Method for producing porous carbon material

Patent metadata

Field	Value
Publication number	US-11377358-B2
Application number	US-202016802722-A
Country	US
Kind code	B2
Filing date	Feb 27, 2020
Priority date	Mar 4, 2016
Publication date	Jul 5, 2022
Grant date	Jul 5, 2022

Abstract

A novel method for producing a porous carbon material which makes it possible to easily produce a porous carbon material having a desired shape. The method includes immersing a carbon-containing material having a desired shape and composed of a compound, alloy or non-equilibrium alloy containing carbon in a metal bath, the metal bath having a solidification point that is lower than a melting point of the carbon-containing material, the metal bath being controlled to a lower temperature than a minimum value of a liquidus temperature within a compositional fluctuation range extending from the carbon-containing material to carbon by decreasing the other non-carbon main components, to thereby selectively elute the other non-carbon main components into the metal bath while maintaining an external shape of the carbon-containing material to give a porous carbon material having microvoids.

First claim

What is claimed is:

1. A method for producing a porous carbon material comprising
bringing a starting carbon-containing material having a desired shape and composed of a compound, alloy or non-equilibrium alloy containing carbon into contact with a molten metal to selectively elute non-carbon components into the molten metal while maintaining the external shape of the starting carbon-containing material to give a carbon material having microvoids, wherein
the molten metal has a solidification point that is lower than a melting point of the starting carbon-containing material, and
a temperature of the molten metal is controlled to be at a temperature that is lower than a minimum value of a liquidus temperature that is observed with respect any composition of the range of compositions that arise as a result of the starting carbon-containing material being converted into the carbon material having microvoids.

2. The method according to claim 1 for producing a porous carbon material, wherein the starting carbon-containing material is formed to have a desired shape before being brought into contact with the molten metal.

3. The method according to claim 2 for producing a porous carbon material, wherein the starting carbon-containing material is formed to be spherical by rapidly cooling to solidify a carbon-containing metal melt and thereafter the starting carbon-containing material is brought into contact with the molten metal to thereby give a spherical carbon material having microvoids.

4. The method according to claim 1 for producing a porous carbon material, wherein the starting carbon-containing material is immersed in a metal bath composed of the molten metal to thereby selectively elute the non-carbon components into the metal bath to give the carbon material.

5. The method according to claim 1 for producing a porous carbon material, wherein a solid metal having a solidification point that is lower than a melting point of the starting carbon-containing material is arranged so as to contact the starting carbon-containing material, and the solid metal is heated and turned into the molten metal to thereby selectively elute the non-carbon components into the molten metal to give the carbon material.

6. The method according to claim 1 for producing a porous carbon material, wherein the carbon material is released from the molten metal and thereafter is subjected to an acid or alkali aqueous solution to selectively elute an adherent mixture alone that adheres to a periphery of the carbon material or to an inside of the microvoids and that includes components of the molten metal and/or the non-carbon components.

7. The method according to claim 1 for producing a porous carbon material, wherein the molten metal is composed of Ag, Bi, Cu, Ga, Ge, Hg, In, Ir, Pb, Pt, Rh, Sb, Sn, or Zn, or is composed of a mixture that is an alloy of at least one of those components as a base metal of the alloy, and wherein the non-carbon components are composed of any one or a mixture including more than one of Al, B, Be, Ca, Ce, Cr, Dy, Er, Eu, Fe, Gd, Hf, Ho, K, La, Li, Lu, Mg, Mn, Mo, Na, Nb, Nd, Pr, Sc, Se, Si, Sm, Sr, Ta, Ti, V, W and Zr.

8. The method according to claim 1 for producing a porous carbon material, wherein selectively eluting the non-carbon components into the molten metal is performed in an inert atmosphere or a vacuum atmosphere, or performed in air with flux added to the molten metal.

Assignees

• Tohoku Techno Arch Co Ltd
• Tpr Co Ltd

Inventors

• Kato Hidemi
• Tsuda Masashi
• Takano Yugo
• Suzuki Yosuke
• CHINO Tsutomu
• Kamata Koji
• Muronaka Shota

Classifications

• C22C32/0084

  carbon or graphite as the main non-metallic constituent · CPC title

• C22C1/1005

  Pretreatment of the non-metallic additives (pretreatment of non-metallic fibres C22C47/02) · CPC title

• C01P2006/16

  Pore diameter · CPC title

• C01P2006/12

  Surface area · CPC title

• C01B32/05 Primary

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