WO2010116682A1 - アルミニウム多孔質焼結体の製造方法およびアルミニウム多孔質焼結体 - Google Patents
アルミニウム多孔質焼結体の製造方法およびアルミニウム多孔質焼結体 Download PDFInfo
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- WO2010116682A1 WO2010116682A1 PCT/JP2010/002308 JP2010002308W WO2010116682A1 WO 2010116682 A1 WO2010116682 A1 WO 2010116682A1 JP 2010002308 W JP2010002308 W JP 2010002308W WO 2010116682 A1 WO2010116682 A1 WO 2010116682A1
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- 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
- B22F3/1125—Making porous workpieces or articles by using decomposable, meltable or sublimatable fillers involving a foaming process
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- 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
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- 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
- B22F3/02—Compacting only
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- 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
- B22F3/1003—Use of special medium during sintering, e.g. sintering aid
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- 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
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- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/002—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature
- B22F7/004—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature comprising at least one non-porous part
- B22F7/006—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of porous nature comprising at least one non-porous part the porous part being obtained by foaming
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/0408—Light metal alloys
- C22C1/0416—Aluminium-based alloys
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- 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
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- C22C21/00—Alloys based on aluminium
- C22C21/02—Alloys based on aluminium with silicon as the next major constituent
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- C22C21/00—Alloys based on aluminium
- C22C21/12—Alloys based on aluminium with copper as the next major constituent
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/12—Alloys based on aluminium with copper as the next major constituent
- C22C21/14—Alloys based on aluminium with copper as the next major constituent with silicon
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
- C22C21/12—Alloys based on aluminium with copper as the next major constituent
- C22C21/16—Alloys based on aluminium with copper as the next major constituent with magnesium
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES OR LIGHT-SENSITIVE DEVICES, OF THE ELECTROLYTIC TYPE
- H01G11/00—Hybrid capacitors, i.e. capacitors having different positive and negative electrodes; Electric double-layer [EDL] capacitors; Processes for the manufacture thereof or of parts thereof
- H01G11/66—Current collectors
- H01G11/68—Current collectors characterised by their material
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES OR LIGHT-SENSITIVE DEVICES, OF THE ELECTROLYTIC TYPE
- H01G11/00—Hybrid capacitors, i.e. capacitors having different positive and negative electrodes; Electric double-layer [EDL] capacitors; Processes for the manufacture thereof or of parts thereof
- H01G11/66—Current collectors
- H01G11/70—Current collectors characterised by their structure
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01G—CAPACITORS; CAPACITORS, RECTIFIERS, DETECTORS, SWITCHING DEVICES OR LIGHT-SENSITIVE DEVICES, OF THE ELECTROLYTIC TYPE
- H01G11/00—Hybrid capacitors, i.e. capacitors having different positive and negative electrodes; Electric double-layer [EDL] capacitors; Processes for the manufacture thereof or of parts thereof
- H01G11/74—Terminals, e.g. extensions of current collectors
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- 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
- H01M4/661—Metal or alloys, e.g. alloy coatings
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- 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
- H01M4/666—Composites in the form of mixed materials
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- 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
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- 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
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- 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
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- 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
- Y02E60/13—Energy storage using capacitors
Definitions
- the present invention particularly relates to an aluminum porous sintered body suitable for a current collector of a lithium ion secondary battery or an electric double layer capacitor and a method for producing the same.
- a foam melting method is known.
- a thickening agent is added to molten aluminum to increase the viscosity, and then titanium hydride is added as a blowing agent, and the molten aluminum is produced using hydrogen gas generated by a thermal decomposition reaction of titanium hydride.
- the foamed aluminum obtained by this method has large closed pores of several mm.
- a foamed aluminum having a sponge skeleton by press-fitting aluminum into a mold having sponge urethane as a core and filling aluminum into a cavity formed by burning out urethane.
- a foamed aluminum having a pore diameter of 40 PPI or less that is, a pore diameter of 40 cells or less per inch (pore diameter of about 600 ⁇ m or more) is obtained.
- Patent Document 4 As a third method, aluminum alloy is pressed and infiltrated into a reinforcing material made of hollow ceramics to have closed pores having a pore diameter of 500 ⁇ m or less according to the size of the reinforcing material. There is also a method for obtaining foamed aluminum.
- Patent Document 5 as a fourth method, aluminum is foamed by decomposition of TiH 2 powder by heating and rolling a mixed powder of AlSi alloy powder and TiH 2 powder between aluminum plates. There is a way to make it.
- the foamed aluminum obtained by this method has a large pore size of several mm.
- Patent Document 6 as a fifth method, a metal whose eutectic temperature with aluminum is lower than the melting point of aluminum is mixed with aluminum, and is higher than the eutectic temperature and higher than the melting point of aluminum. There is a method of baking at a low temperature.
