Porous carbon materials and methods of manufacturing the same

Patent metadata

Field	Value
Publication number	US-2017133690-A1
Application number	US-201615335775-A
Country	US
Kind code	A1
Filing date	Oct 27, 2016
Priority date	Nov 5, 2015
Publication date	May 11, 2017
Grant date	—

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 having carbon nano-rods on the surface thereof.

2 . The porous carbon material according to claim 1 , wherein the carbon nano-rods have a height of 10 nm-50 μm and a diameter of 2-1,000 nm, a plurality of carbon nano-rods is present, and each carbon nano-rod is spaced apart from the adjacent carbon nano-rods by a distance of 2-1,000 nm.

3 . The porous carbon material according to claim 1 , which has a porosity of 1-98%.

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

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

6 . 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.

7 . 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.

8 . An electrode for electrochemical reaction, which comprises the porous carbon material as defined in claim 1 .

9 . A method for manufacturing a porous carbon material, comprising:
providing a catalyst for etching to the surface of a carbon material; and etching the carbon material at the region provided with the catalyst for etching to obtain a porous carbon material having carbon nano-rods formed on the surface thereof.

10 . The method for manufacturing a porous carbon material according to claim 9 , 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.

11 . The method for manufacturing a porous carbon material according to claim 10 , wherein the catalyst for etching further comprises a cocatalyst, and the cocatalyst may include 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).

12 . The method for manufacturing a porous carbon material according to claim 9 , wherein the porous carbon material has a specific surface area of 0.5-3,000 m 2 /g.

13 . The method for manufacturing a porous carbon material according to claim 9 , which comprises:
pretreating a carbon material to carry out surface modification thereof; 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.

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

15 . The method for manufacturing a porous carbon material according to claim 13 , 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.

16 . The method for manufacturing a porous carbon material according to claim 13 , 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.

17 . The method for manufacturing a porous carbon material according to claim 9 , which further comprises, 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.

18 . The method for manufacturing a porous carbon material according to claim 17 , 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.

19 . The method for manufacturing a porous carbon material according to claim 18 , wherein the catalyst for forming carbon nanotubes further comprises a cocatalyst, and the cocatalyst may include 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

• B01J37/08

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

• H01M4/96 Primary

  Carbon-based electrodes · CPC title

• B01J23/75

  Cobalt · CPC title

• B01J23/755

  Nickel · CPC title

• H01M8/188

  by recharging of redox couples containing fluids; Redox flow type batteries · CPC title