Carbon foam, assembly and manufacturing method

Patent metadata

Field	Value
Publication number	US-11820714-B2
Application number	US-201917261574-A
Country	US
Kind code	B2
Filing date	Aug 30, 2019
Priority date	Aug 31, 2018
Publication date	Nov 21, 2023
Grant date	Nov 21, 2023

Abstract

A carbon foam formed of carbon fibers, where, at 90% or more of any 20 locations, the carbon fibers have a fiber diameter that is within ±20% of an average fiber diameter.

First claim

The invention claimed is:

1. A carbon foam formed of carbon fibers, wherein
at 90% or more of any 20 locations, the carbon fibers have a fiber diameter that is within ±20% of an average fiber diameter.

2. The carbon foam according to claim 1 , having a surface of 150 cm 2 or more.

3. The carbon foam according to claim 1 , wherein an average fiber diameter of the carbon fibers is 0.1 μm or more and 5.0 μm or less.

4. A carbon foam formed of carbon fibers, wherein
at any 5 locations on a surface, a weight per unit area of 3 cm×3 cm is within ±50% of an average value of weight per unit area.

5. The carbon foam according to claim 4 , wherein
among carbon atoms measured by surface analysis by X-ray photoelectron spectroscopy, a proportion of carbon atoms having a hydroxy group is 5 at % or more and 15 at % or less.

6. The carbon foam according to claim 4 , wherein
among carbon atoms measured by surface analysis by X-ray photoelectron spectroscopy, a proportion of carbon atoms forming a carbonyl group is 9 at % or more and 15 at % or less.

7. The carbon foam according to claim 4 , wherein
among carbon atoms measured by surface analysis by X-ray photoelectron spectroscopy, a proportion of carbon atoms forming a carboxy group is 0.1 at % or more and 5.0 at % or less.

8. The carbon foam according to claim 4 , having a surface of 150 cm 2 or more.

9. The carbon foam according to claim 4 , wherein an average fiber diameter of the carbon fibers is 0.1 μm or more and 5.0 μm or less.

10. An assembly, which is a laminate in which at least a part of the carbon foam according to claim 1 is adhered to at least one surface of an ion exchange membrane having a first surface and a second surface.

11. The assembly according to claim 10 , wherein two or more pieces of the carbon foam are adhered to one surface of the ion exchange membrane.

12. The assembly according to claim 10 , which is a laminate in which the carbon foam is adhered to the first surface and the second surface.

13. The assembly according to claim 10 , which is a laminate in which 30% or more of a surface of the carbon foam is adhered to the ion exchange membrane.

14. The assembly according to claim 10 , wherein
two or more pieces of the carbon foam are adhered to one surface of the ion exchange membrane, and
for the two or more pieces of carbon foam, a void between two pieces of carbon foam adjacent to each other is 10 mm or less.

15. The assembly according to claim 10 , wherein
two or more pieces of the carbon foam are adhered to one surface of the ion exchange membrane, and
for the two or more pieces of carbon foam, a void ratio between two pieces of carbon foam adjacent to each other is 5% or less.

16. The assembly according to claim 10 , wherein
the ion exchange membrane has a membrane thickness of 1 μm or more and 100 μm or less.

17. The assembly according to claim 10 , wherein
the ion exchange membrane has a membrane thickness that is within ±20% of an average membrane thickness.

18. The assembly according to claim 10 , wherein
on an adhesive surface between the carbon foam and the ion exchange membrane, an embedding depth of the carbon foam in the ion exchange membrane is 5 μm or less.

19. The assembly according to claim 10 , wherein
two or more pieces of the carbon foam having different oxidation states on carbon surfaces are adhered to at least one surface of the ion exchange membrane.

20. A method of manufacturing the assembly according to claim 10 , wherein
the ion exchange membrane and the carbon foam are thermocompression bonded under a temperature condition of Tg of the ion exchange membrane+50° C. or lower.

Assignees

• Asahi Chemical Ind

Inventors

• Kanada Yuka
• Suzuki Atsushi
• Yamashita Junya

Classifications

• C04B35/524 Primary

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

• C01B32/20

  Graphite · CPC title

• C01P2002/85

  by XPS, EDX or EDAX data · CPC title

• C01P2004/03

  obtained by SEM · CPC title

• C01P2006/12

  Surface area · CPC title