Porous carbon material, composite material reinforced with carbon material, porous carbon material precursor, porous carbon material precursor production method, and porous carbon material production method

Patent metadata

Field	Value
Publication number	US-10131770-B2
Application number	US-201515121424-A
Country	US
Kind code	B2
Filing date	Feb 13, 2015
Priority date	Feb 26, 2014
Publication date	Nov 20, 2018
Grant date	Nov 20, 2018

Abstract

A carbon material having a continuous porous structure oriented to the stretching axis is provided, which carbon material can be used as a structural material excellent in interfacial adhesion. The porous carbon material has a continuous porous structure in at least a portion thereof, in which the continuous porous structure has an orientation degree measured by a small-angle X-ray scattering method or an X-ray CT method of 1.10 or more.

First claim

The invention claimed is:

1. A porous carbon material having a continuous porous structure in at least a portion thereof, in which the continuous porous structure has an orientation degree measured by a small-angle X-ray scattering method or an X-ray CT method of 1.10 or more, wherein the continuous porous structure is continuous three-dimensionally when a longitudinal section or cross section of the porous carbon material or a surface of pulverized porous carbon material is observed by a scanning secondary electron microscope and when the longitudinal section or cross section of the porous carbon material or surface of pulverized porous carbon material is tilted.

2. The porous carbon material according to claim 1 , wherein a structural period of a major axis side thereof is from 5 nm to 5 μm, and a structural period of a minor axis side thereof is from 10 nm to 20 μm.

3. The porous carbon material according to claim 1 , having a dense layer at least in a portion of a surface thereof.

4. A composite material reinforced with a carbon material, which is obtained by compositing the porous carbon material according to claim 1 with a resin.

5. The porous carbon material according to claim 1 , which is in a form of a fiber.

6. The porous carbon material according to claim 1 , which is in a form of a film.

7. The porous carbon material according to claim 1 , which is in a form of a particle.

8. The porous carbon material according to claim 5 , wherein an aspect ratio calculated by fiber length/fiber diameter is 2 or more.

9. A process for producing a porous-carbon-material precursor, the process comprising:
step 1: a step in which a carbonizable resin and 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 molded and caused to undergo phase separation, thereby obtaining a precursor material having a co-continuous phase separation structure in which the phases in which the carbonizable resin and the eliminable resin constituting the resin mixture occupy 50% by weight or more undergo phase separation in succession with each other; and
step 3: a step in which the precursor material obtained in the step 2 is subjected to stretching.

10. The process for producing a porous-carbon-material precursor according to claim 9 , wherein, in the step 1, from 10 to 90% by weight of the carbonizable resin and from 90 to 10% by weight of the eliminable resin are brought into a compatibly mixed state.

11. The process for producing a porous-carbon-material precursor according to claim 9 , wherein, in the step 3, the stretching is performed multiple times.

12. The process for producing a porous-carbon-material precursor according to claim 9 , further comprising a step of removing the eliminable resin after the step 3.

13. A process for producing a porous carbon material, the process comprising:
step 1: a step in which a carbonizable resin and 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 molded and caused to undergo phase separation, thereby obtaining a precursor material having a co-continuous phase separation structure;
step 3: a step in which the precursor material obtained in the step 2 is subjected to stretching to obtain a porous-carbon-material precursor; and
step 5′: a carbonization treatment step in which the porous-carbon-material precursor obtained in the step 3 is carbonized and the eliminable resin is removed therefrom.

14. A process for producing a porous carbon material, the process comprising:
step 1: a step in which a carbonizable resin and 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 molded and caused to undergo phase separation, thereby obtaining a precursor material having a co-continuous phase separation structure;
step 3: a step in which the precursor material obtained in the step 2 is subjected to stretching to obtain a porous-carbon-material precursor;
step 4: a step in which the eliminable resin is removed from the porous-carbon-material precursor obtained in the step 3; and
step 5: a carbonization treatment step in which the porous-carbon-material precursor from which the eliminable resin has been removed obtained in the step 4 is carbonized.

15. A porous-carbon-material precursor having a co-continuous phase separation structure in at least a portion thereof, in which the co-continuous phase separation structure has an orientation degree measured by a small-angle X-ray scattering method or an X-ray CT method of 1.10 or more.

Assignees

• Toray Industries

Inventors

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

Classifications

• D01F6/54

  of polymers of unsaturated nitriles · CPC title

• D01D5/247

  Discontinuous hollow structure or microporous structure · CPC title

• C04B35/83

  Carbon fibres in a carbon matrix · CPC title

• C04B35/565

  based on silicon carbide · CPC title

• C01P2006/12

  Surface area · CPC title