- the foamed aluminum obtained by this method has a small porosity of around 40% even though the pore diameter can be reduced. For this reason, the amount of the positive electrode active material and the negative electrode active material penetrating into the pores of the foamed aluminum as the current collector is small, and the desired high output and high energy density cannot be achieved.
- sponge urethane is used as a method for producing foamed aluminum having fine open pores that can achieve the purpose of high output and high energy density.
- a second method of press-fitting aluminum into the core mold can be employed.
- Patent Document 7 As a method for producing a foam metal having a high porosity having a small pore size / size open pores in which a large number of minute open pores are evenly arranged, as shown in Patent Document 7, There is a slurry foaming method in which a foamable slurry containing a foaming agent is foamed, dried and then sintered. According to this method, if a raw material powder that can be sintered is available, a high-porosity foam metal having dimensionally open pores having an arbitrary pore size ranging from about 10 PPI to about 500 PPI, that is, a pore size ranging from 2.5 mm to 50 ⁇ m. Can be easily manufactured.
- foaming is performed by containing a foaming agent, or foaming is performed by injecting gas or stirring to sinter the foamable slurry as described above in the foamed state.
- foaming is performed by containing a foaming agent, or foaming is performed by injecting gas or stirring to sinter the foamable slurry as described above in the foamed state.
- the metal powder is sintered by free sintering that is sintered without applying stress such as compression, to obtain a foam metal.
- the aluminum powder has a surface covered with a dense aluminum oxide film of several nm to several tens of nm, which inhibits sintering regardless of the solid phase or liquid phase. For this reason, it is difficult to sinter with free sintering, and therefore homogeneous foamed aluminum cannot be obtained by the slurry foaming method.
- a method for free sintering this aluminum powder a method in which a slurry foaming method is combined with the fifth method described above can be used.
- copper powder which is a metal whose eutectic temperature with aluminum is lower than the melting point of aluminum
- foaming material is mixed with aluminum together with foaming material, and then heated and fired to a temperature higher than the eutectic temperature and lower than the melting point of aluminum.
- Get aluminum aluminum.
- aluminum droplets ooze out on the surface, and a large number of hemispherical aluminum masses formed by solidifying the droplets are formed.
- the foamed aluminum is in the form of a thin plate, as shown in FIG. 4, formation of aluminum lumps was remarkable, and the desired homogeneous foamed aluminum could not be produced.
- Japanese Patent No. 3591055 JP 2009-43536 A Japanese Patent Laid-Open No. 08-209265 JP 2007-238971 A Special table 2003-520292 Japanese Patent Publication No. 61-48566 Japanese Patent No. 3535282
- the present invention has been made in view of such circumstances, and aluminum porous sintering capable of obtaining a high porosity homogeneous foamed aluminum having fine and sized open pores having a pore diameter of 40 PPI or more, that is, 600 ⁇ m or less. It is an object to provide a method for manufacturing a body. Another object of the present invention is to provide an aluminum porous sintered body suitable for a positive electrode current collector of a battery or a capacitor that requires high output and high energy density.
- the inventors of the present invention sintered without forming a lump of droplets even in free sintering.
- the present inventors have found that there are conditions that can be achieved, and have completed the present invention.
- the method for producing an aluminum porous sintered body according to the present invention includes a step of mixing aluminum powder with a sintering aid powder containing titanium to form an aluminum mixed raw material powder, and the aluminum mixed raw material powder is water soluble.
- a step of heating and firing the pre-sintered compact in a non-oxidizing atmosphere, and a temperature at which the aluminum mixed raw material powder starts to melt is Tm ( ),
- the temperature T (° C.) of the heating and baking satisfies Tm ⁇ 10 (° C.) ⁇ T ⁇ 685 (° C.).
- the non-oxidizing atmosphere means an atmosphere that does not oxidize the aluminum mixed raw material powder, including an inert atmosphere or a reducing atmosphere.
- the above-described heating and firing temperature is not the temperature of the aluminum mixed raw material powder, that is, the reaction temperature of the aluminum mixed raw material powder or the like, and means the holding temperature around the aluminum mixed raw material powder.
- the method of the present invention is a method of free-sintering a new aluminum powder, and the sintered body obtained thereby has a uniform and distributed distribution of aluminum and titanium compounds, and more than 2 per 100 ⁇ m linear length. It is a porous sintered body with holes.
- the sintering method of the present invention by combining with a known slurry foaming method, production of a high porosity homogeneous foamed aluminum porous sintered body having fine and sized open pores smaller than a pore diameter of 600 ⁇ m.
- the invention relating to the method has been completed.
