CA1293352C - Production of flat products from particulate material - Google Patents

Production of flat products from particulate material

Info

Publication number
CA1293352C
CA1293352C CA000537491A CA537491A CA1293352C CA 1293352 C CA1293352 C CA 1293352C CA 000537491 A CA000537491 A CA 000537491A CA 537491 A CA537491 A CA 537491A CA 1293352 C CA1293352 C CA 1293352C
Authority
CA
Canada
Prior art keywords
coating
particulate
synthetic resin
particulate material
slurry
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Fee Related
Application number
CA000537491A
Other languages
French (fr)
Inventor
John Bellis
Nigel J. Brooks
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.)
Mixalloy Ltd
Original Assignee
Mixalloy 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 Mixalloy Ltd filed Critical Mixalloy Ltd
Application granted granted Critical
Publication of CA1293352C publication Critical patent/CA1293352C/en
Anticipated expiration legal-status Critical
Expired - Fee Related legal-status Critical Current

Links

Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/632—Organic additives
    • C04B35/634—Polymers
    • C04B35/63404—Polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • C04B35/63436—Halogen-containing polymers, e.g. PVC
    • 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
    • B22F3/22—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces for producing castings from a slip
    • 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
    • B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/006—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of flat products, e.g. sheets
    • 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
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C41/16—Slip casting, i.e. applying a slip or slurry on a perforated or porous or absorbent surface with the liquid being drained away
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/632—Organic additives
    • C04B35/634—Polymers
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
    • C04B35/638—Removal thereof
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • C22C32/0094—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with organic materials as the main non-metallic constituent, e.g. resin
    • 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
    • H01M4/24—Electrodes for alkaline accumulators
    • H01M4/32—Nickel oxide or hydroxide electrodes
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01M—PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00—Electrodes
    • H01M4/02—Electrodes composed of, or comprising, active material
    • H01M4/62—Selection of inactive substances as ingredients for active masses, e.g. binders, fillers
    • H01M4/621—Binders
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2503/00—Use of resin-bonded materials as filler
    • B29K2503/04—Inorganic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2503/00—Use of resin-bonded materials as filler
    • B29K2503/04—Inorganic materials
    • B29K2503/06—Metal powders, metal carbides or the like
    • 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

Abstract

ABSTRACT

Production of Flat Products from Particulate Material A process for producing flat products from particulate material comprises the steps of forming relatively smooth, castable slurry comprising a suspension of particulate material in an aqueous solution, a film-forming binder material and a dispersion of a particulate synthetic resin in an aqueous solution, depositing a coating of this slurry onto a support surface and, heating the deposited coating to a temperature at which a component of the synthetic resin volatilises. The coating may be removed from the support surface as a flat product either before or after heating to volatilise a component of the synthetic resin.

Description

3~

Production of Flat Products from Particulate Material ~ This invention relates to a process of producing ; flat products from particulate material and to flat products produced by such a process. By the term "flat products" is meant products in strip, sheet or . ~ . 5 like~-form or products produced therefrom which have ~: retained a generally flat appearance.
A process for the production of strip from metal :: powder is known in which a~ suspension of powdered metal in a solution of a film-forming binder material in water is coated in the form of a slurry onto a , :
~ : support surface, dried and removed from the support ~
: ~ :
~ ~ surfaoe, rolled and sintered to produce a metal:strip.

