the solidified adhesive 8, it is fixed in the alignment state in the (c) alignment step.

Finally, in the (e) reduction step, the reduction furnace 20
The temperature is raised to 400 ° C. to 600 ° C. in a nitrogen atmosphere with a reducing gas, for example, hydrogen or nitrogen gas, and the mixture is heated for 30 minutes. The temperature is raised to 1200 ° C., and the metal powder in the fibrous metal 3 and the metal base plate 4 are fired. By this firing,
While the binder resin in the fibrous metal 3 is decomposed and removed,
Since the organic substance in the adhesive 8 is decomposed and removed, and the above-mentioned nickel oxide is combined with hydrogen to form a metal, the fibrous metal 3 and the metal base plate 4 are strongly bonded in a molten metal state. Thus, a sword-like metal porous body 21 having a high porosity as shown in FIG. 3 is completed. The metal porous body 21 of FIG.
2 shows a case where a large number of fibrous metals 3 are fixed on both surfaces of the metal base plate 4 in the respective steps (a) to (e) described above.

In the above manufacturing method, the metal base plate 4 is continuously transferred at a constant speed, and the fibrous metal 3 is vertically implanted on the metal base plate 4 during the transfer, and further vertically implanted. After the fibrous metal 3 that has not been subjected to orientation is vertically oriented by the oriented magnet portion 18, the metal base plate 4 and the fibrous metal 3 are integrated by sintering. Therefore, it can be mass-produced with extremely high productivity as compared with a case where a conventional metal foamed porous body is manufactured in a single unit. Moreover, the fibrous metal 3 is vertically implanted on the metal base plate 4 by flocking without using a plating method or the like, and the fibrous metal 3 is temporarily fixed in a vertical state with an adhesive 8 and then fired. It can be easily manufactured with simple, low-cost equipment.

Next, a method for manufacturing a porous metal body according to another embodiment of the present invention will be described with reference to FIGS. In this embodiment, as shown in FIG. 4, the fibrous metal 3 is coated with a resin film 22, and the double-structured fibrous metal 3 covered with the resin film 22 is formed as shown in FIG. It is housed in the hopper 12 and is subjected to flocking by applying a high voltage to remove the metal base plate 4 from the metal wire mesh 13.
Flock on top. Although not shown in FIG. 5 after the (b) flocking step, after the same (c) alignment step and (d) drying step as shown in FIGS. 1 and 2, respectively, (e) ) Lead to the reduction step. In this (e) reduction step, the resin film 22 is decomposed and removed, and the metal porous body 21 having the same form as shown in FIG. 3 is obtained.

In the above embodiment, since the resin film 22 covering the fibrous metal 3 has a large electric resistance, static electricity is easily generated and is sufficiently charged. The metal 3 is established in a state where the resin films 22 are in contact with each other. (E) When the resin film 22 is decomposed and removed in the reduction step, the remaining fibrous metals 3 are arranged at substantially equal intervals corresponding to the thickness of the resin film 22 and are in a state where they are intertwined with each other. Disappears. Thereby, a very high quality porous metal body 21 can be obtained.

FIG. 6 shows a battery 23 composed of an electrode plate using the porous metal body 21 obtained by the above manufacturing method as a core material. In manufacturing the battery 23, the active material is filled between the fibrous metals 3 of the porous metal body 21, and the surface thereof is rolled by a rolling roller or the like. It is wound in a spiral manner with a separator 28 interposed between the plate 27 and the plate 27 and stored in the battery case 29. In the battery 23, the active material is smoothly filled between the sword-shaped fibrous metals 3 to provide a sufficient amount of filling, and the spacing between the fibrous metals 3 is small as described above. Most of the contact is in contact with the fibrous metal 3 and the metal base plate 4 performs a current collecting action, so that the electric resistance is extremely small. As a result, the utilization rate of the active material becomes extremely high, and a large current can be taken out.

[0032]

EXAMPLE As a metal base plate 4, a nickel-plated iron plate having a thickness of 0.06 mm was used. As the fibrous metal 3, nickel powder having a particle size of 1.0 μm is mixed with a butyral resin and isophorone as a solvent, and kneaded with a three-roll mill. The kneaded product is 3 mm long and 3 mm wide by screen printing.
After printing on a film having a release treatment of 0.5 mm and a thickness of 10 μm, the film was dried, washed with water and peeled off.

