Process for producing a hydrogen occluded alloy

Abstract: A hydrogen occluded alloy and a process for producing the above alloy are disclosed. The process mechanically forms the hydrogen occluded alloy having improved initial discharging characteristics. In the above process, either a powdered LaNi 5 alloy or rare earth metals, such as La, Ce, Pr and Nd, or a powdered CaCu 5 alloy of Mm-Mn-Ni-Al-Co is mixed with a powdered Laves alloy of Zr-Mn-V-Cr-Ni alloys into a powdered alloy mixture. Thereafter, the alloy mixture is subjected to mechanical impact by a high energy ball mill with an attritor, thereby mechanically forming the hydrogen occluded alloy. The above process easily controls the manganese component while producing the hydrogen occluded alloy through the mechanical alloying.

Description: The present invention relates in general to a process for producing a hydrogen occluded alloy used as a material for cathodes of nickel-hydrogen secondary cells and, more particularly, to a process for producing a hydrogen occluded alloy suitable for improving the initial discharging characteristics of the cathodes. Nickel-cadmium cells (Ni-Cd cells) have been typically used as alkaline secondary cells. However, Ni-Cd cells are problematic in that they cause serious environmental pollution due to the cadmium. As a substitute for the above Ni-Cd cells, Ni-H cells using hydrogen occluded alloy as their cathodes have been actively studied. The above hydrogen occluded alloy used as the cathode is expected to provide a high capacity of secondary cells. However, the known hydrogen occluded alloy used as the cathodes of the Ni-H cells is still problematic in that the alloy fails to improve the initial discharging capacity of the cells or to extend the expected cyclic life span of the cells. The known hydrogen occluded alloys used as the Ni-H cell's cathodes are typically produced by a paste process. However, the hydrogen occluded alloys produced by the paste process have the following problems. That is, the CaCu 5 -type or LaNi 5 -type alloys have the problem of a low hydrogen gas occlusion ratio, while the Laves phase alloys or the AB 2 alloys have a problem in their initial cyclic characteristics. In order to alleviate the above problems, either an arc melting process or a high temperature sintering process may be used for producing the hydrogen occluded alloys. However, both the arc melting process and the high temperature sintering process still cause a problem in uniformity of alloy as well as in composition of alloy components while producing the hydrogen occluded alloys. This is because the rare earth metals, La and Ce, of CaCu 5 alloys are low melting point metals. That is, the low melting point metals, La and Ce, are melted earlier than the high melting point metals when the metals are alloyed by either the arc melting process or the high temperature sintering process. Therefore, both the arc melting process and the high temperature sintering process cause vaporization of the low melting point metals and segregation of the resulting alloys. EP-A-591606 discloses hydrogen storage alloy particles comprising base particles consisting of hydrogen storage alloy particles and fine particles very firmly bonded to the base particles by a mechanofusion process. The hydrogen storage alloy particles may have Mm-Ni-Mn-Al-Co constituents with MmNi 5 structure, where Mm is misch metal, and the fine particles may be a metal oxide, for example TiO 2 . It is an object of the present invention to provide a process for producing a hydrogen occluded alloy in which the problems described above can be overcome or reduced and which mechanically forms the hydrogen occluded alloy having improved initial discharging characteristics. It is another object of the present invention to provide a hydrogen occluded alloy produced by the process of the invention. In order to accomplish the above objects, the present invention provides mixing a powdered Zr-Mn-V-Cr-Ni alloy of Laves structure with either a powdered Mm-Mn-Ni-Al-Co alloy of LaNi 5 or CaCu 5 structure, where Mm is misch metal, thereby forming a powdered alloy mixture; applying a mechanical impact to said powdered alloy mixture through high energy ball milling using a ball mill with an attritor, thereby mechanically alloying the powdered alloy mixture into alloy powder; removing residual gases from said alloy powder; followed by forming a pellet out of said alloy powder; and heat treating said pellet at 500-700°C in either an inert atmosphere or a vacuum to render uniform the quality of the pellet's alloy. Preferably the process includes the step of testing the hydrogen occlusion characteristics of the alloy powder after said step of removing residual gases. The above process easily controls the manganese component while mechanically alloying. In this specification the symbol Mm denotes Misch metal, being a mixture comprising 40-50 wt% of La, with one or more rare earth metals such as La, Ce, Pr and Nd. The above and other objects, features and other advantages of the present invention will be more clearly understood from the following detailed description taken in conjunction with the accompanying drawing, in which: Figure 1 is a sectional view showing the construction of a mechanical alloying device for producing a hydrogen occluded alloy in accordance with the method of the present invention. In a process for producing the hydrogen occluded alloy according to the process of this invention, 90-99 wt% of powdered Laves-type alloy of the constituents Zr-Mn-V-Cr-Ni is mixed with 1-10 wt% of either powdered LaNi 5 -type alloy or powdered CaCu 5 -type alloy of the constituents Mm-Mn-Ni-Al-Co, thereby forming a powdered alloy mixture in the first step. Thereafter, the Laves-type alloy of the constituents Zr-Mn-V-Cr-Ni and either the LaNi 5 -type alloy or the CaCu 5 -type alloy of the constituents Mm-Mn-Ni-Al-Co are mechanically alloyed. The above mechanical alloying step is performed by high energy ball milling using a ball mill with an attritor. An attritor vibration mill or a shaker mill may be used in the above high energy ball milling. In the high energy ball milling, the ball mill is operated at a relatively high rotating speed of 300-700 rpm for 1-500 hours. 1-5 wt% of either stearic acid or methanol is used as a process controlling agent. The weight ratio of the balls to the powdered alloy mixture is 50:1-150:1. As shown in Figure 1, the powdered alloy mixture coming out of the 1st step is put into a pulverizing cylinder 20 prior to rotating the rods 22 inside the cylinder 20. The rods 22 are initially rotated by handling an operating switch (not shown). As a result of the rotating motion of the rods 22, a plurality of balls 24 contained in the cylinder 20 collide with each other while cascading and rotating in the cylinder 20. Therefore, the powdered alloy mixture, including the Laves-type alloy of the constituents Zr-Mn-V-Cr-Ni and either the LaNi 5 -type or CaCu 5 -type alloy of the constituents Mm-Mn-Ni-Al-Co, in the cylinder 20 is subjected to a large mechanical impact by the balls 24, thereby being formed into a new alloy. In the above mechanical alloying step, the temperature inside the cylinder 20 rises due to the mechanical impact of the balls 24. The designation "CaCu 5 -type alloy of the constituents Mm-Mn-V-Cr-Ni", for example, denotes an alloy of CaCu 5 structure containing each of the said constituents. The rising temperature inside the cylinder 20 is reduced by the cooling water flowing in a cooling chamber defined between the cylinder 20 and a cooling case 18 surrounding the cylinder 20. In this case, the cooling water flows into the chamber at the bottom side of the case 18 and flows out of the chamber at the top side of the case 18. The flowing direction of the cooling water is shown by the arrows in Figure 2. The above new alloy formed by the above mechanical alloying step in turn is heated to 350-600°C in a vacuum. Therefore, the residual gases such as H 2 O O 2 and (OH) 2 of the alloy are exhausted through a gas exhaust port 12 of the device. After removing the residual gases from the alloy, the initial discharging characteristics, the hydrogen occlusion characteristics and the hydrogen discharging characteristics of the resulting alloy are tested prior to checking the operational performance of the hydrogen occluded alloy. In the above process, both a forming step and a heat treating step is performed after the residual gas removing step. The above forming step is for forming the alloy free from the residual gases into an alloy pellet, while the above heat treating step is for rendering uniform the quality of the pellet's alloy. In the heat treating step, the alloy pellet is heated at 500-700°C in either an inert atmosphere or a vacuum. In the above process for producing the hydrogen occluded alloy, the Laves-type alloy is used as the basic metal so as to not only improve both the discharging characteristics and the hydrogen gas occlusion characteristics, but also to overcome the problems caused by the cyclic initial characteristics. The alloy obtained with the process of this invention thus improves the discharging capacity of the cathode. In the above process, the Laves-type alloy and the further alloy having an intrinsic problem in its gas occlusion characteristics are mechanically alloyed. The powdered further alloy is thus uniformly distributed in the Laves alloy used as the basic metal. In this regard, the process of this invention produces an excellent hydrogen occluded alloy having the advantages of both the Laves alloy and a further alloy. The above mechanical alloying step is a solid phase step. The process of this invention thus easily alloys the low melting point rare earth metals, such as La and Ce which are the alloy elements of the CaCu 5 -type or LaN 5 -type alloys. The above process also prevents manganese, or the alloy elements of Laves alloys, from vaporising out or changing into different species, thereby easily controlling the manganese component while mechanically alloying. Having described specific preferred embodiments of the invention with reference to the accompanying drawings, it is to be understood that the invention is not limited to those precise embodiments, and that various changes and modifications may be effected therein by one skilled in the art.

