Eltech Systems Corporation

Oxytech Systems, Inc.

Anthony J Vaccaro

James R Brannan

James J Stewart

Daniel W Gibbons

Andrew S Bean

Janet S Gregg

Vittorio De Nora

Gerald R Pohto

Jean M Hinden

Jeries I Bishara

Eric J Rudd

Donald J Groszek

Rudolf C Matousek

Lawrence J Gestaut

Kenneth J Gregg

John R Griesser

Lawrence L Frank

Robert D Penny

Richard J Kawolics

John P Healy

A process is disclosed, as well as apparatus useful therefor, for continuously electroplating a strip of reticulated foam using multiple electroplating zones that each contain electroplating bath. In each zone there is a cathode and an anode. In at least one electroplating zone there is an insoluble anode, typically as the sole anode. In some of the electroplating zones soluble anodes may be used. As a first cathode, there can be provided a cathode roll outside of the electroplating bath. The reticulated foam is guided in the bath past the anodes, as well as past cathodes, e.g., including a cathode roll which may be positioned outside of the bath. The resulting electroplated foam emerging from the bath has an improved electroplate weight distribution and the process achieves enhanced efficiencies and economies of operation.

Continuously electroplated foam of improved weight distribution

A porous product, typically a metal foam sheet, is produced as a tailored, engineered product. The porous product can have enhanced strength, as well as more desirable electrical and mechanical properties. The product which first exists typically as a flexible, generally polymeric foam sheet in strip form, which strip is produced in the longitudinal direction, is stretched in a direction other than its direction of production. The porous product can have pores which would be anisotropic in form in usual production, which are stretched to at least substantially isotropic form. The product can even be tailored to have pores which are anisotropic in the direction of the stretch. Thus, an engineered product can be produced which, for example, as an open-cell metal foam prepared from a polymeric foam can have conductivity, both thermal and electrical, as well as strength and ductility, tailored for greater uniformity and performance.

Conductive metal porous sheet production

There is now provided an improved manufacturing method for increasing the active material filling density in a small DTR reticulated nickel sheet. The nickel sheet has desirable physical properties such as resistance to breakage and crushing, in repeated bending. This resistance can be for both the surface area and the central area, in the thickness direction of the sheet. Such small DTR sheet has not previously been preferred as a battery electrode material because of a smaller filling density using conventional methods. There is now provided a battery electrode having high filling density of active material, high utilization rate of the impregnated active material and high capacity density with long life. Furthermore, a method of producing such small DTR of reticulated nickel sheet in a continuous and economical manner is disclosed.

High density, high capacity battery electrode

Chlor-alkali electrolytic cells can have separators used with metal cathodes. These cells may often be subject to frequent current interruptions. Particularly where the cathode and separator exhibit extended life, these interruptions may be numerous. There has now been developed a method for providing successful and desirable cathode operation even for such extended cell life. During cell shutdown, the cathode and separator are subjected to an elevated temperature heat treatment. After heating, and optionally following any rewetting of the diaphragm, the cathode is ready in the cell for continued, rejuvenated performance.

Cathode restoration

In the electroplating of certain metals, such as zinc, a metal build-up in the electroplating bath occurs due to a higher anode efficiency than cathode efficiency, in the cell, and also due to chemical dissolution of the anode in the electroplating bath. An electrowinning cell is provided to remove metal from the electroplating bath. The electrowinning cell is operated with a current sufficient to remove metal from the bath substantially equal to that chemically dissolved into the bath as well as the build-up due to the difference in the anodic and cathodic efficiencies.

Process for electroplating

The present invention resides in the discovery that a strip of reticulated foam which is semi-conductive can be continuously electroplated, utilizing a cathode roll which is positioned, in a first electroplating zone, outside of the electroplating bath. An anode is immersed in the electroplating bath. The strip of reticulated foam is first introduced into the electroplating bath and travels in the direction from the anode to the cathode roll prior to contacting the cathode roll. In this way, the strip achieves a partial plate at the anode which provides a current path between the anode and the cathode roll effective for sustaining the plating reaction in said first electroplating zone.

Continuous electroplating of conductive foams

An efficient electrolytic recovery system, having several safety mechanisms, for recovering precious metals from a liquid medium is described. The system includes at least oen electrolysis cell unit having a plurality of reticulate metal foam cathodes. The system of the invention will efficiently recover such precious metals as Au, Ag and Pt. The system may also include a pH adjust means and a means for oxidizing cyanide in the liquid medium.

Efficient electrolytic precious metal recovery system

A highly magnetic isotropic iron oxide powder with a uniform particle size distribution and particle size in the range from 0.005 to 0.2 micrometer consists of a mixed iron oxide exhibiting gamma (Fe.sub.2 O.sub.3) and ferrite (Fe.sub.3 O.sub.4) structure, having the empirical formula Fe.sub.72-x O.sub.96, where x has a value between 2 to 7, an aspect ratio of at most 2:1 and a temperature coefficient of coercivity of less than -0.7% per degree Celcius. The mixed oxide is optionally a cobalt-modified mixed iron oxide containing 2-6% by weight of cobalt and is obtained by heating ultrafine, ferrite particles in a controlled, oxidizing atmosphere at a temperature of 240.degree. C. to 320.degree. C. for a period of one to three hours.

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Mentor, OH, United States of America

Anthony J Vaccaro