Method for Fabricating Polar Plate of Flexible Plastic Graphite Composite

Abstract

A polar plate is fabricated. The polar plate is flexible and made of a plastic graphite composite. No matter a supporting member is used for calendering or not, a thin polar plate with controllable thickness is fabricated. The polar plate is excellent in blocking the through-transmission of vanadium ions and the limit of blending ratio of conductive carbon is broken through. The longitudinal through-transmission volume resistivity (proportional resistance to thickness) is greatly improved by adjusting the blending ratio of conductive carbon for meeting the demand of conductivity. In the mean time, the present invention strengthens the rigidity required for the thin polar plate while providing large-area polar plate fabrication for industrial use and convenience and provides a cooling and pressing method for patterning a composite polar plate. An integrated mold is thus obtained to replace the conventional polar plate which needs to be processed and prepared with runner.

Claims

1. A method for fabricating a polar plate of a flexible plastic graphite composite comprising steps of: (a) ball-milling conductive powder and obtaining 500~1100 parts per hundred rubber (phr) of a conductive powder composition with high carbon (>98%) and low ash (<1%) for at least 0.5 hours (hr) at a speed of at least 200 rounds per minute (rpm); (b) mixing the conductive powder through homogeneous stirring and obtaining a total of 100 phr of a thermoplastic/thermosetting resin adhesive composition of said thermoplastic/thermosetting resin adhesive composition and said conductive powder mixed with a solvent by stirring at least 1 hr; (c) directly and repeatedly calendering said mixture into a rigid plastic sheet by rolling/squeezing and obtaining a requested thickness of said plastic sheet; (d) depositing said plastic sheet to process volatilization under a low-temperature vacuum to remove said solvent; (e) obtaining a composite plastic plate through a process selected from a group consisting of repeatedly calendering said plastic sheet to a requested thickness with at least one supporting member stacked into layers selected from a group consisting of an upper layer together with a lower layer and a plurality of overlapping layers to obtain at least one layer of a plastic composite plate having the at least one supporting member; and (f) graphic-shaping said plastic composite plate with required heat and pressure according to a requested graph to obtain a finished shaped plate.

2. The method according to claim 1, wherein said conductive powder composition further comprises less than 5 weight percent (wt%) of a flame retardant.

3. The method according to claim 1, wherein said thermoplastic/thermosetting resin adhesive composition is selected from a group consisting of a thermoplastic resin, a thermosetting resin, and a combination of said thermoplastic resin and said thermosetting resin.

4. The method according to claim 3, wherein said thermoplastic/thermosetting resin adhesive composition is selected from a group consisting of a halogen crystalline resin, a halogen non-crystalline resin, a non-halogen crystalline resin, and a non-halogen non-crystalline resin; and has a heat deflection temperature (HDT) of 50-300° C.

5. The method according to claim 1, wherein the at least one supporting member is selected from a group consisting of a conductive carbon fabric of carbon fiber bundles with each bundle consisting at least 12,000 monofilaments; a metal with a three-dimensional hollow; and a conductive woven fabric.

6. The method according to claim 5, wherein said metal is a foamed nickel and said conductive woven cloth is made of a material selected from a group consisting of iron and graphite.

7. The method according to claim 1, wherein, in step (c), said rolling/squeezing has a style selected from a group consisting of F-style, Z-style, S-style, and L-style.

8. The method according to claim 1, wherein said graph is at least one line continuously extending and said line is selected from a group consisting of a straight line, a wavy curve, a regular line, and an irregular line.

9. The method according to claim 1, wherein, in step (f), said pressure is a gauge pressure greater than 20 kilograms-force per square centimeter (kgf/cm.sup.2).

10. The method according to claim 1, wherein said finished plate has a volume resistivity at Z-axis not greater than 10.sup.-1 ohm meters.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The present invention will be better understood from the following detailed description of the preferred embodiment according to the present invention, taken in conjunction with the accompanying drawings, in which

[0010] FIG. 1 is the flow view showing the preferred embodiment according to the present invention;

[0011] FIG. 2 is the view showing the structure of the non-supported plastic plate;

[0012] FIG. 3 is the view showing the structure of the plastic composite plate; and

[0013] FIG. 4 is the view showing the graphic-shaping of the polar plate.

DESCRIPTION OF THE PREFERRED EMBODIMENT

[0014] The following description of the preferred embodiment is provided to understand the features and the structures of the present invention.

