Method of manufacturing a metal sheet

A method of manufacturing a porous metal sheet having pores forming a pattern, comprising the steps of supplying metal powders to a peripheral surface, of at least one pattern roller of a pair of rollers, on which a pattern including a large number of concaves is formed; dropping metal powders to the concaves and accumulating metal powders on the peripheral surface of the pattern roller except the concaves; and rolling directly the metal powders accumulated on the peripheral surface of the pattern roller by rotating a pair of the rollers. It is preferable to laminate porous metal sheets or solid metal sheets manufactured by a method other than the above-described method on the metal sheet manufactured by the above-described method.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The present invention relates to a method of manufacturing a metal sheet; a 
metal sheet manufactured by the method; and a battery comprising an 
electrode substrate composed of the metal sheet. The metal sheet has a 
large number of pores forming a pattern and/or solid metal portions having 
no pore and a required shape, thus being preferably used as electrode 
plates or component parts of a battery. It is necessary to manufacture 
pores forming a pattern and/or solid metal portions having no pore and a 
required shape without wasting metal materials. 
2. Description of the Related Art 
Conventionally, as the electrode substrate comprising a positive plate and 
a negative plate of a nickel/hydrogen battery, a nickel/cadmium battery or 
the like, principally, a nickel-plated perforated steel plate (hereinafter 
referred to as punching metal) which has pores formed on nickel-plated 
steel plate by punching is used. The punching metal is charged with an 
active substance to form the electrode plate. The electrode plate of a 
cylindrical battery accommodates belt-shaped positive and negative 
electrodes wound spirally through a separator. The electrode plate of a 
rectangular or square battery accommodates positive and negative 
electrodes layered on each other through a separator. 
With respect to the punching metal, a cold-drawn steel plate having a 
thickness of 60 .mu.m-100 .mu.m is punched to form circular pores of 1.0 
mm-2.5 mm in a required pattern on the steel plate such that the open area 
ratio thereof is 40%-50%. The steel plate is then nickel-plated to 
maintain resistance to corrosion. In this manner, the punching metal thus 
formed is used as the electrode substrate of the battery. 
As the electrode substrate consisting of positive and negative plates of a 
lithium primary battery, mainly, a metal plate (SUS, Ti) is used. The 
metal sheet is processed into a lath to which an active substance is 
applied to form an electrode plate. In a lithium secondary battery, an 
active substance is applied in a required thickness to both surfaces of a 
core material made of an aluminum foil to form a positive plate, while an 
active substance is applied to both surfaces of a core material made of a 
copper foil to form a negative plate. 
As the substrate of an air electrode to be used as the positive electrode 
of an air zinc battery, mainly, a metal screen (nickel-plated SUS mesh or 
the like) is used. An active substance is applied to the metal screen to 
form the electrode plate of the battery. In a lead storage battery which 
is used as a car battery and attracting public attention, cast lattice or 
expanded lattice consisting of lead alloy (Pb/Sb alloy, Pb/Ca alloy, 
Pb/Ca/Sn alloy or the like) is used. An active substance is applied to the 
lattice to form the electrode plate of the storage battery. 
Further, in recent years, as the electrode substrate of the nickel/hydrogen 
battery, the nickel/cadmium battery, and the lithium primary battery, 
porous metal sheets are used. The porous metal sheets are formed as 
follows: Foamed material made of resin, nonwoven sheets made of resin or 
mesh sheets made of resin are chemically plated to make them electrically 
conductive, and electroplated. Then, they are baked for resin removal and 
sintering. 
The punching metal formed by forming pores on the metal plate to use it as 
the electrode substrate of the nickel hydrogen battery or the like has the 
following disadvantages: 
1) Because pore-making processing is carried out by pressing, the portion 
corresponding to pores are cut out from the metal plate. Thus, a large 
quantity of a material is wasted. For example, supposing that an open area 
ratio of the punching metal is 50%, half of the material is wasted, which 
leads to the production of expensive electrode substrates. 
2) Pressing cost required to make pores on the metal plate is high. 
3) Because pores are made on the metal plate two-dimensionally, the open 
area ratio thereof is not more than 50%, which means that there is a 
limitation in the charge amount of an active substance. 
4) In order to increase the capacity of a battery, it is preferable to use 
a thin substrate and having a large open area ratio so as to increase the 
charge amount of an active substance. But for the above-described reason, 
there is a limitation in the open area ratio. When the thickness of the 
metal plate is made to be smaller from 60-80 .mu.m adopted currently to 
less than 60 .mu.m, the material cost is high and moreover, the metal 
plate is plated with a low efficiency. Thus, the processing cost becomes 
high. Further, when the metal plate is thin, it is likely that the metal 
plate is strained or a burr is formed thereon when pores are formed by 
press-cut. 
In a lath processed from a metal plate to use it as the electrode substrate 
of the lithium primary battery, the metal plate is strained and warped by 
stress which has concentrated locally when it is processed into the lath, 
thus becoming uneven. The lath, without cutting for lower costs, is 
corrected for strain and warp by means of a leveler and an active 
substance is applied thereto before it is cut to a standard size. When the 
lath is cut, the strain which occurred in processing the metal plate into 
the lath is regenerated and burrs are liable to be generated. Therefore, 
when the lath is coiled through a separator, a leak is likely to occur due 
to the burr and the strain. It is preferable that in the lithium primary 
battery, the electrode substrate has a possible largest open area ratio so 
that it has a high strength. The lath currently used has an open area 
ratio of 63% at maximum in consideration of its structure. The processing 
cost increases as the open area ratio becomes greater. 
Because pores are formed on a metal screen, cast lattice, and expanded 
lattice to be used as the substrate of an air zinc battery or a lead 
storage battery, there is a limitation in the open area ratio thereof 
because the open area are formed in two-dimensions and further, the 
material cost is increasingly high as the thickness thereof is smaller. In 
addition, the metal screen is plated with a low efficiency. Thus, the 
processing cost becomes high. The expanded lattice has problems similar to 
those of the punching metal or the lath. 
The porous metal sheet developed to replace the punching metal and the lath 
is formed by plating a base material made of resin and baking the plated 
base material to remove resin and sintering to provide a great open area 
ratio. Thus a greater amount of an active substance can be applied to the 
porous metal sheet. But the porous metal sheet has a lower tensile 
strength than the punching metal. Therefore, in applying the active 
substance to the porous metal sheet while it is being pulled on an 
applying line, the line cannot be operated at a high speed. That is, the 
porous metal sheet cannot be produced at a high efficiency. Further, to 
plate the base material made of resin having no electric conductivity, it 
is indispensable to impart electric conductivity thereto as a primary 
processing by carrying out such as chemical plating which is performed in 
a complicated process. Even after the base material of the porous metal 
sheet is allowed to be electrically conductive, it does not have a 
favorable electric conductivity. Thus, the porous metal sheet is 
manufactured at a high cost due to a low productivity in electroplating 
the base material and the consumption of a great electric power. 
