Abstract

An improved apparatus and method of producing metal foam is provided which involves optimizing the natural convection of electrolyte through a foam being electroplated by inclining the foam during plating. A diagonal flow of electrolyte though the foam enhances electrolyte turnover within the foam while increasing electroplating efficiency. Further increases in plating efficiency are provided by shifting current density from higher plating zones to lower plating zones.

IPC Classes  ?

• C25D 5/56 - Electroplating of non-metallic surfaces of plastics
• C25D 3/12 - ElectroplatingBaths therefor from solutions of nickel or cobalt

Abstract

An environmentally friendly process for producing metal biporous foam by using filamentary metal powders such as nickel or copper. The filamentary metal powders are initially wet when combined with a suitable foam former such as methylcellulose. Because the filamentary metal powder is wet, it does not extract water from the foam structure thereby ensuring a highly porous metal foam having both high macroporosity and microporosity.

IPC Classes  ?

• B22F 3/11 - Making porous workpieces or articles
• B22F 1/00 - Metallic powderTreatment of metallic powder, e.g. to facilitate working or to improve properties
• B01D 39/00 - Filtering material for liquid or gaseous fluids
• B22F 5/10 - Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
• B22F 7/00 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting
• B32B 15/02 - Layered products essentially comprising metal in a form other than a sheet, e.g. wire, particles
• B32B 5/18 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by features of a layer containing foamed or specifically porous material

Abstract

A method for producing porous metal plated polymeric foam having uniform pore properties. Polymeric foam buns are horizontally cut along a longitudinal surface thereby lifting off a foam sheet. The sheet is spooled and then reticulated to remove any remaining cell walls and to round off the internal pore struts to enlarge the openings between the adjacent cells. The reticulated foam sheet is unwound and then plated. Slabs may be attached end to end and loop slitted and then reticulated. The resulting plated uniform foam provides a superior substrate for battery plaques and other applications.

IPC Classes  ?

• C23C 18/31 - Coating with metals
• B22D 19/00 - Casting in, on, or around, objects which form part of the product
• B22D 25/04 - Casting metal electric battery plates or the like
• C22C 1/08 - Alloys with open or closed pores
• C23C 16/06 - Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of metallic material
• H01M 4/04 - Processes of manufacture in general