Three-dimensional carbon structures

Patent metadata

Field	Value
Publication number	US-9630848-B2
Application number	US-201314390914-A
Country	US
Kind code	B2
Filing date	Apr 4, 2013
Priority date	Apr 5, 2012
Publication date	Apr 25, 2017
Grant date	Apr 25, 2017

Abstract

The method of the present disclosure is directed towards the formation of a three-dimensional carbon structure and includes the steps of adding a radical initiator to an amount of carbon starting material, forming a mixture, placing the mixture in a mold, maintaining the mixture and the mold at an elevated temperature for a period of time to form a thermally cross-linked molded mixture and removing the thermally cross-linked molded mixture from the mold. The disclosure also includes a three-dimensional carbon structure, with that structure including a thermally cross-linked carbon base material in a predetermined formation.

First claim

What is claimed is:

1. A method of forming a carbon structure, the method comprising the steps of:
providing a carbon material, wherein the carbon material is a nano material selected from the group consisting of multiwalled carbon nanotubes, single walled carbon nanotubes and combinations thereof;
contacting the carbon material with a radical initiator to form a mixture;
heating the mixture for a period of time to form the carbon structure, wherein the hardness of the carbon structure is from about 0.7 MPa to about 4.9 MPa.

2. The method of claim 1 , wherein the ratio of carbon material to radical initiator in the mixture is between 1:0.5 to 1:4.

3. The method of claim 1 , wherein a solvent is added to the mixture.

4. The method of claim 3 , wherein the solvent is chloroform.

5. The method of claim 1 , wherein the mixture is heated to about 60° C. for about 24 hours.

6. The method of claim 1 , wherein the radical initiator is selected from the group consisting of a peroxide, benzoyl peroxide, a compound with a peroxide functional group (ROOR'), methyl ethyl ketone peroxide, Di-tert-butyl peroxide, benzoyl peroxide, acetone peroxide, bisacylphosphine oxide (BAPO), aluminophosphate (MAPO), tert-Amylperoxy-2-ethyl (TAPO) or azobisisobutyronitrile (AIBN) and combinations thereof.

7. The method of claim 1 , wherein the elastic modulus of the carbon structure is from about 16 MPa to about 84 MPa.

8. The method of claim 1 , wherein the carbon structure has a pore diameter of between about 125 nm and about 325 μm.

9. The method of claim 1 , wherein the carbon structure has a porosity of about 20% to about 95%.

10. The method of claim 1 , wherein the carbon structure has a dimension greater than about 1 mm.

11. The method of claim 1 , further comprising annealing the carbon structure at about 150° C. for about 20 minutes.

12. A method of forming a carbon structure, the method comprising the steps of:
providing a carbon material;
contacting the carbon material with a radical initiator to form a mixture;
heating the mixture for a period of time to form the carbon structure, wherein the carbon structure has a pore diameter of between about 125 nm and about 325 μm.

13. The method of claim 12 , wherein the elastic modulus of the carbon structure is from about 16 MPa to about 84 MPa.

14. The method of claim 12 , wherein the hardness of the carbon structure is from about 0.7 MPa to about 4.9 MPa.

15. The method of claim 12 , wherein the carbon structure has a porosity of about 20% to about 95%.

16. The method of claim 12 , further comprising annealing the carbon structure at about 150° C. for about 20 minutes.

17. A method of forming a carbon structure, the method comprising the steps of:
providing a carbon material;
contacting the carbon material with a radical initiator to form a mixture;
heating the mixture for a period of time to form the carbon structure, wherein the carbon structure has a porosity of about 20% to about 95%.

18. The method of claim 17 , wherein the elastic modulus of the carbon structure is from about 16 MPa to about 84 MPa.

19. The method of claim 17 , wherein the hardness of the carbon structure is from about 0.7 MPa to about 4.9 MPa.

20. The method of claim 17 , wherein the carbon structure has a pore diameter of between about 125 nm and about 325 μm.

21. The method of claim 17 , further comprising annealing the carbon structure at about 150° C. for about 20 minutes.

Assignees

• Univ New York State Res Found
• The Res Found For The State Of New York

Inventors

• Sitharaman Balaji
• Lalwani Gaurav

Classifications

• C01B32/15

  Nano-sized carbon materials · CPC title

• Y10S977/742

  Carbon nanotubes, CNTs · CPC title

• C01B32/16

  Preparation · CPC title

• C01P2006/16

  Pore diameter · CPC title

• C01B2202/02

  Single-walled nanotubes · CPC title