The aluminum foil and the copper foil are used as the electrode substrate 
of the lithium secondary battery. While the solid metal foil made of the 
aluminum foil and the copper foil is being pulled, an active substance is 
applied to both surfaces thereof in the same thickness. Because the foil 
has a low strength, it cannot be pulled at a high speed and further, it is 
not easy to apply the active substance in the same thickness to the upper 
and lower surfaces of the foil. When the active substance is applied 
nonuniformly to the foil, a part thereof is not active in discharge and 
charge times. Hence, the active substance cannot be utilized with a high 
efficiency in a battery case. 
The conditions required for the electrode substrate are as described below. 
The conventional electrode substrates do not satisfy all of the 
conditions. 
(a) The substrate has a high electric conductivity. That is, the substrate 
is required to have a smooth electricity-collecting action, with a low 
internal resistance set. 
(b) The substrate has a high open area ratio. That is, it allows a large 
amount of an active substance to be applied thereto, thus increasing the 
capacity of a battery. 
Even though it has a high open area ratio and thus allows a large amount of 
the active substance to be applied thereto, a electricity-collecting 
action cannot be accomplished smoothly if the area of contact between the 
active substance and metal is small. Therefore, the substrate is required 
to have a high open area ratio and the area of contact between the active 
substance and metal is large. 
(c) The substrate is thin and has a high tensile force. That is, if the 
substrate is thin, it can be accommodated in a battery case in a large 
amount, thus enhancing the capability of the battery. If the substrate is 
thin, its tensile force becomes low. Consequently, the pulling speed of 
the substrate is slow in applying the active substance thereto, which 
results in a low productivity. Accordingly, the substrate is thin and has 
a high tensile force. 
(d) The substrate has an electricity-collecting lead and can be processed 
into a required shape at a low cost. 
SUMMARY OF THE INVENTION 
The present invention has been made in view of the above-described 
problems. It is accordingly an object of the present invention to satisfy 
the above-described demand. It is another object of the present invention 
to provide a method of manufacturing a thin metal sheet having a high 
electrical conductivity and having a high open area ratio provided without 
wasting material so as to improve the capability of a battery by a fewer 
number of manufacturing processes and at a low cost. It is a further 
object of the present invention to provide a solid metal sheet (without 
pores) with a required shape and which is used as component parts of the 
battery. 
In order to solve the above-described problems, there is proposed a method 
of manufacturing a porous metal sheet having pores forming a pattern, 
comprising the steps of supplying metal powders to a peripheral surface, 
of at least a pattern roller of a pair of rollers, on which a pattern 
consisting of a large number of concaves is formed; dropping metal powders 
to the concaves and accumulating metal powders on the peripheral surface 
of method eliminates the need for the provision of a punching process or a 
plating manufacturing process. Because metal powders can be compressed and 
rolled by the rollers, they can be integrated into each other at a 
temperature lower than the melting point of a metal even though the 
melting point of the metal is high, and metal powders of different kinds 
can be mixed with each other. 
Further, there is provided a method of manufacturing a porous metal sheet 
having a metal solid portion having no pore and a required shape, 
comprising the steps of supplying metal powders to a peripheral surface, 
of at least of a pattern roller of a pair of rollers, on which a pattern 
consisting of a large number of concaves is formed on a portion except a 
continuous portion corresponding to a required shape dropping metal 
powders to the concaves and accumulating metal powders on the peripheral 
surface of the pattern roller except the concaves; and rolling directly 
the metal powders accumulated on the peripheral surface of the pattern 
roller by rotating a pair of the rollers. 
As described above, because the concaves are formed on the portion of the 
pattern roller other than the continuous portion of the required shape, a 
metal sheet having solid portions can be continuously formed thereon. In 
this manner, the metal sheet consisting of the solid portions having the 
required shape can be obtained without the pattern roller except the 
concaves; and rolling directly the metal powders accumulated on the 
peripheral surface of the pattern roller by rotating a pair of the 
rollers. 
According to the above-described method, when metal powders are supplied to 
the surface of the pattern roller having the concaves formed thereon, 
metal powders drop to the concaves of the peripheral surface of the 
pattern roller and the concave-unprovided portion thereof. The metal 
powders which have dropped to the concaves are not rolled, but those which 
have dropped to the concave-unprovided portion of the peripheral surface 
of the pattern roller are accumulated in a certain thickness. When a pair 
of the rollers is rotated in this state, the metal powders which have 
dropped to the concave-unprovided portion of the pattern roller are 
directly rolled between the rollers, while the metal powders which have 
dropped to the concaves can be collected. Therefore, the metal powders 
corresponding to pores to be formed on the metal sheet are not wasted but 
can be recycled. Further, the thickness of the layer of metal powders can 
be adjusted by adjusting the amount of metal powders to be supplied to the 
surface of the pattern roller. In this manner, the thickness of the metal 
sheet to be manufactured can be easily adjusted to as small as about 30 
.mu.m. The method of the present invention allows the metal sheet to be 
manufactured in a simple process. That is, the wasting material. 
In the manufacturing method , the pattern roller may be heated to roll 
metal powders . When powders of Au, Ag, Sn, Pb, In or C are used, it is 
not necessary to heat the pattern roller. 
It is possible to roll metal powders by a pair of flat rollers each having 
a smooth peripheral surface again after the metal powders are rolled by a 
pair of the rollers including the pattern roller. The pair of the flat 
rollers may be heated. 
That is, metal powders may be rolled again by a pair of the flat rollers 
having the normal room temperature or heated to a certain temperature 
after they are rolled by a pair of the rollers including the pattern 
roller having the normal room temperature or heated to a certain 
temperature. It depends on the kind of metal powders which are used 
whether metal powders are rolled at the normal room temperature or at a 
temperature higher than the normal room temperature, and whether they are 
rolled again by a pair of the flat rollers after they are rolled by a pair 
of the rollers including the pattern roller. Preferably, a pair of the 
rollers including the pattern roller and a pair of the flat rollers are 
heated to 300.degree. C.-400.degree. C. The air in the periphery thereof 
may be heated to heat them. 
After the metal powders are rolled by a pair of the rollers including the 
pattern roller or a pair of the flat rollers, the metal powders may be 
sintered. Metal powders are sintered in a nonoxidizing atmosphere at a 
temperature, for example, higher than 1000.degree. C. for about 15 
minutes. It is possible to sinter and roll the metal powders by a pair of 
the flat rollers appropriately and repeatedly as desired, and regardless 
of order after the metal powders are compressed by a pair of the rollers 
including the pattern roller. 
Preferably, metal powders are temper-rolled after the metal powders are 
rolled by a pair of the rollers including the pattern or a pair of the 
flat rollers or after the metal powders are sintered. It is preferable to 
roll the metal powders into a metal sheet having a thickness of 2-500 
.mu.m by means of a pair of tempering rollers. 
The metal powders are supplied to the pattern roller by spreading them from 
above the pattern roller. A knife installed alongside the pattern roller 
adjusts the thickness of the metal powders to a required one. For 
spreading the metal powders, a sieve installed above the pattern roller is 
vibrated to spread the metal powders to the upper surface of the pattern 
roller. Instead, an inclined belt is provided above the pattern roller to 
feed the metal powders to the pattern roller, with a scraping knife 
provided at the lower end of the belt for scraping the metal powders. 