- the above-mentioned aluminum mixed raw material powder is mixed with a water-soluble resin binder, water, and a plasticizer composed of at least one of polyhydric alcohol, ether and ester to obtain a viscous composition.
- the viscous composition is dried in a state where the bubbles are mixed to form the pre-sintered compact, and then the pre-sintered compact is heated and fired.
- the aluminum mixed raw material powder is molded by a known slurry foaming method to obtain a foamed pre-sintered molded body, which is sintered to produce an aluminum porous sintered body.
- a porous body having two different types of pores, that is, pores surrounded by the formed sponge skeleton and pores formed in the sponge skeleton itself is obtained.
- the average particle diameter of the aluminum powder may be 2 to 200 ⁇ m.
- r and W are 1 ( ⁇ m) ⁇ r ⁇ 30 ( ⁇ m), 1 ⁇ W ⁇ 20 (mass%), and 0.1 ⁇ W / r ⁇ 2 may be satisfied.
- the sintering aid powder may be either one or both of titanium and titanium hydride.
- a water-insoluble hydrocarbon organic solvent having 5 to 8 carbon atoms may be added to the viscous composition.
- the water-soluble resin binder may be contained within a range of 0.5% to 7% of the mass of the aluminum mixed raw material powder.
- a surfactant in the range of 0.02 to 3% of the mass of the aluminum mixed raw material powder may be added to the aluminum mixed raw material powder.
- the pre-sintered molded body may be obtained as a plate-shaped molded body by stretching the viscous composition to a thickness of 0.05 mm to 5 mm and drying it.
- the aluminum porous sintered body of the present invention has a metal skeleton having a three-dimensional network structure made of a perforated metal sintered body, and has pores between the metal skeletons.
- the total porosity is 70 to 99% because the —Ti compound is dispersed and 20 or more pores are formed per 1 cm of the linear length.
- an aluminum mixed raw material powder obtained by mixing aluminum powder with a sintering aid powder containing titanium is set to Tm ⁇ 10 (° C.) ⁇ T ⁇ 685 (° C.).
- An aluminum porous sintered body having two or more openings per linear length of 100 ⁇ m can be obtained by heating and firing at a temperature T to be satisfied.
- the reason for limiting the heating and firing temperature to Tm-10 (° C.) or higher is that the temperature at which the aluminum powder contained in the aluminum mixed raw material powder and the sintering aid powder containing titanium start the reaction is Tm-10 (° C. That's why.
- the melting point of aluminum is described as Tm because the pure aluminum melting point is 660 ° C., but industrially utilized aluminum contains iron and silicon as impurities, so the melting point is lower than 660 ° C. is there.
- the reason why the heating and firing temperature is limited to 685 ° C. or less is that when heated and held at a temperature higher than that temperature, a drop-shaped lump of aluminum is generated in the sintered body.
- the aluminum mixed raw material powder is mixed with a water-soluble resin binder, water and a plasticizer to form a viscous composition, and dried in a state where air bubbles are mixed in the viscous composition to obtain a pre-sintered molded body.
- this pre-sintered compact is heated and fired in the above temperature range.
- the pre-sintered compact is a sponge skeleton structure (three-dimensional skeleton structure, foamed skeleton structure of open pores)
- the obtained sintered body has pores surrounded by the sponge skeleton and the sponge skeleton itself.
- the porous aluminum body has pores having two different forms from the pores formed in the above.
- the pre-sintered molded body which is so viscous that the viscous composition can be molded into a desired shape and dried in a state where air bubbles are mixed with the viscous composition, has a desired handling strength.
- the aluminum powder is prepared. That is, when the average particle diameter becomes small, it is necessary to increase the mass of the water-soluble resin binder with respect to the mass of the aluminum powder to ensure the viscosity and handling strength. However, when the mass of the water-soluble resin binder increases, the amount of carbon remaining in the aluminum increases when the pre-sintered molded body is heated and fired, thereby inhibiting the sintering reaction. On the other hand, when the particle diameter of the aluminum powder is too large, the strength of the porous sintered body is lowered.
- the average particle diameter of the aluminum powder is 2 ⁇ m or more, thereby preventing the sintering reaction from being hindered by increasing the mass of the water-soluble resin binder. Furthermore, it is preferable to set it as 200 micrometers or less, and this ensures the intensity
- the blending ratio W of the sintering aid powder exceeds 20% by mass, the sintering aid powder has contact points in the aluminum mixed raw material powder, and the reaction heat of aluminum and titanium cannot be controlled and is desired. No porous sintered body can be obtained. For this reason, 0.1 (mass%) ⁇ W ⁇ 20 (mass%). More preferably, 1 (mass%) ⁇ W ⁇ 20 (mass%).
