Spherical, porous carbon structure and a production method therefor

Patent metadata

Field	Value
Publication number	US-9368801-B2
Application number	US-201013823770-A
Country	US
Kind code	B2
Filing date	Dec 9, 2010
Priority date	Sep 17, 2010
Publication date	Jun 14, 2016
Grant date	Jun 14, 2016

Abstract

The present application relates to a spherical, porous structure which is formed using a mold taking the form of a spherical nanoparticle aggregate, and relates to a production method therefor. According to one aspect of the present application, the production method for the spherical, porous structure comprises: the use of a mold taking the form of a spherical nanoparticle-carbon precursor aggregate comprising a carbon precursor on the surfaces of a plurality of nanoparticles, formed by removing solvent from droplets comprising the carbon precursor and the plurality of nanoparticles.

First claim

What is claimed is:

1. A production method of a spherical porous carbon structure via a sacrificial template process, the production method comprising:
using a spherical nanoparticle-carbon precursor coaggregate as a template,
wherein the spherical nanoparticle-carbon precursor coaggregate is formed by:
removing a solvent from a droplet including plural nanoparticles and a carbon precursor, the spherical nanoparticle-carbon precursor coaggregate including the carbon precursor on a surface of the plural nanoparticles, and
removing the solvent to form a spherical nanoparticle coaggregate by self assembly from the plural nanoparticles included in an oil-in-water type droplet or a water-in-oil type droplet.

2. The production method of a spherical porous carbon structure of claim 1 , further comprising:
forming a spherical nanoparticle-carbon coaggregate by calcining the spherical nanoparticle-carbon precursor coaggregate in a reducing atmosphere; and
removing the plural nanoparticles included in the spherical nanoparticle-carbon coaggregate.

3. The production method of a spherical porous carbon structure of claim 1 , wherein the nanoparticle includes an inorganic particle, an organic particle, or a combination particle thereof.

4. The production method of a spherical porous carbon structure of claim 1 , wherein the carbon precursor is prepared by a method including:
a condensation polymerization reaction of a monomer selected from the group consisting of phenol-formaldehyde, phenol, furfuryl alcohol, resorcinol formaldehyde (RF), aliphatic hydrocarbon-based or aromatic hydrocarbon-based aldehydes including 1 to 20 carbon atoms, sucrose, glucose, xylose, and their combinations by using an acidic catalyst or a basic catalyst; or
an addition polymerization reaction of a monomer selected from the group consisting of divinylbenzene, acrylonitrile, vinylchloride, vinylacetate, styrene, methacrylate, methylmethacrylate, ethyleneglycol, dimethacrylate, urea, melamin, CH 2 ═CRR′ (for which R and R′ are independently represent an alkyl group or an aryl group including 1 to 20 carbon atoms, respectively), and their combinations by using a polymerization initiator.

5. The production method of a spherical porous carbon structure of claim 1 , further comprising:
permeating the carbon precursor to pores of the spherical nanoparticle coaggregate, and
forming the carbon precursor from the surface of a nanoparticle at the core of the spherical nanoparticle coaggregate.

6. The production method of a spherical porous carbon structure of claim 1 , wherein an oil phase of the oil-in-water type droplet or the water-in-oil type droplet includes an aliphatic hydrocarbon-based organic solvent or an aromatic hydrocarbon-based organic solvent.

7. The production method of a spherical porous carbon structure of claim 1 , wherein the spherical nanoparticle-carbon precursor coaggregate is formed by adjusting the size of the nanoparticle and/or the quantity of carbon precursor included in the droplet, in which the carbon precursor is included from a surface of nanoparticle at the core of the spherical nanoparticle-carbon precursor coaggregate to a surface of nanoparticle at the exterior of the spherical nanoparticle-carbon precursor coaggregate.

8. The production method of a spherical porous carbon structure of claim 2 , wherein the removing of the nanoparticles included in the spherical nanoparticle-carbon coaggregate includes removing the nanoparticles by dissolution.

9. A spherical porous carbon structure produced by claim 1 , wherein the spherical porous carbon structure includes an inverse opal structure.

10. The spherical porous carbon structure of claim 9 , wherein the spherical porous carbon structure includes a three-dimensional pore assembly.

11. The spherical porous carbon structure of claim 9 , wherein pores in the spherical porous carbon structure are connected to one another.

12. The spherical porous carbon structure of claim 9 , wherein a pore in the spherical porous carbon structure has a size of from about 100 nm to about 1 μm.

13. The spherical porous carbon structure of claim 9 , wherein the spherical porous carbon structure has a size of from about 1 μm to about 100 μm.

14. A spherical porous metallic catalyst body comprising the spherical porous carbon structure of claim 9 , including a metal particle or a metal coating layer.

15. The spherical porous metallic catalyst body of claim 14 , wherein the metal particle or the metal coating layer includes one or more metals selected from the group consisting of Pt, Ru, Rh, Os, Ir, Re, Co, Ni, Ti, Cu, Zr, Sr, Zn, In, Yr, La, V, Mo, W, Sn, Nb, Mg, Al, Y, Sc, Sm, Pd, and Ga.

16. A fuel cell comprising the spherical porous metallic catalyst body of claim 14 .

Assignees

• Moon Jun Hyuk
• Cho Chang-Yeol
• Kang Ji-Hwan
• Jin Woo Min
• Shin Juhwan
• Univ Sogang Ind Univ Coop Foun

Inventors

• Moon Jun Hyuk
• Cho Chang-Yeol
• Kang Ji-Hwan
• Jin Woo Min
• Shin Juhwan

Classifications

• H01M4/625

  Carbon or graphite · CPC title

• H01M4/926

  on carbon or graphite · CPC title

• Y10T428/2982

  Particulate matter [e.g., sphere, flake, etc.] · CPC title

• H01M4/9083

  on carbon or graphite · CPC title

• H01M4/8657 Primary

  layered · CPC title