As another method of supplying the metal powders to the pattern roller, the 
metal powders are supplied to a steel belt. The belt is fed to the gap 
between a pair of the rollers. The metal powders supplied to the 
concave-unprovided portion of the pattern roller are compressed in 
cooperation with the pattern roller and the flat roller. It is possible to 
supply paste-like metal powders to the belt and feed it to the pattern 
roller, and convey to a pair of the rollers after the paste-like metal 
powders are dried and greased. 
According to another aspect of the present invention, a method of 
manufacturing a porous metal sheet, comprising the steps of layering, on 
at least one surface of a metal sheet manufactured by the method according 
to any one of above mentioned methods, one or more of the metal sheet 
manufactured by the method according to any one of above-mentioned 
methods, a different kind of porous metal sheet, a different kind of solid 
metal sheet or solid metal foil having no pore, a metal sheet or a metal 
foil each having a large number of pores formed thereon, a metal mesh 
sheet, a metal screen, a three-dimensional reticulate foamed sheet, a 
porous fibrous resin sheet or a porous fibrous mesh sheet or two or more 
kinds of the sheets; and integrating the sheets by plating, evaporating 
the sheets layered on the metal sheet or bonding the sheets to each other. 
That is, a metal sheet manufactured by the method of the present invention 
is layered on one or both surfaces of a metal sheet manufactured by 
supplying metal powders to a pair of the rollers including the pattern 
roller. Otherwise, a metal sheet or a metal foil each having a large 
number of pores formed thereon is layered on one or both surfaces of the 
metal sheet manufactured by using the said pattern roller. The sheet 
consisting of the sheets layered on each other is electroplated to 
integrate them with each other. Further, a three-dimensional reticulate 
foamed sheet, a porous fibrous resin sheet such as a nonwoven sheet or a 
mesh sheet layered on the metal sheet manufactured by the pattern roller 
is electroplated to allow the foamed sheet, the nonwoven sheet or the mesh 
sheet to be a porous metal sheet and simultaneously integrate the porous 
metal sheet and the metal sheet manufactured by the pattern roller with 
each other. In this manner, the metal sheet having a layered structure is 
manufactured. 
Further, there is provided a metal sheet manufactured by the method 
described in any one of the above mentioned methods, and a metal sheet of 
an electrode substrate of a battery is manufactured by the method 
described. The metal sheet manufactured by the above method can be allowed 
to have a thickness of 2-500 .mu.m and favorably, 10-60 .mu.m. The open 
area ratio of the porous metal sheet can be adjusted to 10-99% by 
adjusting the area of the concaves to be formed on the pattern roller. 
When the porous metal sheet is used as an electrode substrate of a 
battery, the open area ratio thereof can be increased to 99% for 
increasing the application amount of an active substance. 
Metal powder constituting the metal sheet consists of Ni, Al, Cu, Fe, Ag, 
Zn, Sn, Pb, Sb, Ti, In, V, Cr, Co, C, Ca, Mo, Au, P, W, Rh, the oxide 
thereof, the sulfide thereof, a compound of any one of the metals or a 
mixture of the metals. 
The size of the metal powders is 100 .mu.m-0.1 .mu.m. The shape of the 
metal powders are spike-shape, filament-shape, sphere-shape, flake-shape, 
branch-shape or the like. As the electrode substrate of a lithium battery, 
metal powders containing the spike-shaped ones and branch-shaped ones or 
the like mixed with each other can be preferably used. 
The pores of the metal sheet can form any desired pattern by forming 
concaves of a desired shape on the pattern roller. For example, the shape 
of the pores of the metal sheet can be punched pore-shaped, reticulate, 
honeycomb-shaped, lath-shaped, lattice-shaped, expanded-shaped, 
screen-shaped or lace-shaped. 
The metal sheet may have a lead portion in which pores are not formed at 
regular intervals. 
The metal sheet of the present invention consists of a porous metal sheet 
by layering, on at least one surface of a metal sheet described in any one 
of the said methods, the metal sheet manufactured by using the pattern 
roller, a solid metal sheet, a solid metal foil, a metal sheet or a metal 
foil each having a large number of pores formed thereon, metal mesh sheet, 
a metal screen, a three-dimensional reticulate foamed sheet, a porous 
fibrous resin sheet, a mesh sheet, and/or a porous metal sheet which is 
manufactured by baking the sheet to remove resin and sintering after 
plating, evaporating, coating fine metal powders or spray-coating melted 
metal a three-dimensional reticulated foamed sheet, a porous fibrous resin 
sheet, a mesh sheet, a sheet composed by layering those sheets on each 
other or two or more kinds of those sheets. 
Further, a three-dimensional reticulate porous metal sheet or a porous 
fibrous metal sheet is layered on both surfaces of the metal sheet 
described in any one of the said methods; the metal sheet manufactured by 
using the pattern roller is sandwiched between the two three-dimensional 
reticulate porous metal sheets or between the two porous fibrous metal 
sheets; and a diameter of a pore or an open area ratio of the two 
three-dimensional reticulate porous metal sheets, and a diameter of a 
metal fiber and an open area ratio of the two porous fibrous metal sheets 
layered on both surfaces of the metal sheet are different each other. In 
the above layered metal sheet, the strength and pulling strength of the 
outer side thereof is differentiated from the inner side thereof. When an 
active substance-applied porous metal sheet having such a layered 
structure is used as an electrode plate of a battery, the metal is 
provided in the battery in such a manner that the side thereof having a 
higher pulling strength is positioned at the outer side in coiling it 
spirally in the battery. In such an electrode plate, the metal sheet can 
be prevented from being cracked easily. 
Further, there is proposed a battery in which the metal sheet manufactured 
by any one of the said methods is used as an electrode substrate. 
Further more, there is provided a roller having a pattern roller having 
concaves formed thereon and used in the manufacturing method as above 
described. 
That is, when a pair of the rollers having the pattern roller in the above 
described is used, the porous metal sheet can be manufactured easily, and 
the porous metal sheet providing a solid portion having a required shape 
by cutting the metal sheet can be manufactured.

DESCRIPTION OF THE PREFERRED EMBODIMENTS 
The embodiments of the present invention will be described below with 
reference to drawings. 
FIGS. 1 through 5 show the first embodiment of the present invention. In 
the first embodiment, a metal sheet of a single layer having circular 
pores formed thereon in a pattern is manufactured. The circular pores are 
formed not by punching but by the method according to the present 
invention which will be described below. 
FIG. 1 shows a pair of pressure rollers, namely, a pattern roller 1 and a 
flat roller 2. As shown in FIGS. 1 and 2, the pattern roller 1 has, on its 
peripheral surface, a plurality of hemispherical concaves 1a formed 
lengthwise and widthwise at regular intervals and each having a 
predetermined diameter. The flat roller 2 has a smooth surface. Portions 
each having a predetermined width L1 having the concaves 1a formed thereon 
are spaced at regular intervals of L2. As shown in FIG. 5, the pattern 
roller 1 comprises the portions each having the width L1 for forming 
porous sheet sections 10 and the portions each having the width L2 for 
forming lead sections 11 consisting of a solid portion. Although the 
concaves 1a are not formed on the flat roller 2, concaves may be formed 
thereon. In the first embodiment, the diameter and the length of the 
effective surface of each of the pattern roller 1 and the flat roller 2 
are 150 mm and 100 mm, respectively. 