- the reaction heat of aluminum and titanium may become too large, In some cases, the temperature of the aluminum melted by the heat of reaction further increases, the viscosity decreases, and droplets are generated.
- the surface layer with a substantially constant thickness from the exposed surface side of the titanium particles within a range in which the calorific value can be controlled by the blending amount and particle size of titanium It was found that only the part reacted with aluminum. Thus, it was experimentally derived that it is desirable that 1 ( ⁇ m) ⁇ r ⁇ 30 ( ⁇ m) and 0.1 ⁇ W / r ⁇ 2 in order to prevent the generation of droplets.
- titanium hydride as a sintering aid powder has a titanium content of 95% by mass or more and is dehydrogenated at 470 to 530 ° C. to be titanium, so that it is thermally decomposed by the above-mentioned heating and firing. It becomes titanium. For this reason, reaction efficiency with aluminum powder can be improved by using titanium and / or titanium hydride as a sintering aid powder.
- the viscous composition can be foamed by adding a water-insoluble hydrocarbon-based organic solvent having 5 to 8 carbon atoms to mix bubbles.
- the water-soluble binder when the water-soluble binder is contained in excess of 7% of the mass of the aluminum mixed raw material powder, the amount of carbon remaining in the pre-sintered molded body during heating and firing is increased, and the sintering reaction is caused. Be inhibited. On the other hand, if it is less than 0.5%, the handling strength of the green body before sintering cannot be ensured. Therefore, it is preferably contained within the range of 0.5% to 7% of the mass of the aluminum mixed raw material powder.
- the viscous composition when stretched to a thickness of 0.05 mm to 5 mm to obtain a molded body before sintering as a plate-shaped molded body, the plate-shaped molded body is sintered to obtain a lithium ion secondary battery.
- an aluminum porous sintered body suitable as a current collector for an electric double layer capacitor can be obtained.
- the porous aluminum sintered body of the present invention not only does the positive electrode active material not peel off when wound around the outer periphery of a cylindrical battery element as a positive electrode current collector, but also an active material associated with charge and discharge
- the positive electrode active material does not easily fall off due to the expansion and contraction of the resin, and can be used stably.
- FIG. 2 is a SEM photograph of foamed aluminum of Example 1. It is a partially expanded SEM photograph figure of FIG. 2 is an SEM photograph of foamed aluminum of Comparative Example 1. It is the photograph of the foamed aluminum obtained by the method which combined the slurry foaming method with the 5th method in the prior art as a method of free sintering aluminum powder.
- the method for producing an aluminum porous sintered body of the present embodiment includes an aluminum mixed raw material powder preparation step in which aluminum and titanium hydride are mixed with aluminum powder to obtain an aluminum mixed raw material powder, and the aluminum mixed raw material powder is water-soluble.
- a viscous composition preparation step of preparing a viscous composition by mixing a water-soluble resin binder, water and a plasticizer, and drying in a state where bubbles are mixed in the viscous composition to obtain a pre-sintered molded body.
- Tm-10 (° C.) ⁇ heating and firing temperature T ⁇ 685 (° C.).
- Tm (° C.) is a temperature at which the aluminum mixed raw material powder starts to melt.
- aluminum powder having an average particle size of 2 to 200 ⁇ m is used. This is because when the average particle size is small, a large amount of water-soluble resin binder is added to the aluminum powder, and the viscous composition is viscous to the extent that it can be molded into a desired shape. Needs to have handling strength. However, if a large amount of the water-soluble resin binder is added, the amount of carbon remaining in the aluminum increases when the pre-sintered molded body is heated and fired, and the sintering reaction is inhibited. On the other hand, when the particle diameter of the aluminum powder is too large, the strength of the foamed aluminum is lowered. Therefore, as the aluminum powder, those having an average particle diameter in the range of 2 to 200 ⁇ m, more preferably in the range of 7 to 40 ⁇ m are used as described above.
- titanium and / or titanium hydride are mixed with the aluminum powder. This is because the aluminum powder is mixed with titanium, and the pre-sintered compact is heated and fired at a heating and firing temperature T satisfying Tm-10 (° C.) ⁇ heating and firing temperature T ⁇ 685 (° C.). This is because it is possible to perform free sintering of aluminum without generating drop lumps.
- titanium hydride (TiH 2 ) has a titanium content of 47.88 (molecular weight of titanium) / (47.88 + 1 (molecular weight of hydrogen) ⁇ 2) of 95% by mass or more and 470 to 530. Since it is dehydrogenated at 0 ° C. to become titanium, it is thermally decomposed to titanium by the above-mentioned heating and firing. Accordingly, free sintering of aluminum is possible without generating droplet lumps even when titanium hydride is mixed.
