Porous carbon and method of manufacturing same

Patent metadata

Field	Value
Publication number	US-11584651-B2
Application number	US-201214002425-A
Country	US
Kind code	B2
Filing date	Mar 9, 2012
Priority date	Mar 9, 2011
Publication date	Feb 21, 2023
Grant date	Feb 21, 2023

Abstract

A porous carbon that has an extremely high specific surface area while being crystalline, and a method of manufacturing the porous carbon are provided.
A porous carbon has mesopores 4 and a carbonaceous wall 3 constituting an outer wall of the mesopores 4 , wherein the carbonaceous wall 3 has a portion forming a layered structure. The porous carbon is fabricated by mixing a polyamic acid resin 1 as a carbon precursor with magnesium oxide 2 as template particles; heat-treating the mixture in a nitrogen atmosphere at 1000° C. for 1 hour to cause the polyamic acid resin to undergo heat decomposition; washing the resultant sample with a sulfuric acid solution at a concentration of 1 mol/L to dissolve MgO away; and heat-treating the noncrystalline porous carbon in a nitrogen atmosphere at 2500° C.

First claim

The invention claimed is:

1. A porous carbon comprising:
mesopores,
a carbonaceous wall constituting an outer wall of the mesopores, the carbonaceous wall forming a mesh three-dimensional network structure, and
micropores,
wherein the micropores are each formed in a position facing the mesopores in the carbonaceous wall,
wherein the carbonaceous wall has a portion forming a layered structure, and
wherein the porous carbon consists of carbon.

2. The porous carbon according to claim 1 , wherein the specific surface area is 200 m 2 /g or more.

3. The porous carbon according to claim 1 , wherein the mesopores are open pores, and the hollow portions are connected to each other.

4. The porous carbon according to claim 1 , wherein the capacity of the mesopores is 0.2 ml/g or more.

5. The porous carbon according to claim 1 , wherein the bulk density is from 0.1 g/cc to 1.0 g/cc.

6. The porous carbon according to claim 1 , wherein the thickness of the portion forming a layered structure is from 1 nm to 100 nm.

7. A porous carbon comprising:
mesopores,
a carbonaceous wall constituting an outer wall of the mesopores, the carbonaceous wall forming a mesh three-dimensional network structure, and
micropores,
wherein the micropores are each formed in a position facing the mesopores in the carbonaceous wall, wherein a peak is present at a Bragg angle 2θ of 26.45° in an X-ray diffraction spectrum to a CuKα ray (wavelength 1.541 angstroms) of the carbonaceous wall, and
wherein the porous carbon consists of carbon.

8. The porous carbon according to claim 7 , wherein the specific surface area is 200 m 2 /g or more.

9. The porous carbon according to claim 7 , wherein the mesopores are open pores, and the hollow portions are connected to each other.

10. The porous carbon according to claim 7 , wherein the capacity of the mesopores is 0.2 ml/g or more.

11. The porous carbon according to claim 7 , wherein the bulk density is from 0.1 g/cc to 1.0 g/cc.

12. The porous carbon according to claim 7 , wherein the carbonaceous wall has a portion forming a layered structure.

13. The porous carbon according to claim 7 , wherein the specific resistance is 1.0×10 2 Ω·cm or less.

14. A method of manufacturing a porous carbon consisting of carbon, the porous carbon having a three-dimensional network structure, wherein
a noncrystalline carbonaceous carbonized body having mesopores is manufactured by the steps of: mixing a flowable material containing an organic resin with template particles comprising at least one alkaline-earth metal compound selected from the group consisting of an oxide, a hydroxide, a carbonate and an organic acid salt of an alkaline-earth metal, to prepare a mixture; carbonizing the mixture in a non-oxidizing atmosphere to prepare a carbonized substance; and removing the template particles in the carbonized substance to obtain the noncrystalline carbonaceous carbonized body having mesopores, wherein the carbon yield of the flowable material is from 40% to 85%,
the noncrystalline carbonaceous carbonized body having mesopores is subjected to a crystallization treatment to heat a target in a non-oxidizing atmosphere or a reduced-pressure atmosphere at a temperature equal to or higher than a temperature at which the noncrystalline carbonaceous carbonized body having mesopores is crystallized, thereby obtaining the porous carbon comprising: the mesopores; a carbonaceous wall constituting an outer wall of the mesopores, the carbonaceous wall forming the three-dimensional network structure, the carbonaceous wall having a portion forming a layered structure; and micropores each formed in a position facing the mesopores in the carbonaceous wall.

15. The method of manufacturing a porous carbon according to claim 14 , the diameters of the template particles are substantially the same as each other.

16. The method of manufacturing a porous carbon according to claim 14 , wherein the flowable material shows flowability at a temperature of 200° C. or lower.

17. The method of manufacturing a porous carbon according to claim 14 , wherein the flowable material is at least one selected from the group consisting of a polyimide containing at least one nitrogen or fluorine atom in its unit structure, a phenolic resin and a pitch.

18. The method of manufacturing a porous carbon according to claim 14 , wherein in the step of removing the template particles, the remaining ratio of the template particles after the removing is restricted to 0.5% or less.

19. The porous carbon according to claim 1 , wherein the capacity of the micropores is 0.12 ml/g or more.

20. The porous carbon according to claim 7 , wherein the capacity of the micropores is 0.12 ml/g or more.

21. The method of manufacturing a porous carbon according to claim 14 , wherein the crystallization treatment is conducted at a temperature of 2000° C. or lower.

22. The porous carbon according to claim 12 , wherein the thickness of the portion forming a layered structure is from 1 nm to 100 nm.

23. A porous carbon comprising:
mesopores,
a carbonaceous wall constituting an outer wall of the mesopores, the carbonaceous wall forming a mesh three-dimensional network structure, and
micropores,
wherein the micropores are each formed in a position facing the mesopores in the carbonaceous wall,
wherein the carbonaceous wall has a portion being graphitized,
wherein the porous carbon consists of carbon, and
wherein the capacity of the micropores is 0.12 ml/g or more.

24. The porous carbon according to claim 23 , wherein the specific surface area is 200 m 2 /g or more.

25. The porous carbon according to claim 23 , wherein the mesopores are open pores, and the hollow portions are connected to each other.

26. The porous carbon according to claim 23 , wherein the capacity of the mesopores is 0.2 ml/g or more.

27. The porous carbon according to claim 23 , wherein the bulk density is from 0.1 g/cc to 1.0 g/cc.

Assignees

• Morishita Takahiro
• Orikasa Hironori
• Tatsumi Makoto
• Ohta Naoto
• Okada Masaki
• Toyo Tanso Co

Inventors

• Morishita Takahiro
• Orikasa Hironori
• Tatsumi Makoto
• Ohta Naoto
• Okada Masaki

Classifications

• C01B32/348

  Metallic compounds · CPC title

• C01P2006/11

  Powder tap density · CPC title

• C04B35/524

  obtained from polymer precursors, e.g. glass-like carbon material · CPC title

• C01P2006/40

  Electric properties · CPC title

• C01P2006/12

  Surface area · CPC title