As shown in FIG. 3, a vibrating device 4 vibrates a sieve 3 supported 
thereby and positioned above the pattern roller 1, in a left-and-right 
direction, having a mesh portion 3a formed on the bottom surface thereof. 
Metal powders (P) are spread over the upper surface of the pattern roller 
1 by sieving them. A predetermined amount of metal powders (P) is supplied 
to the sieve 3 from a hopper 5 through a feeder 6 which feeds a 
predetermined quantity of the metal powders (P) per unit time period. 
Knives 7A and 7B are provided below a portion (A) of contact between the 
pattern roller 1 and the flat roller 2, with the knives 7A and 7B in 
contact with the peripheral surface of the pattern roller 1 and the flat 
roller 2, respectively. A suction device 8 for sucking metal powders which 
have remained on the peripheral surface of the pattern roller 1 is 
provided below the pattern roller 1 at the downstream side in the 
rotational direction of the pattern roller 1. 
In the first embodiment, nickel powders in the shape of a spike and having 
diameters 2-7 .mu.m are spread directly to the upper surface of the 
pattern roller 1 in the order of the hopper 5, the feeder 6, and the sieve 
3. As shown in FIG. 4 (A), the metal powders (P) which have dropped to the 
concaves 1a are prevented from being accumulated to the level of the 
peripheral surface 1b of the pattern roller 1, i.e., they do not project 
from the peripheral surface 1b. The metal powders (P) accumulate to a 
predetermined thickness on the peripheral surface 1b to form a layer 
having the predetermined thickness. 
Upon rotation of the pattern roller 1 and the flat roller 2 in this state, 
at the portion of contact (A) between the pattern roller 1 and the flat 
roller 2, the metal powders (P) on the peripheral surface 1b of the 
pattern roller 1 are compressed by the flat roller 2 at a load of 15 tons, 
thus being rolled as a thin compressed metal sheet (S). As shown in FIG. 4 
(B), because the metal powders (P) accommodated inside the concaves 1a do 
not project from the peripheral surface 1b of the pattern roller 1, they 
are not compressed by the flat roller 2. With the rotation of the pattern 
roller 1, they pass the contact point (A), thus dropping from the concaves 
1a when the concaves 1a turn downward. With the continuous rotation of the 
pattern roller 1 and the flat roller 2, the compressed metal sheet (S) 
thus formed at the contact point (A) becomes out of contact with the 
peripheral surface 1b of the pattern roller 1 and that of the flat roller 
2, thus being fed downstream, as shown in FIG. 3. If the compressed metal 
sheet (S) has attached to the peripheral surface 1b of the pattern roller 
1 or that of the flat roller 2, the knife 7A or the knife 7B releases it 
therefrom. 
The metal powders (P) accommodated inside the concaves 1a fall owing to 
their own weight caused by the rotation of the pattern roller 1. If they 
have remained in the concaves 1a, the suction device 8 sucks them. The 
metal powders (P) which have dropped from the concaves 1a and been sucked 
to the suction device 8 are returned to the hopper 5 and recycled so that 
the metal powders (P) are not wasted. 
The metal powders (P) are rolled by the pattern roller 1 and the flat 
roller 2 at the normal room temperature. As shown in FIG. 5, the 
compressed metal sheet (S) formed by rolling the metal powders (P) and fed 
downstream from the contact point (A) comprises the porous sheet sections 
10 corresponding to the portions of the pattern roller 1 having the width 
L1; and the belt-shaped lead sections 11 consisting of solid portion and 
corresponding to the portions of the pattern roller 1 having the width L2. 
Each of the porous sheet sections 10 comprises pores 13 corresponding to 
the concaves 1a of the pattern roller 1; and a portion 14 corresponding to 
the peripheral surface 1b of the pattern roller 1 and surrounding the 
pores 13. 
As shown in FIG. 3, the metal sheet (S) comprising the porous sheet 
sections 10 and the lead sections 11 alternating with each other is 
continuously fed into a sintering oven 15 in which it is sintered in a 
nonoxidizing atmosphere at 750.degree. C. for about 15 minutes. In the 
first embodiment, the metal sheet (S) was contracted by 1-2% as a result 
of the sintering. 
After the metal sheet (S) is sintered, it is rolled as follows: It is 
passed through a pair of flat rollers 16 and 17 heated to 300.degree. 
C.-400.degree. C. by applying a load of 5 tons thereto to roll it again. 
Then, the metal sheet (S) is continuously fed into a sintering oven 18 to 
sinter it again in a nonoxidizing atmosphere at 1,150.degree. C. for about 
15 minutes, with the result that it was contracted by 0.1%-0.2%. 
After the metal sheet (S) is sintered in the sintering oven 18, it is 
passed between a pair of tempering rollers 19A and 19B to adjust the 
thickness of the metal sheet (S) to a predetermined thickness. Then, the 
metal sheet (S) is wound around a roller as a coil (C). 
The porous metal sheet which is preferably used as the electrode substrate 
of a battery is manufactured by the above-described process. The metal 
sheet of the first embodiment has a thickness of 30 .mu.m and an open area 
ratio of 57%. 
In the first embodiment, the metal powders (P) are spread directly over the 
pattern roller 1 from the sieve 3. But the following method may be 
adopted: As shown in FIG. 6 (A), an inclined belt 20, a doctor knife 21, 
and a scraping knife 22 are provided. That is, the belt 20 is provided 
above the pattern roller 1 so as to supply the metal powders (P) from the 
hopper 5 to the belt 20. A predetermined amount of the metal powders (P) 
is supplied to the pattern roller 1 through the doctor knife 21 provided 
at an upper position of the belt 20 such that it is positioned alongside 
the belt 20. The scraping knife 22 provided at the lower end of the belt 
20 such that it is positioned alongside the belt 20 is used to supply the 
metal powders (P) from the belt 20 to the upper surface of the pattern 
roller 1. 
Further, as shown in FIG. 6 (B), similarly to the manner shown in FIG. 6 
(A), it is possible to mix organic adhesive agent with the metal powders 
(P) in the hopper 5 to form paste and supply it to the belt 20; supply a 
predetermined amount of the metal powders (P) to the pattern roller 1 
through the doctor knife 21; dry and degrease the paste by means of a 
drying means 23 installed at an intermediate position of the belt 20; and 
supply it to the upper surface of the pattern roller 1 through the 
scraping knife 22. 
Further, as shown in FIG. 6 (C), a conduit 24 may be connected with the 
take-out opening of the hopper 5 at the lower end thereof. The conduit 24 
is vibrated by a vibration means 25 to supply the metal powders (P) from 
the take-out opening of the hopper 5 to the upper surface of the pattern 
roller 1. 
FIG. 7 shows the second embodiment of the present invention. The pattern 
roller 1 and the flat roller 2 are vertically provided, with an endless 
steel conveyor belt 30 sandwiched therebetween. The sieve 3 of the first 
embodiment is provided at the upstream side of the pattern roller 1 and 
the flat roller 2 in the feeding direction so that the sieve 3 is vibrated 
to supply the metal powders (P) to the upper surface of the belt 30 in a 
predetermined thickness. 