[0015] Please refer to FIG. 1 to FIG. 4, which are a flow view showing a preferred embodiment according to the present invention; a view showing the structure of a non-supported plastic plate; a view showing the structure of a plastic composite plate; and a view showing the graphic-shaping of a polar plate. As shown in the figures, the present invention is a method for fabricating a polar plate of a flexible plastic graphite composite, comprising the following steps: [0016] (a) Ball-milling conductive powder s11: 500~1100 parts per hundred rubber (phr) of a conductive powder composition with high carbon (>98%) and low ash (<1%) is provided to be ball-milled at least 0.5 hours (hr) at a speed of at least 200 rounds per minute (rpm) for forming a conductive powder. [0017] (b) Mixing through homogeneous stirring s12: A total of 100 phr of a thermoplastic/thermosetting resin adhesive composition is provided to mix the thermoplastic/thermosetting resin adhesive composition and the conductive powder with a solvent by stirring at least 1 hr for forming a mixture, where the thermoplastic/thermosetting resin adhesive composition is a thermoplastic resin, a thermosetting resin, or a combination of the thermoplastic resin and the thermosetting resin. [0018] (c) Calendering to form sheet s13: After directly and repeatedly calendering the mixture into a plastic sheet 1 with rigidity by rolling/squeezing, a requested thickness is obtained. [0019] (d) Removing solvent s14: The plastic sheet 1 is deposited under a temperature higher than the boiling point of the solvent for 20~50° C. (°C) to process volatilization under a normal pressure or a low-temperature vacuum to remove the solvent. [0020] (e) Stacking: (e1) An unsupported plastic plate 10 is directly formed from the plastic sheet 1, whose structure is shown in FIG. 2; or (e2) the plastic sheet 1 is repeatedly calendered to a requested thickness with at least one supporting member stacked into an upper layer together with a lower layer or a plurality of overlapping layers to form at least one layer of a plastic composite plate having supporting member, whose structure is shown in FIG. 3 with diagram (a) showing a single-layer-supported plastic composite plate 20 and diagram (b) showing a multi-layer-supported plastic composite plate 30. [0021] (f) Graphic-shaping s16: According to a requested graph, the unsupported plastic plate 10 or the single-layer- or multi-layer-supported plastic composite plate 20,30 is graphic-shaped with required heat and pressure provided on forming the requested graph to obtain a finished plate 10a,20a,30a as shown in FIG. 4, where the pressure is a gauge pressure greater than 20 kilograms-force per square centimeter (kgf/cm.sup.2) and the finished plate 10a,20a,30a has a volume resistivity at Z-axis not greater than 10.sup.-1 ohm meters.

[0022] Thus, a novel method for fabricating a polar plate of a flexible plastic graphite composite is obtained.

[0023] In a state-of-use, the conductive powder composition further comprises less than 5 weight percent (wt%) of a flame retardant.

[0024] In a state-of-use, the thermoplastic/thermosetting resin adhesive composition is a halogen crystalline resin, a halogen non-crystalline resin, a non-halogen crystalline resin, or a non-halogen non-crystalline resin; and has a heat deflection temperature (HDT) of 50~300° C.

[0025] In a state-of-use, the supporting member is a conductive carbon fabric of carbon fiber bundles with each bundle consisting at least 12,000 monofilaments; a metal with a three-dimensional hollow, such as a foamed nickel; or a conductive woven fabric, which is made of iron or graphite.

[0026] In a state-of-use, the rolling/squeezing has a F-style, Z-style, S-style, or L-style.

[0027] In a state-of-use, the graph is at least one line continuously extending and the line is a straight line, a wavy curve (as shown in FIG. 4), a regular line, or an irregular line.

[0028] Hence, no matter a supporting member is used for calendering or not, a polar plate with controllable thickness is fabricated. The polar plate is excellent in blocking the through-transmission of vanadium ions and the limit of blending ratio of conductive carbon is broken through. The longitudinal through-transmission volume resistivity (proportional resistance to thickness) is greatly improved by adjusting the blending ratio of conductive carbon for meeting the demand of conductivity. In the mean time, the present invention strengthens the rigidity required for the polar plate for providing large-area polar plate fabrication for industrial use and convenience, and provides a cooling and pressing method for patterning a composite polar plate. An integrated mold is thus obtained to replace the conventional polar plate which needs to be processed and prepared with runner.

[0029] To sum up, the present invention is a method for fabricating a polar plate of a flexible plastic graphite composite, whereno matter a supporting member is used for calendering or not, a polar plate with controllable thickness is fabricated; the polar plate is excellent in blocking the through-transmission of vanadium ions and the limit of blending ratio of conductive carbon is broken through; and the longitudinal through-transmission volume resistivity is greatly improved by adjusting the blending ratio of conductive carbon (proportional resistance to thickness) for meeting the demand of conductivity.

[0030] The preferred embodiment herein disclosed is not intended to unnecessarily limit the scope of the invention. Therefore, simple modifications or variations belonging to the equivalent of the scope of the claims and the instructions disclosed herein for a patent are all within the scope of the present invention.