Methods for forming carbon opal templates and their use in forming inverse opals

Patent metadata

Field	Value
Publication number	US-10099965-B2
Application number	US-201715477983-A
Country	US
Kind code	B2
Filing date	Apr 3, 2017
Priority date	Jun 18, 2012
Publication date	Oct 16, 2018
Grant date	Oct 16, 2018

Abstract

Carbon opals, a form of colloidal crystal, are composed of ordered two-dimensional or three-dimensional arrays of Monodispersed Starburst Carbon Spheres (MSCS). Methods for producing such carbon opals include oxidizing as-synthesized MSCS, for example by heating in air, to increase surface charge. Such oxidation is believed to decrease settling rates of a colloidal suspension, enabling formation of an ordered colloidal crystal. Inverse opals, composed of any of a wide variety of materials, and based on a carbon opal template, have a reciprocal structure to a carbon opal. Inverse opals are formed by methods including: forming a carbon opal as described, impregnating a desired material into pores in the carbon opal to produce a hybrid structure, and removing the carbon portion from the hybrid structure.

First claim

What is claimed is:

1. A method for producing an inverse opal, the method comprising:
oxidizing monodispersed starburst carbon spheres (MSCS) having an initial pore volume, to obtain hydrophilic MSCS having zeta potential more negative than −15 mV and a post-oxidation pore volume that is at least 92% of the initial pore volume;
depositing the hydrophilic MSCS on a surface to obtain a carbon opal;
depositing a material onto the surface of the hydrophilic MSCS such that the coating material penetrates into pores defined in the hydrophilic MSCS, to obtain a hybrid opal; and
removing carbon from the hybrid opal to obtain the inverse opal.

2. The method as recited in claim 1 , comprising oxidizing monodispersed starburst carbon spheres (MSCS) to obtain hydrophilic MSCS having zeta potential more negative than −20 mV.

3. The method as recited in claim 1 , comprising oxidizing monodispersed starburst carbon spheres (MSCS) to obtain hydrophilic MSCS having zeta potential more negative than −40 mV.

4. The method as recited in claim 1 , wherein the coating material comprises at least one of a metal, a chalcogenide, a semiconductor, an inorganic nitrides, and an inorganic oxide.

5. The method as recited in claim 1 , wherein the coating material comprises at least one of a hafnium oxide, an aluminum oxide, a Group II-VI compound semiconductors, and aluminum nitride.

6. The method as recited in claim 1 , wherein the coating material comprises an inorganic oxide.

7. The method as recited in claim 1 , wherein the coating material comprises hafnium dioxide.

8. The method as recited in claim 1 , wherein depositing a material onto the surface of the hydrophilic MSCS comprises at least one of atomic layer deposition (ALD), chemical vapor deposition (CVD), chemical bath deposition, and selective ionic layer adsorption and reaction (SILAR).

9. The method as recited in claim 1 , wherein oxidizing MSCS comprises maintaining MSCS at a temperature of at least 300° C. under air for at least 30 minutes.

10. The method as recited in claim 1 , wherein oxidizing MSCS comprises maintaining MSCS at a temperature of at least 400° C. under air for at least 30 minutes.

11. The method as recited in claim 1 , comprising oxidizing monodispersed starburst carbon spheres (MSCS) to obtain hydrophilic MSCS having zeta potential more negative than −20 mV and specific surface area greater than 1000 m 2 /g.

12. The method as recited in claim 1 , comprising oxidizing monodispersed starburst carbon spheres (MSCS) to obtain hydrophilic MSCS having zeta potential more negative than −20 mV and specific surface area greater than 1300 m 2 /g.

13. A method to produce a carbon opal comprising an ordered array of monodispersed starburst carbon spheres (MSCS), the method comprising:
heating the MSCS, composed substantially of carbon, under an oxidative atmosphere at a temperature less than 450° C. to obtain hydrophilic MSCS having zeta potential more negative than −20 mV; and
depositing the hydrophilic MSCS on a surface to form the carbon opal.

14. The method as recited in claim 13 , comprising depositing the hydrophilic MSCS on a surface in a single layer to form the carbon opal having a single layer.

15. The method as recited in claim 13 , comprising depositing the hydrophilic MSCS on a surface in two or more layers to form the carbon opal having two or more layers.

16. The method as recited in claim 13 , comprising depositing the hydrophilic MSCS on a surface in three or more layers to form the carbon opal having three or more layers.

17. The method as recited in claim 13 , comprising depositing the hydrophilic MSCS on a surface in five or more layers to form the carbon opal having five or more layers.

18. The method as recited in claim 13 , comprising heating the MSCS, composed substantially of carbon, under an oxidative atmosphere at a temperature of at least 300° C. for at least 30 minutes.

19. The method as recited in claim 13 , comprising heating the MSCS, composed substantially of carbon, under an oxidative atmosphere at a temperature of at least 400° C. for at least 30 minutes.

20. The method as recited in claim 13 , comprising heating the MSCS, composed substantially of carbon, under an oxidative atmosphere to obtain hydrophilic MSCS having zeta potential more negative than −20 mV and specific surface area greater than 1300m 2 /g.

Assignees

• Toyota Eng & Mfg North America
• Univ Illinois

Inventors

• Yano Kazuhisa
• Goodman Matthew
• Braun Paul Vannest

Classifications

• C01P2006/14

  Pore volume · CPC title

• C01P2006/16

  Pore diameter · CPC title

• B32B5/18

  characterised by features of a layer {of} foamed material · CPC title

• C04B2235/5445

  submicron sized, i.e. from 0,1 to 1 micron · CPC title

• C04B35/528

  obtained from carbonaceous particles with or without other non-organic components · CPC title