Macroreticular carbonaceous material useful in energy storing devices

• US 20050058589A1
• Filed: 09/02/2004
• Published: 03/17/2005
• Est. Priority Date: 09/12/2003
• Status: Active Grant

• Current Assignee: Rohm and Haas Company (Dow, Inc.)
• Original Assignee: Rohm and Haas Company (Dow, Inc.)
• Inventors: Lundquist, Eric Gustave, Parker, Garth R.
• Granted Patent: US 7,419,649 B2
• Time in Patent Office: Days
• US Class Current: 423/445.R
• CPC Class Codes: C01B 32/00 Carbon; Compounds thereof C01B21/00, C01B23/00 take precedence; percarbonates C01B15/10; carbon black C09C1/48
• CPC Class Codes: C04B 2111/00853 in electrochemical cells or batteries, e.g. fuel cells
• CPC Class Codes: C04B 35/52 based on carbon, e.g. graphite
• CPC Class Codes: C04B 38/0054 the pores being microsized or nanosized
• CPC Class Codes: C04B 38/0064 Multimodal pore size distribution
• CPC Class Codes: C04B 38/0074 expressed as porosity percentage
• CPC Class Codes: H01G 11/24 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 Class Codes: H01G 11/32 Carbon-based
• CPC Class Codes: H01M 2004/021 Physical characteristics, e.g. porosity, surface area
• CPC Class Codes: H01M 4/133 Electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
• CPC Class Codes: H01M 4/583 Carbonaceous material, e.g. graphite-intercalation compounds or CFx
• CPC Class Codes: H01M 4/587 for inserting or intercalating light metals
• CPC Class Codes: H01M 4/625 Carbon or graphite
• CPC Class Codes: H01M 4/96 Carbon-based electrodes
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y10S 977/948 Energy storage/generating using nanostructure, e.g. fuel cell, battery

Abstract

The present invention relates to an energy storage device comprising a macroreticular carbonaceous material having a distribution of micropores, mesopores and macropores wherein the macroreticular carbonaceous material has a total surface area of from greater than 500 m²/g to 2500 m²/g and wherein 20% to 80% of the total surface area is due to pores with diameters of from 17 angstroms to 100,000 angstroms. In addition, the present invention relates to an energy storage device comprising a macroreticular carbonaceous material having at least one first distinct peak representing a pore size of less than or equal to 20 angstroms when measured utilizing H-K dv/dlog(W) pore size distribution and at least one second distinct peak representing a pore size greater than 20 angstroms when measured utilizing BJH dv/dlog(D) pore size distribution.

Claims

1. An energy storage device comprising a macroreticular carbonaceous material having a distribution of micropores, mesopores and macropores wherein the macroreticular carbonaceous material has a total surface area of from greater than 500 m²/g to 2500 m²/g and wherein 20% to 80% of the total surface area is due to pores with diameters of from 17 angstroms to 100,000 angstroms.

2. The energy storage device according to claim 1 wherein the macroreticular carbonaceous material has a total surface area of from greater than 800 m²/g to 2500 m²/g.

3. The energy storage device according to claim 1 wherein 24% to 60% of the total surface area is due to pores with diameters of from 17 angstroms to 100,000 angstroms.

4. The energy storage device of claim 1 comprising a macroreticular carbonaceous material wherein measurement of pore size distribution of the macroreticular carbonaceous material yields at least one first distinct peak representing a pore size of less than or equal to 20 angstroms when measured utilizing H-K dv/dlog(W) pore size distribution and at least one second distinct peak representing a pore size greater than 20 angstroms when measured utilizing BJH dv/dlog(D) pore size distribution.

5. The energy storage device of claim 4 wherein the at least one second distinct peak represents a pore size greater than 30 angstroms when measured utilizing BJH dv/dlog(D) pore size distribution.

6. The energy storage device of claim 4 wherein the at least one second distinct peak represents a pore size greater than 50 angstroms when measured utilizing BJH dv/dlog(D) pore size distribution.

7. The energy storage device of claim 4 wherein the at least one second distinct peak represents a pore size greater than 100 angstroms when measured utilizing BJH dv/dlog(D) pore size distribution.

9. The energy storage device of claim 1 or claim 8 where the energy storage device is a capacitor, a battery, a fuel cell, a power stabilization device, or an electrocapacitive deionization device.

11. The carbonaceous material of claim 1 or claim 8 wherein figure of merit is measured and is greater than 5 W/g in organic electrolyte and greater than 25 W/g in aqueous electrolyte.

12. The carbonaceous material of claim 1 or claim 8 wherein the carbonaceous material is in a form selected from the group consisting of powders, granules, monoliths, beads, sheets, blocks, threads, filaments, tubes, papers, membranes, felts, foams, plates, fabrics and nonwovens.

16. The use of the energy storage device of claim 1 or claim 8 in automobile applications, power quality, engine starting, energy storage in photovoltaic, energy storage in windmills, medical applications, mobile propulsion systems, military and defense electronics, transportation systems, business and commercial electronics, consumer electronics, audio systems, and consumer appliances.

8. An energy storage device comprising a carbonaceous material wherein measurement of pore size distribution of the carbonaceous material yields at least one first distinct peak representing a pore size less than 20 angstroms when measured utilizing H-K dv/dlog(W) pore size distribution and at least one second distinct peak representing a pore size greater than 125 angstroms when measured utilizing BJH dv/dlog(D) pore size distribution.

10. A carbon based energy storage device wherein capacitance decreases less than 100% in an organic electrolyte and less than 75% in an aqueous electrolyte in going from 0.1 Hz to 1000 Hz.

13. A macroreticular carbonaceous material produced by pyrolysis of a macroreticular phenol/formaldehyde polymer wherein the phenol/formaldehyde polymer is formed by a base catalyzed condensation reaction of phenol with formaldehyde at a phenol/catalyst ratio of less than 50.

14. A process for making a carbonaceous material comprising pyrolysis of a polymer wherein pore size and density can be changed by swelling or shrinking the pores of the polymer prior to pyrolysis.

15. The carbonaceous material of claim 14 wherein the carbonaceous material is macroreticular.