- the average particle diameter of titanium or titanium hydride is r ( ⁇ m) and the blending ratio of titanium or titanium hydride is W (mass%), 1 ( ⁇ m) ⁇ r ⁇ 30 ( ⁇ m), 0. 1 (mass%) ⁇ W ⁇ 20 (mass%) and 0.1 ⁇ W / r ⁇ 2. That is, in the case of titanium hydride powder having an average particle size of 4 ⁇ m, since 0.1 ⁇ W / 4 ⁇ 2, the compounding ratio W is 0.4 to 8% by mass. In the case of titanium powder having an average particle diameter of 20 ⁇ m, since 0.1 ⁇ W / 20 ⁇ 2, the compounding ratio W is 2 to 40% by mass. However, from 0.1 (mass%) ⁇ W ⁇ 20 (mass%), 2 to 20 mass%.
- the average particle diameter of titanium hydride is 0.1 ( ⁇ m) ⁇ r ⁇ 30 ( ⁇ m), preferably 1 ( ⁇ m) ⁇ r ⁇ 30 ( ⁇ m), more preferably 4 ( ⁇ m). ⁇ r ⁇ 20 ( ⁇ m). If it is 1 ⁇ m or less, there is a risk of spontaneous ignition. On the other hand, if it exceeds 30 ⁇ m, the titanium hydride becomes titanium particles coated with a compound of aluminum and titanium after sintering. This is because the compound phase of aluminum and titanium is easily peeled off from the titanium particles, and a desired strength cannot be obtained in the sintered body. *
- the reaction heat of aluminum and titanium may become too large depending on the particle size of the sintering aid powder, In some cases, the temperature of the aluminum melted by heat is further increased, the viscosity is lowered, and droplets are generated.
- the surface layer with a substantially constant thickness from the exposed surface side of the titanium particles within a range in which the calorific value can be controlled by the blending amount and particle size of titanium It was found that only the part reacted with aluminum. Thus, it was experimentally derived that it is desirable that 1 ( ⁇ m) ⁇ r ⁇ 30 ( ⁇ m) and 0.1 ⁇ W / r ⁇ 2 in order to prevent the generation of droplets.
- the average particle diameter of titanium is r
- the number of titanium particles is N
- the added mass of titanium is Assuming that w, the specific gravity of titanium is D, and the amount of decrease in the titanium particle size due to the reaction with aluminum is d, the heat of reaction Q is proportional to the volume of the reacted titanium, and therefore Q ⁇ 4 ⁇ r 2 dN.
- the viscous composition preparation step at least one of polyvinyl alcohol, methylcellulose and ethylcellulose is added as a water-soluble resin binder to the aluminum mixed raw material powder, and polyethylene glycol, glycerin and diphthalate are used as plasticizers. At least one of N-butyl is added, and distilled water and alkylbetaine as a surfactant are added.
- the addition amount is set within the range of 0.5% to 7% of the mass of the aluminum mixed raw material powder.
- the content exceeds 7% of the mass of the aluminum mixed raw material powder, the amount of carbon remaining in the pre-sintered molded body or the like during heating and firing is increased and the sintering reaction is inhibited. If it is less than 0.5%, the handling strength of the green body before sintering cannot be ensured.
- 0.02% to 3% of the mass of the aluminum mixed raw material powder is added to the alkylbetaine.
- bubbles are effectively generated when mixing the water-insoluble hydrocarbon organic solvent described later.
- inhibition of the sintering reaction due to an increase in the amount of carbon remaining in the pre-sintered compact or the like is prevented.
- the mixture is further foamed by mixing a water-insoluble hydrocarbon organic solvent having 5 to 8 carbon atoms to prepare a viscous composition in which bubbles are mixed.
- a water-insoluble hydrocarbon organic solvent having 5 to 8 carbon atoms at least one of pentane, hexane, heptane and octane can be used.
- the viscous composition is stretched and applied to a thickness of 0.05 mm to 5 mm on the release agent-coated surface of the belt-like polyethylene sheet. Then, the ambient temperature and humidity are controlled for a certain period of time to size the bubbles, and then dried at a temperature of 70 degrees with an air dryer. At that time, the viscous composition is applied by a doctor blade method, a slurry extrusion method, a screen printing method, or the like.
- the dried viscous composition is peeled off from the polyethylene sheet and cut into a predetermined shape such as a circle having a diameter of 100 mm as necessary to obtain a green body before sintering.
- the above-mentioned sintered compact is placed on an alumina setter on which zirconia powder is spread, and is heated and held at 520 ° C. for 1 hour in an argon atmosphere with a dew point of ⁇ 20 ° C. or lower.