Claims: A process for producing a hydrogen occluded alloy comprising the steps of: mixing a powdered Zr-Mn-V-Cr-Ni alloy of Laves structure with a powdered Mm-Mn-Ni-Al-Co alloy of LaNi 5 or CaCu 5 structure, where Mm is misch metal, thereby forming a powdered alloy mixture; applying a mechanical impact to said powdered alloy mixture through high energy ball milling using a ball mill with an attritor, thereby mechanically alloying the powdered alloy mixture into alloy powder; removing residual gases from said alloy powder; followed by the steps of: forming a pellet out of said alloy powder; and heat treating said pellet at 500-700°C in either an inert atmosphere or a vacuum to render uniform the quality of the pellet's alloy. A process according to claim 1, including testing the hydrogen occlusion characteristics of said alloy powder after the gas removal step. The process according to claim 1, wherein the mechanical alloying step of forming the alloy powder is performed using either an attritor vibration mill or a shaker mill. The process according to claim 1, wherein said high energy ball milling is performed under the conditions of a ball mill rotating speed of 300-700 rpm, a processing time of 1-500 hours, using either stearic acid or methanol as a process controlling agent and weight ratio of the balls to the powdered alloy mixture of 50:1-150:1. The process according to claim 1, wherein the amount of Zr-Mn-V-Cr-Ni alloy is 90-99 wt%, while the amount of Mm-Mn-Ni-Al-Co alloy is 1-10 wt%.

Inventors: CHOI JONG-SEO, CHOI KWI-SEUK, JOO KYU-NAM, KIM GEUN-BAE, LEE KWANG-MIN, LEE SANG-WON, CHOI, JONG-SEO, CHOI, KWI-SEUK, JOO, KYU-NAM, KIM, GEUN-BAE, LEE, KWANG-MIN, LEE, SANG-WON
Applicants: SAMSUNG DISPLAY DEVICES CO LTD, SAMSUNG DISPLAY DEVICES CO., LTD.
Application year: 1995
Main classification: C22C1
IPC codes: C22C19, H01M4, B22F9, C22C1, H01M10