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While this process has been employed successfully to produce a broad range of strip products, only limited success has been achieved in producing thin flexible unsintered strips of materials which can be employed in applications where the properties of enhanced flexible strength, water resistance and an ability to retain a stable form in hostile environments are a pre-requisite. The present invention sets out to provide a process by which such products can be produced.
According to the present invention in one aspect, there is provided a process for producing flat products from particulate material which comprises forming a relatively smooth, castable slurry oomprising a suspension of particulate material~in a liquid solution, a ~ilm-~orming binder material and a dispersion of a particulate synthetic resin in a liquid solution, depositing a coating of: this slurry onto a support sur~ace and, heating the deposited ao aoating to a temperature at which a component of the synthetic~ resin volatilises. ;
The coating may be removed from the support surfac~e aa a flat product either before or a~ter heating~ to~volatilise a component of the synthet~ic resin. Further the coating may be cooled before being removed rrom the support surface. Preferably, the coating i5 cooled to a temperature of below 100 C.
:

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In one embodiment of the invention, the deposited coating is heated to a temperature at which the resin coalesces. Alternatively, the coating may be heated to a temperature above that at which a component of the synthetic resin volatilises and below that at which coalescence of the resin occurs.
Preferably, the dispersion of a particulate resin in a liquid solution is added to an initially formed slurry of the suspension of particulate material in a liquid solution and the film-forming binder material. The liquid is preferably water.
The particulate material may comprise a metallic powder, a non-metallic powder or a mixture of such powders. The particulate material may be magnetic or non-magnetic. In one particular embodiment, the particulate material consists of a blend of nickel hydrate and graphite powders.
In still further embodiments, the materiâl comprises a particulate abrasive material, e.g.
diamond powder or a super-conducting material, e.g. a titanium or niobium alloy or a metal-ceramic or ceramic material having super conducting properties.
The film-forming binder material preferably comprises methyl cellulose. A plasticlser may be added to the slurry; typically, the plasticiser oomprises polyethylene glycol or glycerol.

:

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The synthetic resin preferably comprises a fluorinated polymer such as polytetrafluoroethylene.
In this case, the deposited coating is heated to a o o temperature in the range 230 C to 260 C to effect volatisation of a component of the synthetic resin or to a temperature in excess of 260 C if partial coalescence is required, or to a temperature of o o betwe~en 355 C and 400 C if full coalescence is to be achieved. Alternative synthetic resins which may be employed include polyvinylchloride, and a butyl rubber dispersion in water. Other polymers which can be dispersed or otherwise incorporated into a slurry and which can be made into a coherent film by heat treatment may be employed.
15The thin, flexible flat product may be rolled to effect compaction either before or after heating to a temperature at or above that at which a resin component volatilises. Additionally, or ~ alternatively,~ a flexible flat product of the process ; ~ ~ 20 may be bonded to one or both sides of a preformed flak ~ product of metallic and/or non-metallic material ' Such bonding may be effected mechanically by feeding the flat products in interfacial contact into the nip of a pair of compaction rolls. At least one of the 25 ~ flat products =ay be subjected to back tension during ~ compaction.

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In one embodiment of the invention, a thin flexible flat product consisting essentially of nickel hydrate and graphite is bonded to one or each side of a porous nickel flat product by passing the individual strips while in interfacial contact between the nip of a pair of compaction rolls. The porous nickel material may be subjected to a degree of back tension during the bonding process. The mechanically bonded flat products may be subjected to a second compaction to enhance the mechanical bond.
According to the present invention in a further aspect there is provided a process for producing flat products from particulate material which comprises forming a castable slurry comprising, in a liquid solution, particulate metallic and/or non-metallic material, a film-forming binder and a synthetic resin in particulate form, depositing the slurry as a coating onto a support surface and heating the deposited coating to a temperature at or in excess of that at which a component of the synthetic resin ~; volatilises. The coating may subsequently be oooled nd then removed from the support surface as a thin ~` flexible flat product.
According to the present invention in a still further aspect there is provided a thin, flexible ~lat product comprising metallic and/or non-metallic :: :

