Multifunctional hierarchical porous carbon aerogels

Patent metadata

Field	Value
Publication number	US-2026034531-A1
Application number	US-202319099870-A
Country	US
Kind code	A1
Filing date	Aug 2, 2023
Priority date	Aug 2, 2022
Publication date	Feb 5, 2026
Grant date	—

Abstract

A novel method for forming unique carbon aerogels may be provided. The method may include drying a precursor composition including an organic molecule. The method may include generating a porous aerogel by graphitizing the organic molecule (such as a self-assembling protein, a sugar, etc.). The organic molecule may be a phase transition material, where the heating leads to formation of a viscous melt pool, and further heating of which releases gases such as CO 2 , NH 3 , H 2 S, SO 2 , etc. Due to the use of such a phase transition material, generating the porous aerogel may be accomplished without a separate gas generant. The graphitizing may include heating the precursor composition to a first temperature of 300-1200° C. at a first heating rate. The graphitizing may include holding the precursor composition at the first temperature for a holding time no more than 48 hours.

First claim

1 . A method for manufacturing a carbon aerogel, comprising:
drying a precursor composition including an organic molecule; and generating a porous aerogel by graphitizing the organic molecule, the graphitizing including:
heating the precursor composition to a first temperature of 300-1200° C. at a first heating rate; and
holding the precursor composition at the first temperature for a holding time no more than 48 hours;
wherein generating the porous aerogel is accomplished without a separate gas generant.

2 . The method of claim 1 , wherein the precursor composition is heated to the first temperature in an atmosphere consisting of nitrogen, argon, or a combination thereof.

3 . The method of claim 1 , wherein the organic molecule comprises a protein-based precursor and/or a sugar-based precursor.

4 . The method of claim 3 , wherein the protein-based precursor is ovalbumin, whey protein, Bovine serum albumin, collagen gelatin, or a combination thereof.

5 . The method of claim 1 , wherein the first temperature is 300-1000° C.

6 . The method of claim 1 , wherein the heating rate is at least 100° C./min.

7 . The method of claim 1 , wherein the heating rate is no more than 100° C./min.

8 . The method of claim 7 , wherein the heating rate is no more than 40° C./min.

9 . The method of claim 8 , wherein the heating rate is 1-10° C./min.

10 . The method of claim 9 , wherein the heating rate is 3-10° C./min.

11 . The method of claim 1 , wherein the precursor composition consists of the organic molecule.

12 . The method of claim 1 , wherein the precursor composition consists of the organic molecule and one or more particles.

13 . The method of claim 12 , wherein the particles are present in a total concentration of no more than 20 mg/mL of the organic molecule.

14 . The method of claim 12 , wherein the particles comprise a metal or a metalloid.

15 . The method of claim 12 , wherein the particles comprise a non-metal.

16 . The method of claim 1 , wherein the precursor composition consists of the organic molecule and one or more metal particle precursors.

17 . A carbon aerogel formed by the method of claim 1 .

18 . A carbon aerogel, comprising: micro-sized large graphitic carbon sheets interconnected with carbon fibers via covalent bonding; wherein the carbon aerogel comprises a plurality of micro-sized pores, and a plurality of nano-sized pores: wherein the carbon aerogel has a density of no more than 0.1 g/cm 3 ; wherein the carbon fibers have an average fiber width of 46 μm or less; wherein the carbon aerogel has a carbon content of at least 60%; and wherein the graphitic carbon sheets contain a plurality of structural defects.

19 - 31 . (canceled)

32 . A filtration system comprising:
a housing having an input and output; and a carbon aerogel of claim 18 within the housing, disposed in a fluid path between the input and output.

33 . A method for separation of materials, comprising:
passing a fluid containing a liquid and al least one additional material through a carbon aerogel of claim 18 ; wherein the carbon aerogel comprises one or more O-residual groups, N-residual groups, or both, associated with the plurality of nano-sized pores of the carbon aerogel, the plurality of structural defects of the carbon aerogel, or both.

34 - 40 . (canceled)

Assignees

• Univ Princeton

Inventors

• Arnold Craig B
• Ozden Sehmus
• Priestley Rodney D
• Wani M Shaharyar

Classifications

• C02F2103/08

  Seawater, e.g. for desalination · CPC title

• C02F2101/32

  Hydrocarbons, e.g. oil · CPC title

• C02F1/283

  using coal, charred products, or inorganic mixtures containing them · CPC title

• C01B32/05 Primary

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

• B01J20/28045

  Honeycomb or cellular structures; Solid foams or sponges · CPC title