When the metal powders (P) supplied over the belt 30 have reached the 
contact point (A) between the rollers 1 and 2, they enter the concaves 1a 
and remain on the belt 30 without being compressed by the pattern roller 
1, whereas the metal powders (P) which have dropped over the peripheral 
surface 1b of the pattern roller 1 are compressed and rolled at a load of 
12 tons by the flat roller 2. Thus, as in the case of the manner shown in 
FIG. 5, the metal sheet (S) formed by rolling the metal powders (P) and 
having the porous sheet sections 10 and the lead sections 11 is fed 
downstream from the contact point (A). 
The metal powders (P) which are present on the concaves 1a are sucked by a 
suction device 31 installed on the belt 30 which is fed to the downstream 
side in the feeding direction of the compressed metal sheet (S). When the 
metal powders (P) have still attached to the belt 30, a cleaning roller 32 
installed at the downstream side of the suction device 31 is brought into 
contact with the belt 30 to remove them therefrom. The metal powders (P) 
which have attached to the pattern roller 1 are removed therefrom by the 
suction device 31 and the knife 37. Because the metal powders (P) which 
have remained on the belt 30 and the pattern roller 1 are not compressed, 
they are recycled, similarly to the first embodiment. 
The metal sheet (S) formed by the rollers 1 and 2 and fed downstream from 
the contact point (A) is continuously fed into the sintering oven 15 to 
sinter it in a nonoxidizing atmosphere at 750.degree. C. for about 15 
minutes. In the second embodiment, the metal sheet (S) was contracted by 
2%-3% as a result of the sintering. After the metal sheet (S) is sintered, 
it is rolled as follows: It is passed through the flat rollers 16 and 17 
by applying a load of 5 tons thereto to roll it again. Then, the metal 
sheet (S) is continuously fed into the sintering oven 18 to sinter it 
again in a nonoxidizing atmosphere at 1,150.degree. C. for about 15 
minutes, with the result that it was contracted by 0.5%. Thereafter, it is 
passed between a pair of the tempering rollers 19A and 19B to adjust the 
thickness of the metal sheet (S) to a predetermined thickness. Then, the 
metal sheet (S) is wound around a roller as a coil (C). The porous metal 
sheet of the second embodiment thus formed has a thickness of 28 .mu.m and 
an open area ratio of 57%. 
FIGS. 8 (A)-8 (C) show modifications of the method of supplying metal 
powders to the belt 30. As shown in FIG. 8 (A), the metal powders (P) are 
supplied directly to the upper surface of the belt 30 and the amount of 
the metal powders (P) is adjusted by a doctor knife 34 placed over the 
belt 30 so as to feed a constant amount thereof to the pattern roller 1. 
As shown in FIG. 8 (B), it is possible to supply paste-like metal powders 
over the belt 30; adjust the amount thereof by means of the doctor knife 
34; and dry and degrease it by means of a drying means 35; and supply it 
to the surface of the pattern roller 1. Further, as shown in FIG. 8 (C), a 
conduit 36 may be connected with the take-out opening of the hopper 5 at 
the lower end thereof to supply the metal powders (P) from the take-out 
opening of the hopper 5 to the belt 30. In each of the above 
modifications, a knife 37 and a suction device 38 are installed over the 
peripheral surface of the pattern roller 1 to remove metal powders which 
have remained thereon. 
FIGS. 9 (A)-9 (D) show metal sheets manufactured by compression and 
rolling, with the concaves 1a formed on the pattern roller 1 shaped into 
quadrangular, hexagonal, rhombic, and triangular. Pores of a porous metal 
sheet S-1 shown in FIG. 9 (A) form the shape of a lattice; Pores of a 
porous metal sheet S-2 shown in FIG. 9 (B) form the shape of a honeycomb; 
Pores of a porous metal sheet S-3 shown in FIG. 9 (C) form the shape of a 
lath; and pores of a porous metal sheet S-4 shown in FIG. 9 (D) are in the 
shape of triangles arranged lengthwise and widthwise. The shape of pores 
to be formed on the porous metal sheet can be determined according to the 
shape of the concaves 1a formed on the pattern roller 1. Further, the open 
area ratio of the porous metal sheet can be adjusted to a desired one. 
The method of manufacturing the lath-shaped porous metal sheet S-3 shown in 
FIG. 9 (C) is described below. Using an apparatus similar to that shown in 
FIG. 8 (A), the concaves 1a of the pattern roller 1 are rhombic. The 
hopper is supplied with electrolyzed branch-shaped copper powders having 
diameters 10-40 .mu.m. The copper powders are supplied to the belt 30, 
with the doctor knife 34 adjusting the amount thereof to a predetermined 
amount so as to supply them in a predetermined amount directly to the 
upper surface of the pattern roller 1. The copper powders are compressed 
by the rollers 1 and 2 at the normal room temperature at a load of 4 tons. 
Then, a metal sheet having pores in the shape of a lath is fed downstream, 
and sintered in a nonoxidizing atmosphere at 960.degree. C. for about 10 
minutes. Then, it is passed through a pair of flat rollers by applying a 
load of 2 tons thereto to roll and temper it again. The resulting porous 
metal sheet has a thickness of 20 .mu.m, an open area ratio of 40%, and 
tensile force of 2.5 kgf/20 mm. 
The third embodiment relates to a method of manufacturing a metal sheet 
having circular solid metal portions. As shown in FIG. 10 (A), a pattern 
roller 1' has, on its peripheral surface, a circular portion 1'c having a 
required shape; a concave portion 1'a shown by oblique lines; and a 
connection portion 1'd connecting the circular portions 1'c with each 
other. 
Using the pattern roller 1', metal powders are dropped to the concave 
portion 1'a, and metal powders on the circular portion 1'c and the 
connection portion 1'd are compressed. As a result, a metal sheet S' 
having a circular solid metal portion 40 connected with a connection 
portion 41 is formed. Similarly to the first and second embodiments, the 
metal sheet S' is sintered and rolled by tempering rollers. The metal 
sheet S' manufactured by rolling and sintering is cut at the connection 
portion 41 thereof to provide a metal sheet S" to be used as component 
parts of a circular battery, as shown in FIG. 10 (C). 
FIG. 11 shows a metal sheet S' manufactured as a modification of the metal 
sheet of the third embodiment by a method similar to that of the third 
embodiment. In the metal sheet S', rectangular portions shown by oblique 
lines in FIG. 11 (A) are unrequired portions 45, and portions other than 
the unrequired portions 45 are cut as shown by one-dot chain line of FIG. 
11 (A) to provide a metal sheet S" to be used as an L-shaped lead of a 
battery consisting of a solid metal portion shown in FIG. 11 (B). 
In the third embodiment shown in FIGS. 10 and the modification shown in 
FIG. 11, the portions to be cut off from a material metal sheet is formed 
as pores on the pattern roller. Thus, a material can be used without 
wasting a large amount of metal. Further, the metal sheet consisting of 
the solid portion can be allowed to be thin as desired. The metal sheet 
consisting of the solid portion can be preferably used in addition to 
component parts of a battery. 
