Process for molding complex beta''-alumina shapes for sodium/sulfur batteries
This patent describes a method for manufacturing dimensionally precise, highly contoured green bodies which comprise a sacrificial binder composition densely packed with powdered beta''-alumina precursor particulate solids, by compression molding a mixture of the beta''-alumina precursor particulate solids and the sacrificial binder. The method consists of: 1.) providing a mixture of about 40-60 volume percent sinterable particulate solids consisting essentially of a particle size distribution of powdered beta''-alumina precursor particulate comprising alpha-alumina and about 60-40 volume percent organic sacrificial binder in a mold; 2.) applying heat and pressure to the first and second amounts between the mold member and another mold member; 3.) maintaining the heat and pressure for a time sufficient to knit together portions of the first and second amounts in conformity with the cavity. The binder consists essentially of: (a) a thermoplastic block copolymer component selected from the group consisting of linear, radial and linear and radial block copolymers; (b) two oils having different boiling point ranges selected from the group consisting of oil, at least about 75 percent by weight of which boils in a range between about 285/sup 0/-260/sup 0/C; (c) two waxes having different boiling point ranges and selected from the group consisting of wax which melts at a temperature in a range between about 50/sup 0/C-80/sup 0/C, at least 75 percent by weight of which boils at temperatures in a range between about 315/sup 0/C-490/sup 0/C; (d) a first stiffening thermoplastic polymer which is glassy or crystalline at 20/sup 0/-25/sup 0/C, has a softening point between about 80/sup 0/-250/sup 0/C, and comprises aromatic monomeric units associable with block copolymer (a); and (e) a second stiffening thermoplastic polymer, different from the first polymer and which is glassy or crystalline at 20/sup 0/-25/sup 0/C.
- Assignee:
- Ford Motor Co., Dearborn, MI
- Patent Number(s):
- US 4568502
- OSTI ID:
- 5961297
- Resource Relation:
- Patent File Date: Filed date 18 Nov 1983
- Country of Publication:
- United States
- Language:
- English
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Related Subjects
36 MATERIALS SCIENCE
ALUMINIUM OXIDES
MOLDING
SODIUM-SULFUR BATTERIES
BINDERS
BOILING POINTS
CHEMICAL COMPOSITION
COMPRESSION
COPOLYMERS
HEATING
HIGH TEMPERATURE
MEDIUM TEMPERATURE
MOLDING MATERIALS
PARTICULATES
POWDERS
PRESSURIZING
WAXES
ALUMINIUM COMPOUNDS
CHALCOGENIDES
ELECTRIC BATTERIES
ELECTROCHEMICAL CELLS
FABRICATION
MATERIALS
METAL-NONMETAL BATTERIES
ORGANIC COMPOUNDS
ORGANIC POLYMERS
OTHER ORGANIC COMPOUNDS
OXIDES
OXYGEN COMPOUNDS
PARTICLES
PHYSICAL PROPERTIES
POLYMERS
THERMODYNAMIC PROPERTIES
TRANSITION TEMPERATURE
250901* - Energy Storage- Batteries- Design & Development
250903 - Energy Storage- Batteries- Materials
Components
& Auxiliaries
360201 - Ceramics
Cermets
& Refractories- Preparation & Fabrication