335;2 particulate material contained in a synthetic resin matrix.
The invention will now be described by way of example only with reference to the following description and Example in which a thin flexible strip was produced from a blend of nickel hydrate and graphite powders and is bonded mechanically to one or both sides of a thin porous strip of nickel.
In order to produce samples which do not dissolve and lose their original shape/dimension when submerged in water, slurries comprising a mix of the powder blend and various quantities of a dispersion of particulate polytetrafluoroethylene in water were produced. In each case, the resultant mix tended to .
coagulate to form a rubber-like lumpy consistency which could not efficiently be cast onto a support , ~ surface. Addition of water both before and after the ~; addition of the dispersion of particulate polytetrafluoroethylene did not prove to be beneficial.
It was only after a controlled amount of methyl cellulose was~added to the slurry that the coagulant content of the slurry was dispersed to produce a slurry which could properly be oast. It was found that 25~ the addit~ion of the methyl cellulose in advanoe of the addi~tion of the disperslon of particulate : ~: : :: : : :

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polytetrafluoroethylene produced no coagulation until the latter was added to excess.
Further slurry mixes were produced so that a suitable slurry composition for subsequent processing could be established. Typically, the ratio of particulate material to water of the initially formed slurry was found to lie in the range of 3.4 : 1 and 4.2 : l for metallic materials and 0.6 : 1 and 0.74 : 1 for a slurry containing a mix of nickel hydrate powder blended with a graphite powder.
Typically, the dispersion of particulate polytetrafluoroethylene comprised an aqueous solution containing approximately 60~ polytetrafluoroethylene by weight. Typically, 160 mls of this dispersion was required for each kilogram of particulate material employed.
After drying strip samples produced from the slurry at normal drying temperatures of approximately 150 C, the samples proved to be handleable but still fairly brittle. However, on heating to a temperature o o in the range 230 C to 260 C, a component Or the polytetrafluoroethylene dispersion volatised. Partial coalescence of the polytetrafluoroethylene may also have occurred. On cooling from this temperature range, the samples were found to have adequate flexibility ~ and to retain their shape/dimensions when submerged in ; ~ water with no apparent dissolution occurring.

1~33S~

Example A slurry comprising a mix of nickel hydrate powder blended with a graphite powder, a controlled quantity of methyl cellulose and a dispersion of polytetrafluoroethylene was produced by the method described above, cast onto a support surface and o o heated to a temperature in the range 230 C to 260 C.
The dried product was removed from the support surface in this strip form. At this stage, the gauge of the strip was approximately 1 to 2 millimeters.
Some samples of the thin, flexible strip produced were then compacted by themselves and others compacted in interfacial contact with each side of a strip of porous nickel. In the latter case, The gauge of the nickel strip at this stage was approxlmately 0.004". The compaction load applied was found to be :
important in that insufficien~t loading produced a weak mechanical bond whilst excessive loading caused the product to break up In the mill.
A tendency for creasing of the strips to occur as they passed through the mill was overcome by applying a controlled back tension to the nickel strip during roll compaction.
One other example of a strip produced by the process descrlbed is a nickel hydrate/graphite strip ` subsequently bonded to a strip of perforated nickel.

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g It is to be understood that the Example and accompanying description is merely exemplary of the invention and that various modifications or compositioned changes may be affected without departing from the true scope of the invention.
Thus a wide range of particulate material may be employed to produce strips of a variety of physical and chemical properties. Thus, the particulate material may have magnetic or non-magnetic properties;
it may be metallic or non-metallic; it may have high or low hardness charateristics (e.g. the material may comprise diamond powder if good abrasive characteristics are, for example, required; or it may be a super-conducting material of a metallic (e.g. a titanium or niobium alloy), metal ceramic or ceramic material.