- Pre-baking is performed. This removes the binder solution of the water-soluble resin binder component, plasticizer component, distilled water and alkylbetaine of the pre-sintered molded body, and when titanium hydride is used as the sintering aid powder. Is dehydrogenated.
- the pre-sintered molded body after the temporary firing is heated and fired at a heating and firing temperature T satisfying Tm-10 (° C.) ⁇ heating and firing temperature T ⁇ 685 (° C.) to obtain aluminum foam.
- Tm-10 (° C.) ⁇ heating and firing temperature T ⁇ 685 (° C.)
- Tm-10 (° C.) ⁇ melting and firing temperature
- the pre-sintered molded body may be once heated and held in air at 300 ° C. to 400 ° C. for about 10 minutes to remove the binder, and then heated to a predetermined temperature in an argon atmosphere and fired. .
- the foamed aluminum thus obtained has a metal skeleton having a three-dimensional network structure made of a porous metal sintered body, and has pores between the metal skeletons. Further, the Al—Ti compound is dispersed in the porous metal sintered body, and 20 or more pores are formed per 1 cm of the linear length, and the total porosity is 70 to 90%. It is suitably used as a current collector for secondary batteries and electric double layer type capacitors.
- a sintering aid powder other than titanium or titanium hydride may be used, and sintering including titanium as a sintering aid element.
- An auxiliary powder may be used.
- the method for producing foamed aluminum in the aluminum mixed raw material powder preparation step, aluminum and / or titanium hydride are mixed with the aluminum powder as a sintering aid powder to produce an aluminum mixed raw material powder. . Then, the viscous composition produced in the viscous composition preparation step is foamed and heated and fired at a temperature T satisfying Tm ⁇ 10 (° C.) ⁇ T ⁇ 685 (° C.) in the sintering step.
- Tm ⁇ 10 (° C.) ⁇ T ⁇ 685 (° C.) there are two types of pores different in shape, that is, a pore having a pore diameter of less than 600 ⁇ m surrounded by the sponge skeleton and two or more micropores per 100 ⁇ m linear length formed in the sponge skeleton itself.
- a homogeneous foamed aluminum can be obtained at a high rate.
- the titanium hydride has a titanium content of 95% by mass or more and is dehydrogenated at 470 to 530 ° C. to become titanium, so that it is thermally decomposed to titanium by the above-mentioned heating and firing. Therefore, it is considered that titanium hydride contributes to the production of foamed aluminum by the above-described heating and firing, as is the case with titanium.
- the viscous composition preparation step and the sintering step the viscous composition is stretched and applied to a thickness of 0.05 mm to 5 mm on the surface of the strip-like polyethylene sheet where the release agent is applied.
- a pre-sintering process to form a pre-sintered shaped body of a predetermined shape, by performing a post-sintering process, it can be used according to applications such as a current collector of a lithium ion secondary battery or an electric double layer capacitor. Foamed aluminum can be obtained.
- Examples 1 to 16 an Al powder having an average particle size of 2.1 ⁇ m, 9.4 ⁇ m, 24 ⁇ m, 87 ⁇ m and 175 ⁇ m, a Ti powder having an average particle size of 9.8 ⁇ m, 24 ⁇ m and 42 ⁇ m, an average particle size of 4.2 ⁇ m, 9.1 ⁇ m and A 21 ⁇ m TiH 2 powder is prepared. Then, according to the above-mentioned embodiment, aluminum mixed raw material powders 1 to 10 in which Ti powder and / or TiH 2 powder are mixed with Al powder at the ratio shown in Table 1 are prepared, and binder solution 1 with the composition shown in Table 2 is prepared. ⁇ 5 were prepared. These and a water-insoluble hydrocarbon-based organic solvent were kneaded in the proportions shown in Table 3 to produce viscous compositions of Examples 1 to 16.
- the viscous compositions of Examples 1 to 16 were applied to a polyethylene sheet coated with a release agent by stretching using a doctor blade method, and the temperature and humidity were controlled to be maintained for a certain period of time. Was sized. Then, it was dried at a temperature of 70 ° C. with an air dryer. Table 3 shows the application thickness of the viscous composition and the temperature, humidity and holding time. Then, the dried viscous composition was peeled off from the polyethylene sheet and cut into a circle having a diameter of 100 mm to obtain pre-sintered molded bodies of Examples 1 to 16.
- the shrinkage rate and porosity of the foamed aluminum of Examples 1 to 16 obtained as described above were calculated. Further, the number of three-dimensional vacancies was measured from a stereoscopic microscope photograph, and the number of pores in the skeleton was measured from a scanning electron microscope (SEM) photograph. The obtained SEM photograph confirmed the presence or absence of droplet solidification. Furthermore, the presence of an Al—Ti compound was confirmed on the surface of the skeleton of the foamed aluminum by surface analysis using an electron beam microanalyzer (EPMA). The results are shown in Table 5, the SEM photograph of the foamed aluminum of Example 1 is shown in FIG. 1, and a partially enlarged photograph thereof is shown in FIG.