In the first through third embodiments, after metal powders are rolled by 
means of the rollers 1 and 2 at the normal room temperature, the resulting 
metal sheet is sintered in the sintering oven 15; the sintered metal sheet 
is rolled again by the flat rollers 16 and 17; the rolled sheet is 
sintered again by the sintering oven 18. Metal powders of Au, Ag, Sn, Pb, 
In, and C are not required to be sintered, but may be only rolled. 
As described above, in the process of manufacturing the porous metal sheet 
(S) or the metal sheet S' having the solid portion are formed by rolling 
metal powders at the normal room temperature by means of the pattern 
roller 1 and the flat roller 2. In addition, the metal sheet (S) or the 
metal sheet S' can be formed in various processes depending on the kind of 
metal powders. 
That is, thin metal sheets can be processed from metal powders in 
appropriate combinations of the following six processes. 
1) Rolling by means of rollers comprising a pattern roller. 
2) Rolling by means of rollers including a heated pattern roller 
3) Re-rolling by means of a flat roller 
4) Re-rolling by means of a heated flat roller 
5) Sintering in a sintering oven 
6) Tempered rolling by means of flat rollers 
In the rolling to be carried out by the roller having the heated pattern 
roller of the process (2), at least the pattern roller 1 is heated to 
300.degree. C.-400.degree. C. previously and a predetermined amount of 
metal powders is supplied to the upper surface of the pattern roller 1, 
similarly to the first through third embodiments. In this case, the metal 
powders are rolled at the portion (A) of contact between the pattern 
roller 1 and the flat roller 2 at a load of 7 tons to form a metal sheet. 
Instead of heating the pattern roller 1 itself, the temperature of the 
atmosphere in which the roller is provided may be heated to 300.degree. 
C.-400.degree. C. Further, the surface of the pattern roller may be heated 
to a high temperature. 
When the heated pattern roller 1 is used, a metal sheet may be manufactured 
by only rolling metal powders. Otherwise, as shown in FIG. 12, the metal 
sheet is sintered in a nonoxidizing atmosphere at 1,150.degree. C. for 
about 15 minutes, and tempered by the tempering rollers 19A and 19B to 
manufacture a porous metal sheet. The resulting porous metal sheet has a 
thickness of 34 .mu.m and an open area ratio of 57%. 
The combination of the processes (1)-(6) for manufacturing the porous metal 
sheet is as shown below. 
(a) Process (1) or process (2) 
(b) Process (3), (4), (5) or (6) is carried out subsequently to process (1) 
or (2). For example, (1)+(3), (2)+(4), (1)+(6), (2)+(6), and the like. 
(c) Process (3) or (4) is carried out subsequently to process (1) or (2), 
and then, process (5) or (6) is carried out. For example, (1)+(3)+(5), 
(2)+(3)+(6), (1)+(4)+(5), and the like. 
(d) Process (3) or (4) is carried out subsequently to process (1) or (2), 
and then, processes (5) and (6) are carried out sequentially. For example, 
(1)+(3)+(5)+(6), (2)+(4)+(5) +(6), and the like. 
(e) Process (3) or (4) is carried out subsequently to process (1) or (2), 
and then, process (5) is carried out. Finally, process (3) or (4) is 
carried out. For example, (1)+(3)+(5) +(4), (2)+(3)+(5)+(3), and the like. 
(f) Process (3) or (4) is carried out subsequently to process (1) or (2), 
and then, process (5) is carried out. Then, process (3) or (4) is carried 
out. Finally, process (5) or (6) is carried out. For example, 
(1)+(3)+(5)+(4)+(5), (2)+(4)+(5)+(3) +(6), and the like. 
(g) Process (3) or (4) is carried out subsequently to process (1) or (2), 
and then, process (5) is carried out. Then, process (3) or (4) is carried 
out. Thereafter, processes (5) and (6) are carried out sequentially. For 
example, (1)+(3)+(5) +(4)+(5)+(6), (2)+(4)+(5)+(3)+(5)+(6), and the like. 
FIGS. 13 (A)-13 (G) show metal sheets (SS) manufactured by the method 
according to the fourth embodiment. The metal sheets (SS) are formed by 
layering one or more sheets or two or more kinds of those sheets described 
below on one or both surfaces of the porous metal sheet (S) manufactured 
by the method of the first or second embodiment and then, by plating, 
evaporating or bonding the layered a sheet or sheets so as to integrate 
them with the porous metal sheet (S): 
(1) The porous metal sheet (S) manufactured by the method of the first or 
second embodiment; That is, the porous metal sheets (S) are layered on 
each other. 
(2) Porous metal sheets manufactured by methods other than those of the 
present invention; That is, a plurality of porous metal sheets formed 
according to the inventions filed previously by the present applicant are 
appropriately used. 
(3) Solid metal plates or solid metal foils; 
(4) Metal plates or metal foils having a large number of pores formed 
thereon; 
(5) Three-dimensional reticulate foamed sheets made of such as sponge, 
porous fibrous resin or mesh sheets: 
A metal sheet (SS) having a layered structure shown in FIG. 13 is described 
below. Before obtaining a three-dimensional reticulate porous metal sheet 
50, a sheet of polyurethane sponge is bonded to one surface of the porous 
metal sheet (S) with adhesive agent. Then, the sheet of polyurethane 
sponge and the porous metal sheet (S) integrated therewith are plated and 
then, heated for resin removal and sintering to process the polyurethane 
sponge into the three-dimensional reticulate porous metal sheet 50 
integrated with the metal sheet (S). 
It is possible to laminate, on one surface of the porous metal sheet (S), 
the three-dimensional reticulate porous metal sheet 50 formed by plating 
and heating the three-dimensional reticulate foamed sheet of polyurethane 
sponge for resin removal and sintering, and then plating the layered sheet 
of the three-dimensional reticulate porous metal sheet 50 and the porous 
metal sheet (S) to integrate both sheets with each other. Instead of the 
three-dimensional reticulate resin sheet, needless to say, it is possible 
to use porous metal sheets formed by plating sheets described below and 
baking them for resin removal and sintering: Porous fibrous organic sheets 
made of synthetic resin, natural fiber, cellulose or paper having the 
shape of such as fabric, knit, nonwoven fabric, felt, screen, expanded, 
lath, punched pores-like; organic mesh sheets made of synthetic resin, 
natural fiber, cellulose or paper; inorganic sheets made of such as metal, 
glass, carbon or the like. 
In particular, preferably, sheets of polyurethane sponge are bonded to both 
surfaces of the metal sheet (S), and then, the metal sheet (S) and the two 
sheets of polyurethane sponge sandwiching it therebetween is plated. In 
this manner, the three-dimensional reticulate porous metal sheet 50 is 
layered on both surfaces of the metal sheet (S). That is, because the 
metal sheet (S) having a high electric conductivity is positioned between 
the two sheets of polyurethane sponge, the electric conductivity becomes 
higher from both upper and lower surfaces toward the center thereof. 
Therefore, the two sheets of polyurethane sponge can be plated 
sufficiently into the interior in the thickness direction thereof unlike 
the conventional art. 
