Method for producing porous carbon materials having mesopores and catalyst support for a fuel cell produced using same

Patent metadata

Field	Value
Publication number	US-9379389-B2
Application number	US-201113885174-A
Country	US
Kind code	B2
Filing date	Nov 16, 2011
Priority date	Nov 16, 2010
Publication date	Jun 28, 2016
Grant date	Jun 28, 2016

Abstract

The present invention relates to a method for producing porous carbon materials comprising the following steps: (S1) forming carbon coatings on surfaces of ceramic nanoparticles; (S2) mixing carbon precursors and ceramic nanoparticles on which carbon coatings are formed in the step (S1); (S3) heat-treating the mixture of the ceramic nanoparticles having carbon coatings thereon and carbon precursors, prepared in the step (S2) to carbonize the mixture; and (S4) removing the ceramic nanoparticles from the material obtained in the step (S3). The method for producing porous carbon materials according to the present invention enables porous carbon materials in which mesopores are uniformly distributed, to be mass produced with low costs. The porous carbon materials having mesopores may be used as catalyst supports for fuel cells, and thus may be used in producing electrodes for fuel cells.

First claim

The invention claimed is:

1. A method of producing a porous carbon material having mesopores, comprising:
(S1) forming a carbon film on surfaces of ceramic nanoparticles;
(S2) mixing the ceramic nanoparticles having the carbon film obtained in (S1) with a carbon precursor;
(S3) heat-treating a mixture obtained in (S2) comprising the ceramic nanoparticles having the carbon film and the carbon precursor so as to be carbonized; and
(S4) removing the ceramic nanoparticles from a material obtained in (S3),
wherein (S1) comprises placing the ceramic nanoparticles in an electrical furnace, adding a gaseous carbon-containing compound, and performing pyrolysis at 350˜950° C., thereby forming the carbon film on the surfaces of the ceramic nanoparticles.

2. The method of claim 1 , wherein the ceramic nanoparticles are selected from the group consisting of SiO 2 , Al 2 O 3 , MgO, CaCO 3 , zeolite, aluminosilicate, and mixtures thereof.

3. The method of claim 1 , wherein the ceramic nanoparticles have a particle size of 2˜100 nm.

4. The method of claim 1 , wherein in (S1), the carbon film is formed at a thickness of 1˜10 nm on the surfaces of the ceramic nanoparticles.

5. The method of claim 1 , wherein the gaseous carbon-containing compound is any one selected from the group consisting of hydrocarbons having 1˜4 gaseous carbons, carbon monoxide, alcohols, acetone, acetonitrile and acrylonitride, or a gas mixture comprising the any one and hydrogen.

6. The method of claim 1 , wherein the carbon precursor is selected from the group consisting of isotropic pitch, mesophase pitch, a polycyclic aromatic mixture, a phenol resin, a polystyrene resin, and mixtures thereof.

7. The method of claim 1 , wherein the mixture obtained in (S2) is prepared by mixing 10˜80 wt % of the ceramic nanoparticles having the carbon film and 20˜90 wt % of the carbon precursor.

8. The method of claim 1 , wherein (S3) comprises heat-treating the mixture obtained in (S2) at 200˜400 C for 0.5˜24 hr so as to be stabilized, and then heat-treating the mixture at 700˜1200° C. for 1˜3 hr in an inert atmosphere so as to be carbonized.

9. The method of claim 1 , wherein (S4) comprises immersing the material obtained in (S3) in an acidic solution or an alkaline solution, thus removing the ceramic nanoparticles.

10. The method of claim 9 , wherein the acidic solution is selected from the group consisting of hydrochloric acid, sulfuric acid, nitric acid, phosphoric acid and hydrofluoric acid.

11. The method of claim 9 , wherein the alkaline solution is an aqueous solution including potassium hydroxide or sodium hydroxide.

Assignees

• Jung Doo-Hwan
• Kim Sang-Kyung
• Lim Seong-Yop
• Peck Dong-Hyun
• Lee Byung-Rok
• Nam Ki-Don
• Korea Energy Research Inst

Inventors

• Jung Doo-Hwan
• Kim Sang-Kyung
• Lim Seong-Yop
• Peck Dong-Hyun
• Lee Byung-Rok
• Nam Ki-Don

Classifications

• H01M4/8663 Primary

  Selection of inactive substances as ingredients for catalytic active masses, e.g. binders, fillers · CPC title

• H01M2008/1095

  Fuel cells with polymeric electrolytes · CPC title

• Y02E60/50

  Fuel cells · CPC title

• C01B31/02

  Chemistry & Metallurgy · mapped topic

• H01M4/96

  Carbon-based electrodes · CPC title