Porous carbon materials and methods of manufacturing the same

Patent metadata

Field	Value
Publication number	US-10454115-B2
Application number	US-201615335775-A
Country	US
Kind code	B2
Filing date	Oct 27, 2016
Priority date	Nov 5, 2015
Publication date	Oct 22, 2019
Grant date	Oct 22, 2019

Abstract

Provided is a porous carbon material having carbon nano-rods on the surface thereof. The porous carbon material has an increased specific surface area and an increased electrochemically active area, and thus may be expected to provide improved performance, when used as an electrode for electrochemical reactions. In addition, the carbon nano-rods of the porous carbon material are formed through an etching process using a catalyst for etching formed on the carbon material, and thus the carbon material may have various functions.

First claim

What is claimed is:

1. A porous carbon material comprising:
carbon nano-rods formed on a surface of a carbon material, wherein the carbon nano-rods have a shape of a column,
wherein the carbon nano-rods have a height of 10 nm-50 μm and a diameter of 2-1,000 nm, and each carbon nano-rod is spaced apart from adjacent carbon nano-rods among the carbon nano-rods by a distance of 2-1,000 nm, and
wherein the carbon nano-rods are extended in a longitudinal direction from the surface of the porous carbon material.

2. The porous carbon material according to claim 1 , wherein the porous carbon material has a porosity of 1-98%.

3. The porous carbon material according to claim 1 , wherein the porous carbon material has a specific surface area of 0.5-3,000 m 2 /g.

4. The porous carbon material according to claim 1 , wherein the carbon nano-rods are formed by etching a carbon material.

5. The porous carbon material according to claim 1 , which further comprises carbon nanotubes formed in the pores or on the surface of the carbon nano-rods.

6. The porous carbon material according to claim 1 , wherein the carbon material comprises at least one selected from the group consisting of carbon felt, carbon paper, carbon cloth, carbon fibers, hollow carbon fibers, carbon nanotubes, graphene fibers, graphene sheets, graphene oxide fibers, graphene oxide sheets, graphite plates, graphite powder, graphite sheets, carbon black powder, active carbon powder and composite graphite comprising a polymer in combination with graphite.

7. An electrode for electrochemical reaction, comprising the porous carbon material of in claim 1 .

8. A method for manufacturing a porous carbon material, comprising:
providing a catalyst for etching the surface of a carbon material; and
etching the carbon material with the catalyst for etching to obtain a porous carbon material comprising carbon nano-rods formed on a surface of the carbon material, wherein the carbon nano-rods have a shape of a column,
wherein the carbon nano-rods have a height of 10 nm-50 μm and a diameter of 2-1,000 nm, and each carbon nano-rod is spaced apart from adjacent carbon nano-rods among the carbon nano-rods by a distance of 2-1,000 nm, and
wherein the carbon nano-rods are extended in a longitudinal direction from the surface of the porous carbon material.

9. The method for manufacturing a porous carbon material according to claim 8 , wherein the catalyst for etching comprises at least one selected from the group consisting of nickel (Ni), cobalt (Co), iron (Fe), manganese (Mn), ruthenium (Ru), vanadium (V), titanium (Ti), chromium (Cr), copper (Cu), zinc (Zn), tin (Sn), aluminum (Al), silicon (Si), rhodium (Rh), molybdenum (Mo), zirconium (Zr), tungsten (W), osmium (Os), iridium (Ir) and oxides thereof.

10. The method for manufacturing a porous carbon material according to claim 9 , wherein the catalyst for etching further comprises a cocatalyst, and the cocatalyst comprises at least one selected from the group consisting of lithium (Li), potassium (K), sodium (Na), rubidium (Rb), cesium (Ce), magnesium (Mg), calcium (Ca), strontium (Sr), barium (Ba) and radium (Ra).

11. The method for manufacturing a porous carbon material according to claim 8 , wherein the porous carbon material has a specific surface area of 0.5-3,000 m 2 /g.

12. The method for manufacturing a porous carbon material according to claim 8 , further comprising:
pretreating a carbon material to carry out surface modification;
dispersing a catalyst precursor on the pretreated carbon material;
heat-treating the catalyst precursor at a temperature of 100-800° C. to form a catalyst for etching on the surface of the carbon material; and
heat-treating the carbon material having the catalyst for etching thereon at a temperature of 250-1,000° C. to form a porous carbon material having carbon nano-rods on the surface thereof.

13. The method for manufacturing a porous carbon material according to claim 12 , wherein the surface modification is carried out at a temperature of 200-900° C.

14. The method for manufacturing a porous carbon material according to claim 12 , wherein the catalyst precursor comprises at least one selected from the group consisting of metal nitrates, metal acetates, metal sulfates, metal carbonates, metal oxides and metal chlorides.

15. The method for manufacturing a porous carbon material according to claim 12 , wherein the carbon material is etched partially to form the carbon nano-rods, when the carbon material having the catalyst for etching thereon is heat-treated.

16. The method for manufacturing a porous carbon material according to claim 8 , further comprising, after the porous carbon material is obtained, dispersing a catalyst for forming carbon nanotubes to the porous carbon material, followed by reaction with a carbon source to form carbon nanotubes in the pores or on the surface of the carbon nano-rods.

17. The method for manufacturing a porous carbon material according to claim 16 , wherein the catalyst for forming carbon nanotubes comprises at least one selected from the group consisting of nickel (Ni), cobalt (Co), iron (Fe), manganese (Mn), ruthenium (Ru), vanadium (V), titanium (Ti), chromium (Cr), copper (Cu), zinc (Zn), tin (Sn), aluminum (Al), silicon (Si), rhodium (Rh), molybdenum (Mo), zirconium (Zr), tungsten (W), osmium (Os), iridium (Ir) and oxides thereof.

18. The method for manufacturing a porous carbon material according to claim 17 , wherein the catalyst for forming carbon nanotubes further comprises a cocatalyst, and the cocatalyst comprises at least one selected from the group consisting of lithium (Li), potassium (K), sodium (Na), rubidium (Rb), cesium (Ce), magnesium (Mg), calcium (Ca), strontium (Sr), barium (Ba) and radium (Ra).

Assignees

• Korea Inst Sci & Tech

Inventors

• Ha Heung Yong
• Lee Hyuck
• Hwang Jinyeon

Classifications

• B01J37/0203

  the impregnation liquid containing organic compounds · CPC title

• B01J23/75

  Cobalt · CPC title

• B01J37/08

  Heat treatment {(B01J37/0009, B01J37/0018 take precedence)} · CPC title

• C01B32/00

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

• H01M4/96 Primary

  Carbon-based electrodes · CPC title