Further, the porous metal sheet having the layered structure thus formed 
has a high strength because the metal sheet (S) is positioned at the 
center thereof. Thus, it has a high pulling strength, thus allowing an 
active substance to be applied thereto at a high speed. It is difficult to 
allow the porous metal sheet to have a high strength in increasing the 
open area ratio thereof when the amount of metal per area to be applied to 
polyurethane sponge is reduced and the diameters of skeletons surrounding 
pores are reduced. But it is possible to allow the porous metal sheet to 
have a required strength because the metal sheet (S) formed by rolling 
metal powders has a high strength. When the mesh sheet used in place of 
the metal sheet (S) and polyurethane sponge are layered on each other, it 
is necessary to plate in an amount more than 300 g/m.sup.2 to the 
polyurethane sponge. But in layering the metal sheet (S) and the 
polyurethane sponge on each other, it is possible to reduce the amount of 
plating metal to be applied to the polyurethane sponge to 200 g/m.sup.2. 
Thus, the open area ratio of the porous metal sheet can be increased. 
In forming the plated metal sheet (SS) comprising polyurethane sponge 
sheets bonded to both surfaces of the metal sheet (S), it is possible to 
differentiate the diameter of pores of one polyurethane sponge sheet to be 
bonded to one surface of the metal sheet (S) and that of the other sheet 
to be bonded to the other surface thereof. The active substance-applied 
metal sheet (SS) having such a structure can be used as a high-quality 
electrode plate of a cylindrical battery, by coiling it, with the larger 
diameter-pore positioned at the peripheral side and with the smaller 
diameter-pore positioned at the inner peripheral side. In such an 
electrode plate, the active substance is not removed easily from the metal 
sheet (SS), and the metal sheet (SS) is not cracked easily. 
In a metal sheet (SS) shown in FIG. 13 (B), a three-dimensional reticulate 
foamed sheet made of polyurethane sponge and a mesh sheet made of resin 
are layered on one surface of the porous metal sheet (S) formed by rolling 
metal powders by means of the pattern roller of the first embodiment, and 
a three-dimensional reticulate foamed sheet made of polyurethane sponge is 
layered on the other surface thereof. Then, the four sheets layered on 
each other are plated. That is, the metal sheet (SS) comprises the metal 
sheet (S), a porous metal sheet 51 consisting of a three-dimensional 
reticulate porous metal sheet and a metal mesh sheet positioned on-one 
surface of the metal sheet (S), and the three-dimensional reticulate 
porous metal sheet 50 positioned on the other surface thereof, with the 
four sheets layered on each other. 
A metal sheet (SS) shown in FIG. 13 (C) is formed as follows: metal powders 
are attached to the surface of a sheet made of a three-dimensional 
reticulate foamed sheet made of polyurethane sponge and the sheet is baked 
for resin removal and sintering to form a porous metal sheet 52. 
Similarly, metal powders are attached to a nonwoven sheet, and the sheet 
is baked for resin removal and sintering to form a porous metal sheet 53. 
The porous metal sheet 52 is layered on one surface of the porous metal 
sheet (S) formed by rolling metal powders with the pattern roller of the 
first embodiment, and the porous metal sheet 53 is layered on the other 
surface thereof. Then, the layered sheets are plated to form the metal 
sheet (SS) consisting of the three sheets integrated with each other. As 
the metal powders, ultra-fine metal ones flake-shaped ones and/or metal 
powders crushed can be preferably used. 
In the above-described manner, metal powders are attached to each of the 
three-dimensional reticulate foamed sheet made of polyurethane sponge and 
the nonwoven sheet, and then, the two sheets are baked for resin removal 
and sintering to form the porous metal sheet, and then, each porous metal 
sheet is layered on the porous metal sheet (S). Instead, the metal sheet 
(SS) can be formed as follows: The three-dimensional reticulate foamed 
sheet is layered on one surface of the metal sheet (S), and the nonwoven 
sheet is layered on the other surface thereof and then, the metal powders 
are attached to both the three-dimensional reticulate foamed sheet and the 
nonwoven sheet, and then, the three sheets layered on each other are baked 
for resin removal and sintering to form a layered sheet comprising the 
metal sheet (S), the three-dimensional reticulate porous metal sheet, and 
the nonwoven sheet-like porous metal sheet. Further, the porous metal 
sheet consisting of the three sheets layered on each other may be 
electroplated again. 
A metal sheet (SS) shown in FIG. 13 (D) having a layered structure is 
formed as follows. That is, a nonwoven sheet is layered on one surface of 
the porous metal sheet (S) formed by the first embodiment, and then the 
nonwoven sheet is coated with sprayed melted metal. Then, the two sheets 
layered one on the other are baked for resin removal and sintering. The 
porous metal sheet (S) and the nonwoven sheet-like porous metal sheet 54 
layered thereon are plated to form the metal sheet (SS) consisting of the 
two sheets integrated with each other. In forming the metal sheet (SS) in 
the above-described method, it is possible to use a three-dimensional 
reticulate sheet, porous fibrous sheet or a mesh sheet, instead of the 
nonwoven sheet. 
A metal sheet (SS) having a layered structure shown in FIG. 13 (E) is 
formed as follows: A nonwoven fabric-like porous metal sheet 55 formed of 
metal fibers consisting of metal powders is layered on both surfaces of 
the porous metal sheet (S) formed by the first embodiment. Then, the three 
sheets layered on each other as described above are plated. Instead of 
metal fibers made of metal powder, it is possible to use a nonwoven 
fabric-like porous metal sheet consisting of metal fibers formed by a 
convergent drawing method, or metal fiber spinning method, metal foil 
cutting method. Further, it is possible to use a nonwoven fabric-like 
porous metal sheet consisting of metal fibers formed by cutting a metal 
rod or a coiled metal foil by chatter vibration cutting method. The metal 
sheet (SS) consisting of the nonwoven fabric-like porous metal sheet 55 
consisting of fine or small-diameter metal fibers and the metal sheet (S) 
formed by the first embodiment and layered thereon has a high strength and 
a high open area ratio. Further, because the metal sheet (S) has a high 
strength and a high electric conductivity, the layered metal sheet (SS) 
has a high electric conductivity. Therefore, the metal sheet (SS) has a 
high open area ratio and moreover, has a high pulling strength. 
A metal sheet (SS) having a layered structure shown in FIG. 13 (F) is 
formed as follows: Through the intermediary of a screen, slurry-like fine 
metal powders are applied to a base film. Then, the base film is baked, 
treated with chemicals or exfoliate to remove it from the fine metal 
powders. Then, the metal powders are sintered to form a porous metal sheet 
56. Then, the porous metal sheet 56 is layered on one surface of the 
porous metal sheet (S) formed by the first embodiment. Then, the porous 
metal sheet (S) and the porous metal sheet 56 layered thereon are plated 
to form the metal sheet (SS). 
A metal sheet (SS) having a layered structure shown in FIG. 13 (G) is 
formed as follows: Two porous metal sheets (S) formed by the first 
embodiment are layered on each other and are then plated. 