- each of the aluminum foams of Examples 1 to 16 was subjected to a roll rolling test at a rolling reduction of 20%, and the presence or absence of cracks was visually confirmed. Then, it cut out into the rectangular shape of 20 mm x 50 mm, and measured the electrical resistance between opposing corner parts. Next, these rectangular aluminum foams were respectively wound around the outer periphery of a cylindrical body having a diameter of 5 mm, and the presence or absence of cracks was visually confirmed. The results are shown in Table 5.
- Comparative Examples 1 to 9 Next, the comparative aluminum mixed raw material powders 31 to 35 prepared by preparing the same Al powder, Ti powder and TiH 2 powder as in the examples or the aluminum mixed raw material powder 1 of the present invention were used. 5 and foamed aluminum of Comparative Examples 1 to 9 were produced in the same manner as in the Example except that the water-insoluble hydrocarbon-based organic solvent was kneaded at a ratio shown in Table 4. The results of evaluating the foamed aluminum of Comparative Examples 1 to 9 in the same manner as in the Examples are shown in Table 5, and the SEM photographs of the foamed aluminum of Comparative Example 1 are shown in FIG.
- the foamed aluminum of Examples 1 to 16 has 2 to 4 holes per 100 ⁇ m of the skeleton length of the porous metal sintered body and 1-dimensional pores between the metal skeletons. There are 52 or more per inch, that is, 20 or more per 1 cm. Further, no droplet-like lump was formed in the foamed aluminum, the electric resistance was low, and there was no cracking due to the winding test. Therefore, it is suitable for a positive current collector of a battery or a capacitor that requires high output and high energy density.
- LiCoO 2 lithium cobaltate
- PVdE polyvinylidene fluoride
- artificial graphite powder as a conductive material
- a positive electrode active material slurry was prepared by mixing this positive electrode agent with N-methyl-2-pyrrolidone as a solvent.
- cylindrical bodies having diameters of 1 mm, 1.5 mm, 2 mm, 2.5 mm, 3 mm, 3.5 mm, 4 mm, 4.5 mm, and 5 mm were prepared, and the lithium ion batteries of Examples 1 to 16 and Conventional Example 1 were prepared. No. positive electrode was wound. Then, whether or not the active material is peeled is visually observed, and the minimum diameter at which no peeling is observed is shown in Table 5.
Abstract
Description
本願は、2009年3月30日に、日本に出願された特願2009-082498号に基づき優先権を主張し、その内容をここに援用する。
その理由について述べると、このスラリー発泡法では、金属粉末に圧縮等の応力をかけることなく焼結するフリーシンタリングによって焼結して発泡金属を得ることになる。しかし、アルミニウム粉末は表面に数nm~数10nmの緻密な酸化アルミニウム被膜で覆われていて、それが固相、液相を問わずに焼結を阻害する。そのためにフリーシンタリンングでは焼結が困難であって、そのためスラリー発泡法で均質な発泡アルミニウムが得られなかった。