As the adhesive 8, a powder obtained by mixing nickel powder having a particle diameter of 1.0 μm, polyvinyl acetal resin and water as a solvent, and shaking the mixture with a paint shaker to uniformly disperse the nickel powder was used. .

The fibrous metal 3 is charged by a charging hood while being shaken little by little.
Flocking was performed using the metal base plate 4 side coated with a thickness of μm to form the adhesive layer 11 as a ground electrode. Immediately after the flocking, a direct current 1000 gauss magnetic field is applied to the metal base plate 4 in the vertical direction for 10 seconds to remove the fibrous metal 3 that has not been vertically implanted on the metal base plate 4 by the flocking process. Aligned.

Thereafter, drying air is blown at 60.degree. C. for about 20 seconds to dry, and the unbonded fibrous metal 3 is removed by a roll brush while sucking with an exhaust fan, and dried in a drying oven 19 at 60.degree. Dried for minutes. Further, using a reducing furnace 20 purged with nitrogen, the temperature was raised to 500 ° C., and the mixture was allowed to stand for 30 minutes to be heated and oxidized. Then, the ratio of nitrogen to hydrogen is 1: 1
The metal powder in the adhesive 8 and the metal base plate 4 were reduced by raising the temperature to 1000 ° C. in the atmosphere. Thereby, the binder resin in the fibrous metal 3 is decomposed and removed, and the fibrous metal 3
The nickel powder in the inside adhered to the metal base plate 4. Through the above steps, a first porous metal body was manufactured.

On the other hand, a kneaded material obtained by adding a solvent to nickel powder and a resin and kneading the mixture is drawn out by a spinning method, and a fibrous metal 3 having a diameter of 50 μm is coated with a resin film 22 having a thickness of 5 μm to form a double-structure fibrous metal. A metal was formed, and cut into a length of 2 mm to obtain a state shown in FIG. 4, and this was used to produce a second porous metal body using the process shown in FIG.

Nickel hydroxide 90 wt%, Co powder 7 w
After mixing t% and 3 wt% of cadmium hydroxide, a 3 wt% aqueous solution of carboxyl cellulose was added to prepare a slurry active material. The active material was filled into the first and second porous metal bodies while being pressed, and dried. After that, it was pressed and compressed to a thickness of 0.8 mm, and an electrode lead wire was attached.
An mx80 mm positive electrode was fabricated. For the negative electrode,
An alloy of the Mm-Ni-Mn-AI-Co system (Mm is a mixture of rare earth elements) is pulverized as a hydrogen storage alloy, and the alloy having a particle size of 60 μm or less is kneaded with a binder mainly composed of styrene-butadiene rubber. A perforated steel plate (punched metal) was used. The positive electrode 24 and the negative electrode 27 are connected to the nylon separator 2.
8 and wound in a spiral shape, housed in a battery case 29, injected with an electrolyte, and then sealed to produce a cylindrical nickel-metal hydride battery.

The first and second batteries formed using the first and second porous metal bodies, respectively, were compared with a third battery formed using a conventional positive electrode plate using a metal foamed porous body. did. That is, the discharge characteristics of each battery were evaluated. Table 1 shows the discharge capacity (mAh) as a result of charging each battery with a current of 0.1 CmA for 15 hours and then discharging the battery to 1 V under various discharge conditions in an environment of 20 ° C.

(Table 1) Discharge conditions 0.2 C 1.0 C 3.0 C 5.0 C First battery 2000 mAh 1960 mAh 1840 mAh 1620 mAh Second battery 2000 mAh 1960 mAh 1860 mAh 1700 mAh Third battery 2000 mAh 1800 mAh 1600 mAh 1020 mAh As is clear from Table 1 above, the first and second batteries manufactured by the manufacturing method of the present invention are compared with the third battery using the conventional metal foamed porous body. As a result, it was found that the battery had an excellent discharge capacity particularly at a large current. This is because, as described above, the use efficiency of the active material was increased by using the porous metal body manufactured by the present invention as the core material of the electrode plate. Also, the reason why the second battery has a higher discharge capacity than the first battery is that the fibrous metal 3 is
It is considered that the entanglement between the fibrous metals 3 disappeared by the covering, and the fibrous metals 3 were arranged in an ideal sword shape, so that the utilization efficiency of the active material was further increased.

