Bio-based carbon foam

Patent metadata

Field	Value
Publication number	US-12590197-B2
Application number	US-202118246215-A
Country	US
Kind code	B2
Filing date	Sep 27, 2021
Priority date	Sep 28, 2020
Publication date	Mar 31, 2026
Grant date	Mar 31, 2026

Abstract

The present invention relates to bio-based carbon foams, a method for their manufacturing and their use. The method comprises foaming a slurry of cellulose fibres to obtain a cellulose fibre foam, adding a biomass component to the foam, and carbonization of the biomass-cellulose fibre foam.

First claim

The invention claimed is:

1 . A method for the preparation of a bio-based carbon foam, the method comprising
a. suspending cellulose fibres in a liquid medium to obtain a cellulose slurry; b. foaming said cellulose slurry to obtain a cellulose fibre foam; c. adding a biomass component to the cellulose fibre foam to obtain a biomass-cellulose fibre foam,
wherein the biomass component is selected from lignin and lignocellulosic materials; and
d. carbonization of the biomass-cellulose fibre foam to obtain a bio-based carbon foam.

2 . The method according to claim 1 , wherein a weight proportion of the biomass component to the cellulose fibres is between 3:1 to 1:3, as calculated on a dry material.

3 . The method according to claim 1 , wherein the liquid medium for suspending the cellulose fibres is water.

4 . The method according to claim 1 , wherein the cellulose slurry has a concentration of from 0.1-40 wt % cellulose fibres, as calculated on a total weight of the cellulose fibres and liquid medium in the slurry.

5 . The method according to claim 1 , wherein the cellulose fibre foam is cast into a desired shape.

6 . The method according to claim 1 , wherein the cellulose fibre foam is dried.

7 . The method according to claim 6 , wherein the dried cellulose fibre foam is impregnated with a biomass component dispersed in a liquid medium.

8 . The method according to claim 1 , wherein the biomass component is added as a powder to the cellulose fibre foam.

9 . The method according to claim 8 , wherein the biomass-cellulose fibre foam is cast into a desired shape.

10 . The method according to claim 1 , wherein the biomass-cellulose fibre foam is dried.

11 . The method according to claim 1 , wherein the biomass component is lignin.

12 . The method according to claim 1 , wherein the carbonization comprises raising a temperature in one or more steps at rates between 1 to 100° C./min, until a maximum temperature, T max , in the range from 700 to 1500° C., is reached.

13 . The method according to claim 1 , wherein the carbonization is performed under inert gas.

Assignees

• Stora Enso Oyj

Inventors

• Masson David
• Walter Stephan

Classifications

• C04B2111/00017

  Aspects relating to the protection of the environment · CPC title

• C08J2497/02

  Lignocellulosic material, e.g. wood, straw or bagasse · CPC title

• C08J2301/02

  Cellulose; Modified cellulose · CPC title

• C08J2205/04

  characterised by the foam pores · CPC title

• C08J2201/0504

  the liquid phase being aqueous · CPC title