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Claims (21)

1. A process for producing flat products from particulate material which comprises forming a relatively smooth, castable slurry comprising a suspension of particulate material in a liquid solution, a film-forming binder material and a dispersion of a particulate synthetic resin in a liquid solution, depositing a coating of this slurry onto a support surface and, heating the deposited coating to a temperature at which a component of the synthetic resin volatilises.
2. A process as claimed in claim 1, wherein the castable slurry comprises a suspension of particulate material in an aqueous solution.
3. A process as claimed in claim 1, wherein the coating is removed from the support surface as a flat product either before or after heating to volatilise a component of the synthetic resin.
4. A process as claimed in claim 3, wherein the coating is cooled before being removed from the support surface.
5. A process as claimed in claim 4, wherein the coating is cooled to a temperature of below 100°C.
6. A process as claimed in any one of claims 1 to 5, wherein the deposited coating is heated to a temperature at which the resin coalesces.
7. A process as claimed in any one of claims 1 to 5, wherein the coating is heated to a temperature above that at which a component of the synthetic resin volatilises and below that at which coalescence of the resin occurs.
8. A process as claimed in any one of claims 1 to 5, wherein the dispersion of a particulate resin in a liquid solution is added to an initially formed slurry of the suspension of particulate material in a liquid solution and the film-forming binder material.
9. A process as claimed in any one of claims 1 to 5, wherein the particulate material comprises a metallic powder, a non-metallic powder or a mixture of such powders.
10. A process as claimed in any one of claims 1 to 5, wherein the particulate material consists of a blend of nickel hydrate and graphite powders.
11. A process as claimed in any one of claims 1 to 5, wherein the particulate material consists of diamond powder.
12. A process as claimed in any one of claims 1 to 5, wherein the film-forming binder material comprises methyl cellulose.
13. A process as claimed in claim 1, wherein a plasticiser is added to the slurry.
14. A process as claimed in claim 13, wherein the plasticiser comprises polyethylene glycol or glycerol.
15. A process as claimed in claim 1, wherein the synthetic resin comprises a fluorinated polymer such as polytetrafluoroethylene.
16. A process as claimed in claim 15, wherein the deposited coating is heated to a temperture in the range 230°C to 260°C to effect volatilisation of a component of the synthetic resin.
17. A process as claimed in claim 15, wherein the deposited coating is heated to a temperature in excess of 260°C to effect partial coalescence of the synthetic material.
18. A process as claimed in claim 15, wherein the deposited coating is heated to a temperature of between 355°C and 400°C to achieve coalescence of the synthetic material.
19. A process as claimed in any one of claims 1 to 5 and 13 to 18, wherein a flexible flat product of the process is bonded to one or both sides of a preformed flat product of metallic and/or non-metallic material.
20. A process for producing flat products from particulate material which comprises forming a castable slurry comprising, in a solution of water, particulate metallic and/or non-metallic material, a film-forming binder and a synthetic resin in particulate form, depositing the slurry as a coating onto a support surface and heating the deposited coating to a temperature at or in excess of that at which a component of the synthetic resin volatilises.
21. A thin, flexible flat product produced in accordance with a process as claimed in any one of claims 1 to 5, 13 to 18 and 20.
CA000537491A 1986-05-20 1987-05-20 Production of flat products from particulate material Expired - Fee Related CA1293352C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB8612267 1986-05-20
GB868612267A GB8612267D0 (en) 1986-05-20 1986-05-20 Flat products

Publications (1)

Publication Number Publication Date
CA1293352C true CA1293352C (en) 1991-12-24

Family

ID=10598143

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000537491A Expired - Fee Related CA1293352C (en) 1986-05-20 1987-05-20 Production of flat products from particulate material

Country Status (8)

Country Link
US (1) US4772322A (en)
EP (1) EP0246844B1 (en)
JP (1) JPS6322839A (en)
AT (1) ATE50189T1 (en)
CA (1) CA1293352C (en)
DE (1) DE3761619D1 (en)
ES (1) ES2012484B3 (en)
GB (1) GB8612267D0 (en)

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Also Published As

Publication number Publication date
DE3761619D1 (en) 1990-03-15
EP0246844A1 (en) 1987-11-25
JPS6322839A (en) 1988-01-30
ATE50189T1 (en) 1990-02-15
GB8612267D0 (en) 1986-06-25
EP0246844B1 (en) 1990-02-07
US4772322A (en) 1988-09-20
ES2012484B3 (en) 1990-04-01

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