As porous metal sheets to be layered on and integrated with the porous 
metal sheet (S) formed by the first embodiment, it is possible to use a 
porous metal sheet having a large number of pores formed thereon by 
performing punching processing, lath processing or expanded processing on 
a metal plate or a metal foil, a solid metal plate, a solid metal foil, a 
metal mesh sheet, a metal screen or a porous metal sheet formed by 
electro-coating them by using coating including metal powders, and then 
baking them for resin removal and sintering; a porous metal sheet formed 
by applying metal powders to a three-dimensional reticulate sheet by using 
adhesive agent and baking the sheet for resin removal and sintering; or a 
porous metal sheet formed by forming an electrically conductive metal 
layer consisting of fine metal powders applied to a three-dimensional 
reticulate sheet by using adhesive agent and then plating the sheet and 
then baking the sheet for resin removal and sintering. In addition, it is 
possible to laminate a tab-provided porous metal sheet on the porous metal 
sheet (S) formed by rolling metal powders by means of the pattern roller 
and integrate both sheets with each other in such a manner that the tab is 
layered on the solid metal portion of the porous metal sheet (S). 
In forming the metal sheet consisting of the metal sheet (S) and two same 
three-dimensional reticulate porous metal sheets by bonding sheets of 
polyurethane sponge to both surfaces of the metal sheet (S), and then, 
plating the metal sheet (S) and the two sheets of polyurethane sponge or 
by plating the sheets of polyurethane sponge and then layering each plated 
sheet on each surface of the metal sheet (S), it is possible to 
differentiate the pulling strengths of both three-dimensional reticulate 
porous metal sheets from each other by altering the diameter of pores 
thereof, the open area ratio thereof, and the thickness of skeleton 
surrounding the open area. The same is the case with nonwoven fabric-like 
porous metal sheets which are bonded to both surface of the metal sheet 
(S). 
When the metal sheet having the layered structure and an active substance 
applied thereto is spirally coiled to use it as the electrode plate of a 
battery, it is preferable to position the three-dimensional reticulate 
porous metal sheet having the larger diameter-pore at the outer peripheral 
side and the one having the smaller diameter-pore at the inner peripheral 
side so that the outer side of the metal sheet can be stretched in coiling 
it and consequently, the occurrence of crack can be reduced or prevented. 
Evaporation, fusing or any appropriate method can be used in addition to 
plating as the method of integrating the metal sheet (S) formed by rolling 
metal powders by means of the pattern roller with various kinds of porous 
metal sheets, various kinds of metal plates or various kinds of metal 
foils. 
The porous metal sheet formed by the above-mentioned methods is cut to 
required sizes and an active substance is applied thereto to use them as 
the electrode plate of a nickel hydrogen battery, a nickel cadmium battery 
or the like. Because the electrode plate of the present invention is 
thinner than the conventional one, it can be accommodated in a battery in 
an amount more than the conventional one, thus improving the capability 
thereof. Further, the open area ratio of the electrode substrate can be 
adjusted as desired. Furthermore, the open area ratio of the substrate can 
be increased without wasting a material and thus the substrate can be 
manufactured at a low cost. 
In addition, a solid metal plate or a solid metal foil may be fused into 
one surface or both surfaces of the metal sheet of the first or second 
embodiment to form a metal sheet having a layered structure. In addition, 
a metal sheet having a layered structure may be manufactured by plating 
the solid metal plate or the solid metal foil layered on one surface or 
both surfaces of the metal sheet of the first or second embodiment. The 
metal sheet consisting of the solid metal plate or foil layered on the 
metal sheet of the first or second embodiment can be used as the electrode 
substrate of a lithium secondary battery. 
As apparent from the foregoing description, according to the manufacturing 
method of the present invention, concaves of a required pattern are formed 
on the pattern roller of a pair of rollers. In supplying metal powders to 
the pattern roller, those which have dropped to the concaves are not 
rolled but those which have dropped to the concave-unprovided portion of 
the peripheral surface of the pattern roller are compressed. Then, a metal 
sheet formed of metal powders is rolled, sintered, repeatedly, then 
tempered as necessary. In this manner, a porous metal sheet having pores 
having a required shape formed thereon is manufactured. 
The porous metal sheet obtained by the method is thinner than the one 
obtained by the conventional method of punching a metal sheet to form 
pores thereon. When the porous metal sheet is used as an electrode 
substrate, the amount of metal powders to be used for a material per 
centiare can be reduced because the porous metal sheet is thin. Thus, the 
porous metal sheet can be manufactured at a low cost. In addition, the 
porous metal sheet can be accommodated in a battery in an amount more than 
the conventional one, thus improving the capability thereof. 
Furthermore, because the porous metal sheet consists of metal powders, it 
has a high electrical conductivity. Thus, when it is used as an electrode 
plate, it improves the capability of a battery. Because the porous metal 
sheet has a high pulling strength, the manufacturing line thereof can be 
operated at a high speed. Therefore, the porous metal sheet can be 
produced at a high efficiency and thus at a low cost. 
Further, the method of the present invention eliminates the need for the 
provision of a punching process and a plating process required in 
manufacturing a punching metal, thus allowing the porous metal sheet to be 
manufactured in a simple process and hence at a low cost. Moreover, metal 
powders which have dropped to the concaves of the peripheral surface of 
the pattern roller are not compressed by the flat roller, thus being 
recycled without wasting metal powders, which leads to the reduction in 
manufacturing cost. 
Further, because metal is used in the form of powder, they can be 
compresses and united each other under pressure at a temperature lower 
than the melting point of a metal even though the melting point is high. 
In addition, mixed with other kinds of metals. Accordingly, a porous metal 
sheet or a solid metal sheet can be obtained from a required kind of 
metal, the oxide thereof, the sulfide thereof, a simple substrate 
containing a compound of the metal or a mixture thereof. 
Because the metal sheet obtained by rolling metal powders by means of a 
pair of the rollers including the pattern roller is thin, the thickness 
thereof can be adjusted to a required one even though the metal sheet and 
porous metal sheets are layered on each other. Thus, in a layered metal 
sheet, the metal sheet of the present invention can be preferably used. 
When three-dimensional reticulate porous metal sheets or nonwoven 
fabric-like porous metal sheets are layered on the metal sheet 
manufactured by using the pattern roller with the metal sheet sandwiched 
therebetween, the entire sheet thus formed has a high strength because the 
metal sheet having a high pulling strength is positioned at the center 
thereof. Thus, it has a high pulling strength, thus allowing an active 
substance to be applied thereto at a high speed. 
Further, in a layered structure consisting of foamed sheets of polyurethane 
sponge or the like, porous fibrous sheets of resin or mesh sheets layered 
on both surfaces of the metal sheet manufactured by using the pattern 
roller are plated, the electric conductivity from the peripheral side of 
the entire sheet toward the center thereof is allowed to be favorable. 
Thus, the foamed sheets or the mesh sheets can be plated into the interior 
in the thickness direction thereof. That is, the entire metal sheet having 
the layered structure has a high electrical conductivity, thus increasing 
the performance of a battery when an active substance-applied metal sheet 
is used as an electrode plate of the battery. 
Although the present invention has been fully described in connection with 
the preferred embodiments thereof with reference to the accompanying 
drawings, it is to be noted that various changes and modifications are 
apparent to those skilled in the art. Such changes and modifications are 
to be understood as included within the scope of the present invention as 
defined by the appended claims unless they depart therefrom.