Porous carbon material, precursor for porous carbon material, process for producing precursor for porous carbon material, and process for producing porous carbon material

Patent metadata

Field	Value
Publication number	US-10011487-B2
Application number	US-201414778789-A
Country	US
Kind code	B2
Filing date	Mar 11, 2014
Priority date	Mar 22, 2013
Publication date	Jul 3, 2018
Grant date	Jul 3, 2018

Abstract

The present invention provides: a porous carbon material which includes a portion having a continuous porous structure and a portion having no continuous porous structure and has even pore size and matrix size in the material center part thereof, thereby being easy to composite with other materials and being able to be used in various applications; a porous-carbon-material precursor; a process for producing the porous-carbon-material precursor; and a process for producing the porous carbon material. A porous carbon material of the invention is a porous carbon material which includes a portion having a continuous porous structure and a portion having substantially no continuous porous structure, in which the portion having the continuous porous structure has a structural period of 0.002 to 1 μm.

First claim

The invention claimed is:

1. A porous carbon material which comprises a portion having a continuous porous structure having a structure in which branches and pores are respectively continued inward forming a core layer and a skin layer formed around the core layer, wherein the skin layer comprises a portion having substantially no continuous porous structure,
wherein a central part of the continuous porous structure has a structural period of 0.002 to 1 μm,
wherein the continuous porous structure has at least one peak diameter in a range of 2 to 400 nm in a pore diameter distribution curve thereof, and
wherein the portion having substantially no continuous porous structure comprises no pores having a size greater than 1 nm over an area that is not less than a region of a square in which each side of the square corresponds to three times the structural period.

2. The porous carbon material according to claim 1 , having an average porosity of 10 to 80%.

3. The porous carbon material according to claim 2 , which is in a form of a fiber, film, or powder.

4. The porous carbon material according to claim 1 , which is in a form of a fiber, film, or powder.

5. A process for producing the porous carbon material according to claim 1 , the process comprising:
step 1: a step in which 10 to 90% by weight of a carbonizable resin and 90 to 10% by weight of an eliminable resin are brought into a compatibly mixed state to obtain a resin mixture;
step 2: a step in which the resin mixture obtained in the step 1 is caused to undergo phase separation and the separated phases are fixed to obtain a porous-carbon-material precursor; and
step 3: a step in which the porous-carbon-material precursor obtained in the step 2 is carbonized by pyrolysis.

6. The process for producing a porous carbon material according to claim 5 , wherein a product obtained by carbonizing the porous-carbon-material precursor by pyrolysis in the step 3 is further subjected to a pulverization treatment.

Assignees

• Toray Industries

Inventors

• Mihara Takaaki
• Tanaka Kentaro
• Takeuchi Kosaku
• Horiguchi Tomoyuki

Classifications

• C01B32/00

  Carbon; Compounds thereof (C01B21/00, C01B23/00 take precedence; percarbonates C01B15/10; carbon black C09C1/48) · CPC title

• C01B32/25 Primary

  Diamond · CPC title

• C01B31/00

  Chemistry & Metallurgy · mapped topic

• C01B31/02 Primary

  Chemistry & Metallurgy · mapped topic

• C01B32/05 Primary

  Preparation or purification of carbon not covered by groups C01B32/15, C01B32/20, C01B32/25, C01B32/30 · CPC title