Particulate porous carbon material, particulate carbon material aggregate, and production method for particulate porous carbon material

Patent metadata

Field	Value
Publication number	US-10399856-B2
Application number	US-201515511994-A
Country	US
Kind code	B2
Filing date	Aug 31, 2015
Priority date	Sep 18, 2014
Publication date	Sep 3, 2019
Grant date	Sep 3, 2019

Abstract

The present invention relates to a particulate porous carbon material having a continuous porous structure, the particulate porous carbon material satisfying the following A to C: A: branch portions forming the continuous porous structure have an aspect ratio of 3 or higher; B: the branch portions have aggregated through joints interposed therebetween, the number of the aggregated branch portions (N) being 3 or larger; C: a ratio of the number of the aggregated branch portions (N) to the number of the joints (n), N/n, is 1.2 or larger.

First claim

The invention claimed is:

1. A particulate porous carbon material having a continuous porous structure, the particulate porous carbon material satisfying the following A to C:
A: branch portions forming the continuous porous structure have an aspect ratio of 3 or higher;
B: the branch portions have aggregated through joints interposed therebetween, the number of the aggregated branch portions (N) being 3 or larger;
C: a ratio of the number of the aggregated branch portions (N) to the number of the joints (n), N/n, is 1.2 or larger, and
wherein the continuous porous structure has a structural period of 0.002 μm-10 μm.

2. The particulate porous carbon material according to claim 1 , wherein the continuous porous structure has an average porosity of 10-80%.

3. The particulate porous carbon material according to claim 1 , wherein the continuous porous structure has an average porosity of 10-80%.

4. The particulate porous carbon material according to claim 1 , wherein the N/n is 1.5 or larger.

5. The particulate porous carbon material according to claim 1 , wherein the N/n is 1.5 or larger.

6. The particulate porous carbon material according to claim 2 , wherein the N/n is 1.5 or larger.

7. The particulate porous carbon material according to claim 3 , wherein the N/n is 1.5 or larger.

8. The particulate porous carbon material according to claim 1 , which further has a portion having no continuous porous structure.

9. The particulate porous carbon material according to claim 1 , which further has a portion having no continuous porous structure.

10. The particulate porous carbon material according to claim 4 , which further has a portion having no continuous porous structure.

11. The particulate porous carbon material according to claim 1 , which has a particle diameter of 10 nm to 10 μm.

12. The particulate porous carbon material according to claim 4 , which has a particle diameter of 10 nm to 10 μm.

13. A particulate carbon material assembly comprising the particulate porous carbon material according to claim 1 .

14. A particulate carbon material assembly comprising the particulate porous carbon material according to claim 4 .

15. A process for producing a particulate porous carbon material according to claim 1 , the process comprising the following steps in the following order:
step 1: a step in which 10-90% by weight of a carbonizable resin and 90-10% 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 to form a microstructure, and the microstructure is fixed to obtain a precursor;
step 3: a step in which the precursor obtained in the step 2 is stretched;
step 4: a step in which the stretched precursor is carbonized to obtain a porous carbon material; and
step 5: a step in which the porous carbon material obtained in the step 4 is pulverized;
wherein the eliminable resin is removed either between the step 3 and the step 4 or simultaneously with the step 4.

16. A process for producing a particulate porous carbon material according to claim 1 , the process comprising the following steps in the following order:
step 1: a step in which 10-90% by weight of a carbonizable resin and 90-10% 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 to form a microstructure, and the microstructure is fixed to obtain a precursor; and
step 3: a step in which the precursor obtained in the step 2 is stretched, and thereafter further comprising:
a step in which the stretched precursor is pulverized; and
step 4: a step in which the pulverized precursor is carbonized,
wherein the eliminable resin is removed either between the step 3 and the step 4 or simultaneously with the step 4.

Assignees

• Toray Industries

Inventors

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

Classifications

• C01B32/382

  Making shaped products, e.g. fibres, spheres, membranes or foam · CPC title

• C01B32/366 Primary

  by physical processes, e.g. by irradiation, by using electric current passing through carbonaceous feedstock or by using recyclable inert heating bodies · CPC title

• C01B32/05 Primary

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

• C01P2004/54

  Particles characterised by their aspect ratio, i.e. the ratio of sizes in the longest to the shortest dimension · CPC title

• C01P2004/62

  Submicrometer sized, i.e. from 0.1-1 micrometer · CPC title