Ultrapure synthetic carbon materials

Patent metadata

Field	Value
Publication number	US-9580321-B2
Application number	US-201514734993-A
Country	US
Kind code	B2
Filing date	Jun 9, 2015
Priority date	Jul 1, 2009
Publication date	Feb 28, 2017
Grant date	Feb 28, 2017

Abstract

The present application is generally directed to ultrapure synthetic carbon materials having both high surface area and high porosity, ultrapure polymer gels and devices containing the same. The disclosed ultrapure synthetic carbon materials find utility in any number of devices, for example, in electric double layer capacitance devices and batteries. Methods for making ultrapure synthetic carbon materials and ultrapure polymer gels are also disclosed.

First claim

The invention claimed is:

1. An ultrapure synthetic carbon material comprising a BET specific surface area of at least 500 m 2 /g and a total impurity content of less than 500 ppm of elements having atomic numbers ranging from 11 to 92 as measured by proton induced x-ray emission, wherein the carbon material comprises at least 85% carbon by weight as measured by combustion analysis and proton induced x-ray emission.

2. The carbon material of claim 1 , wherein the carbon material is an ultrapure synthetic amorphous carbon material.

3. The carbon material of claim 1 , wherein the carbon material comprises a total impurity content of less than 200 ppm of elements having atomic numbers ranging from 11 to 92 as measured by proton induced x-ray emission.

4. The carbon material of claim 1 , wherein the carbon material comprises at least 90% carbon by weight as measured by combustion analysis and proton induced x-ray emission.

5. The carbon material of claim 1 , wherein the carbon material comprises less than 3 ppm iron as measured by proton induced x-ray emission.

6. The carbon material of claim 1 , wherein the carbon material comprises less than 1 ppm nickel as measured by proton induced x-ray emission.

7. The carbon material of claim 1 , wherein the carbon material comprises less than 5 ppm sulfur as measured by proton induced x-ray emission.

8. The carbon material of claim 1 , wherein the carbon material comprises less than 1 ppm chromium as measured by proton induced x-ray emission.

9. The carbon material of claim 1 , wherein the carbon material comprises less than 1 ppm copper as measured by proton induced x-ray emission.

10. The carbon material of claim 1 , wherein the carbon material comprises less than 100 ppm sodium, less than 300 ppm silicon, less than 50 ppm sulfur, less than 100 ppm calcium, less than 20 ppm iron, less than 10 ppm nickel, less than 140 ppm copper, less than 5 ppm chromium and less than 5 ppm zinc as measured by proton induced x-ray emission.

11. The carbon material of claim 1 , wherein the carbon material comprises less than 50 ppm sodium, less than 50 ppm silicon, less than 30 ppm sulfur, less than 10 ppm calcium, less than 2 ppm iron, less than 1 ppm nickel, less than 1 ppm copper, less than 1 ppm chromium and less than 1 ppm zinc as measured by proton induced x-ray emission.

12. The carbon material of claim 1 , wherein the carbon material comprises less than 10% oxygen as determined by combustion analysis.

13. The carbon material of claim 1 , wherein the carbon material comprises less than 5% oxygen as determined by combustion analysis.

14. The carbon material of claim 1 , wherein the carbon material comprises less than 10% hydrogen as determined by combustion analysis.

15. The carbon material of claim 1 , wherein the carbon material comprises less than 5% hydrogen as determined by combustion analysis.

16. The carbon material of claim 1 , wherein the carbon material comprises less than 5% nitrogen as determined by combustion analysis.

17. The carbon material of claim 1 , wherein the carbon material comprises less than 2.5% nitrogen as determined by combustion analysis.

18. The carbon material of claim 1 , wherein the carbon material comprises a pyrolyzed ultrapure polymer cryogel.

19. The carbon material of claim 1 , wherein the carbon material comprises an activated ultrapure polymer cryogel.

20. The carbon material of claim 1 , wherein the BET specific surface area is at least 1000 m 2 /g.

21. The carbon material of claim 1 , wherein the BET specific surface area is at least 1500 m 2 /g.

22. The carbon material of claim 1 , wherein the carbon material comprises a BET specific surface area of at least 2000 m 2 /g.

23. The carbon material of claim 1 , wherein the carbon material comprises a BET specific surface area of at least 2400 m 2 /g.

24. The carbon material of claim 1 , wherein the carbon material comprises a pore volume of at least 0.7 cc/g.

25. A device comprising the carbon material of claim 1 .

26. The device of claim 25 , wherein the device is an electric double layer capacitor (EDLC) device comprising: a) a positive electrode and a negative electrode wherein each of the positive and the negative electrodes comprise the ultrapure synthetic carbon material; b) an inert porous separator; and c) an electrolyte; wherein the positive electrode and the negative electrode are separated by the inert porous separator.

27. The device of claim 26 , wherein the EDLC device comprises a gravimetric power of at least 15 W/g.

28. The device of claim 26 , wherein the EDLC device comprises a volumetric power of at least 10 W/cc.

29. The device of claim 26 , wherein the EDLC device comprises a gravimetric energy of at least 20.0 Wh/kg.

30. The device of claim 26 , wherein the EDLC device comprises a volumetric energy of at least 10.0 Wh/liter.

31. The device of claim 26 , wherein the EDLC device comprises a gravimetric capacitance of at least 25 F/g as measured by constant current discharge from 2.7 V to 0.1 V with a 5 second time constant employing a 1.8 M solution of tetraethylammonium-tetrafluoroborate in acetonitrile electrolyte and a current density of 0.5 A/g.

32. The device of claim 26 , wherein the EDLC device comprises a volumetric capacitance of at least 20 F/cc as measured by constant current discharge from 2.7 V to 0.1 V with a 5 second time constant employing a 1.8 M solution of tetraethylammonium-tetrafluoroborate in acetonitrile electrolyte and a current density of 0.5 A/g.

33. The device of claim 25 , wherein the device is a battery.

34. The device of claim 33 , wherein the device is a lithium/carbon battery, zinc/carbon, lithium air battery or lead acid battery.

35. An electrode comprising the carbon material of claim 1 .

Assignees

• Basf Se

Inventors

• Feaver Aaron M
• Costantino Henry R
• Scott William D

Classifications

• H01M4/583

  Carbonaceous material, e.g. graphite-intercalation compounds or CFx · CPC title

• C01P2006/80

  Compositional purity · CPC title

• H01G11/24

  characterised by structural features of the materials making up or comprised in the electrodes, e.g. form, surface area or porosity; characterised by the structural features of powders or particles used therefor · CPC title

• H01M10/052

  Li-accumulators · CPC title

• B29C70/42

  for producing articles of definite length, i.e. discrete articles · CPC title