本実施形態のアルミニウム多孔質焼結体の製造方法は、アルミニウム粉末にチタンおよび/または水素化チタンを混合してアルミニウム混合原料粉末とするアルミニウム混合原料粉末調製工程と、このアルミニウム混合原料粉末に水溶性樹脂結合剤と水と可塑剤とを混合して粘性組成物を調製する粘性組成物調製工程と、この粘性組成物に気泡を混合させた状態で乾燥させて焼結前成形体を得る焼結前工程と、焼結前成形体を非酸化性雰囲気にてTm-10(℃)≦加熱焼成温度T≦685(℃)を満たす加熱焼成温度Tで加熱焼成する焼結工程とを有する。なお、Tm(℃)は、アルミニウム混合原料粉末が溶解を開始する温度である。
これは、以下の理由による。焼結前成形体を融解温度Tm(℃)まで加熱することにより、アルミニウムとチタンとの反応が開始するものと考えられる。しかし、実際にはアルミニウムは不純物としてFeやSiなどの共晶合金元素を微量に含有しており、融点が低下する。このため、Tm-10(℃)まで加熱することにより、アルミニウムとチタンとの反応が開始して発泡アルミニウムを形成するものと考えられるためである。実際に、アルミニウムの融点が660℃であるのに対して、純アルミニウム粉として流通している純度98%~99.7%程度のアトマイズ粉では650℃前後が溶解開始温度となる。
次に、平均粒子径2.1μm、9.4μm、24μm、87μmおよび175μmのAl粉と、平均粒子径9.8μm、24μmおよび42μmのTi粉と、平均粒子径4.2μm、9.1μmおよび21μmのTiH2粉とを用意する。そして、上述の実施の形態に従って、表1に示す割合でAl粉にTi粉および/またはTiH2粉を混合したアルミニウム混合原料粉末1~10を調製し、表2に示す配合組成でバインダー溶液1~5を調製した。それらと非水溶性炭化水素系有機溶剤を表3に示す割合で混練して実施例1~16の粘性組成物を製造した。
次いで、実施例と同一のAl粉、Ti粉およびTiH2粉を用意して調製した比較アルミニウム混合原料粉末31~35又は本発明アルミニウム混合原料粉末1を用いて、表2に示すバインダー溶液1~5と、非水溶性炭化水素系有機溶剤を表4に示す割合で混練した以外は、実施例と同様にして比較例1~9の発泡アルミニウムを製造した。そして、比較例1~9の発泡アルミニウムを実施例と同様の方法にて評価した結果を表5に示すとともに、比較例1の発泡アルミニウムのSEM写真を図3に示した。
Claims (9)
- アルミニウム粉末に、チタンを含む焼結助剤粉末を混合してアルミニウム混合原料粉末とする工程と、
前記アルミニウム混合原料粉末に、水溶性樹脂結合剤と、水と、多価アルコール、エーテルおよびエステルのうちの少なくとも1種からなる可塑剤を混合して粘性組成物とする工程と、
前記粘性組成物に気泡を混合させた状態で乾燥させて焼結前成形体とする工程と、
次いで、前記焼結前成形体を、非酸化性雰囲気において、加熱焼成する工程を有し、
前記アルミニウム混合原料粉末が融解を開始する温度をTm(℃)としたときに、前記加熱焼成の温度T(℃)がTm-10(℃)≦T≦685(℃)を満たすことを特徴とするアルミニウム多孔質焼結体の製造方法。 - 前記アルミニウム粉末の平均粒子径が2~200μmであることを特徴とする請求項1に記載のアルミニウム多孔質焼結体の製造方法。
- 前記焼結助剤粉末の平均粒子径をr(μm)、前記焼結助剤粉末の配合比をW質量%としたときに、前記r及び前記Wは、1(μm)≦r≦30(μm)、1≦W≦20(質量%)、かつ0.1≦W/r≦2を満たすことを特徴とする請求項1に記載のアルミニウム多孔質焼結体の製造方法。
- 前記焼結助剤粉末は、チタンおよび水素化チタンのうちのいずれか一方又は両方であることを特徴とする請求項1に記載のアルミニウム多孔質焼結体の製造方法。
- 前記粘性組成物に、炭素数5~8の非水溶性炭化水素系有機溶剤を添加することを特徴とする請求項1に記載のアルミニウム多孔質焼結体の製造方法。
- 前記水溶性樹脂結合剤は、前記アルミニウム混合原料粉末の質量の0.5%~7%の範囲内で含まれていることを特徴とする請求項1に記載のアルミニウム多孔質焼結体の製造方法。
- 前記アルミニウム混合原料粉末に、前記アルミニウム混合原料粉末の質量の0.02~3%の範囲内の界面活性剤を添加することを特徴とする請求項1に記載のアルミニウム多孔質焼結体の製造方法。
- 前記粘性組成物を厚さ0.05mm~5mmに引き伸ばして乾燥させることにより、前記焼結前成形体を板状成形体として得ることを特徴とする請求項1に記載のアルミニウム多孔質焼結体の製造方法。
- 有孔金属焼結体からなる三次元網目構造の金属骨格を有し、
前記金属骨格間に空孔を有し、
前記有孔金属焼結体にAl-Ti化合物が分散しているとともに、前記空孔が直線長さ1cm当たりに20ヶ以上形成されることにより、全体気孔率が70~99%であることを特徴とするアルミニウム多孔質焼結体。
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US9242297B2 (en) | 2016-01-26 |
CN102438778A (zh) | 2012-05-02 |
US20120107166A1 (en) | 2012-05-03 |
CN102438778B (zh) | 2014-10-29 |
EP2415543B1 (en) | 2021-07-28 |
JP2014031585A (ja) | 2014-02-20 |
TWI471424B (zh) | 2015-02-01 |
KR101321176B1 (ko) | 2013-10-23 |
US9815116B2 (en) | 2017-11-14 |
KR20110122208A (ko) | 2011-11-09 |
EP2415543A1 (en) | 2012-02-08 |
EP2415543A4 (en) | 2018-03-28 |
US20150078949A1 (en) | 2015-03-19 |
TW201107493A (en) | 2011-03-01 |
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