[0040]

As described above, in the method for manufacturing a porous metal body according to the first aspect of the present invention, while continuously transferring the strip-shaped metal base plate, a large number of metal base plates are transferred to the metal base plate being transferred. Since the fibrous metal is fixed in a vertical arrangement, mass production can be performed with high productivity. Moreover, the application of the adhesive,
Since it can be manufactured by an inexpensive and easy process such as flocking and generation of a vertical magnetic field, the manufacturing cost can be reduced. In addition, the fibrous metal is implanted by flocking so as to pierce the adhesive layer on the metal base plate in a vertical direction, and then, by applying a vertical magnetic field, the non-vertical fibrous metal is metal-based. Since it is made to orient perpendicular to the material plate, almost all fibrous metal can be surely vertically opposed to the metal base plate, and since this oriented fibrous metal is integrated by sintering, , Of a required shape can be reliably obtained.

In the method for producing a porous metal body according to the second aspect, the fibrous metal covered with the resin film is implanted on the adhesive layer of the metal base plate. The fibrous metal is arranged at substantially equal intervals corresponding to the thickness of the resin film, and there is no portion where the fibrous metal is entangled with each other, so that a very high quality porous metal body can be obtained.

In the method for manufacturing a porous metal body according to the third aspect, an adhesive obtained by mixing a metal powder of the same kind as the metal powder in the fibrous metal and an organic resin is used. Thus, the fibrous metal and the metal base plate can be more firmly integrated.

In the battery according to the fourth aspect, the active material is smoothly filled between the sword-shaped fibrous metals in the porous metal body so that a sufficient amount of the active material is filled, and the interval between the fibrous metals is as described above. Since most of the active material comes into contact with the fibrous metal and the metal base plate performs a current collecting action, the electric resistance is extremely small. Therefore, the utilization rate of the active material becomes extremely high, and a large current can be obtained.

[Brief description of the drawings]

FIG. 1 is a process chart showing a first half of a method for manufacturing a porous metal body according to an embodiment of the present invention.

FIG. 2 is a process chart showing a latter half process in the embodiment.

FIG. 3 is a side view showing a porous metal body manufactured according to the embodiment.

FIG. 4 is a longitudinal sectional view of a fibrous metal used in a method for manufacturing a porous metal body according to another embodiment of the present invention, and (β).
(A) is a sectional view taken along line A-A.

FIG. 5 is a process chart showing main steps of a method for manufacturing a porous metal body according to another embodiment of the present invention using the above fibrous metal.

FIG. 6 is a partially exploded perspective view showing a battery using a porous metal body manufactured by the manufacturing method of the present invention.

FIG. 7 is a schematic partial cross-sectional view of a conventional porous metal foam.

[Explanation of symbols]

 REFERENCE SIGNS LIST 3 fibrous metal 4 metal base plate 8 adhesive 11 adhesive layer 18 oriented magnet part 19 drying furnace 20 reduction furnace 21 metal porous body 22 resin film 23 battery

 ──────────────────────────────────────────────────の Continued on the front page (72) Katsuhiro Okamoto, Inventor 1006 Kadoma, Kazuma, Osaka Prefecture Inside Matsushita Electric Industrial Co., Ltd.

Claims (4)

[Claims] 1. A method for producing a three-dimensional pseudo-porous metal porous body formed by vertically arranging and joining a large number of fibrous metals on one or both surfaces of a metal base plate, comprising: A step of applying an adhesive to the metal base plate while continuously transferring the metal base plate to form an adhesive layer; and forming a metal powder on the adhesive layer formed on the metal base plate. And flocking the fibrous metal formed by the binder resin, and applying a vertical magnetic field to the metal base plate on which the fibrous metal is implanted by the flocking to form the fibrous metal. A step of orienting the metal substrate plate in a vertical direction, and by decomposing and removing the organic components in the binder resin and the adhesive in the fiber metal by firing, and firing the metal powder in the fibrous metal. Integrated with the metal base plate by sintering Method for producing a porous metal body, characterized in that and a that step. 2. The production of a porous metal body according to claim 1, wherein the fibrous metal implanted on the adhesive layer formed on the metal base plate by flocking has a double structure covered with a resin film. Method. 3. The porous metal body according to claim 1, wherein the adhesive layer is formed by using an adhesive obtained by mixing a metal powder of the same kind as the metal powder in the fibrous metal with an organic resin. Manufacturing method. 4. An electrode plate is formed by filling an active material between fibrous metals using a porous metal body produced by the production method according to any one of claims 1 to 3 as a core material. A battery configured as a positive electrode.