Method of forming fibrous materials and articles therefrom

• US 6,551,533 B1
• Filed: 11/28/2000
• Issued: 04/22/2003
• Est. Priority Date: 11/28/2000
• Status: Expired due to Fees

• Current Assignee: Chemat Technology, Inc.
• Original Assignee: Chemat Technology, Inc.
• Inventors: Huang, Yuhong, Wei, Qiang, Zheng, Haixing
• Primary Examiner(s): Tentoni, Leo B.
• Application Number:
  US09/727,018
• Time in Patent Office: 875 Days
• Field of Search: 264/13, 264/82, 264/103, 264/104, 264/211.11, 264/236, 264/477, 264/494, 264/495, 264/618, 264/621, 264/623, 264/681
• US Class Current: 264/13
• CPC Class Codes: C04B 14/46 Rock wool ; Ceramic or silicate fibres C04B14/40, C04B14/42 take precedence
• CPC Class Codes: C04B 14/4606 added as organic or organo-mineral precursors
• CPC Class Codes: C04B 2103/0067 the ingredients being formed in situ by chemical reactions or conversion of one or more of the compounds of the composition
• CPC Class Codes: C04B 2235/3289 Noble metal oxides
• CPC Class Codes: C04B 30/02 containing fibrous materials
• CPC Class Codes: C04B 35/62231 based on oxide ceramics
• CPC Class Codes: C04B 35/62259 Fibres based on titanium oxide
• CPC Class Codes: C04B 35/6365 Cellulose or derivatives thereof
• CPC Class Codes: C04B 41/455 the coating or impregnating process including a chemical conversion or reaction
• CPC Class Codes: D01F 9/10 by decomposition of organic substances D01F9/12 takes precedence
• 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 11/30 characterised by their material
• CPC Class Codes: H01G 11/46 Metal oxides
• CPC Class Codes: H01G 11/86 specially adapted for electrodes carbonisation or activation of carbon for the manufacture of electrodes H01G11/34
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors

Abstract

A method including synthesizing polymeric precursors via organic acid modification; fabricating a fibrous material of the polymeric precursors; and fabricating a body of the fibrous material. One body has dimensions suitable as an electrode component of an electrical storage device.

Claims

1. A method comprising:

synthesizing polymeric precursors via one of organic acid modification and aminolysis;

fabricating a fibrous material of the polymeric precursors; and

fabricating a body of the fibrous material.

2. The method of claim 1, further comprising:

sintering the body of the fibrous material.

3. The method of claim 2, wherein sintering comprises synthesizing one of an oxide, a carbide, an oxycarbide, and an oxycarbonitride by the introduction into the body of fibrous material of a gas species.

4. The method of claim 1, wherein synthesizing the polymeric precursors comprises polymerizing one of a metal alkoxide and a metal amide.

5. The method of claim 1, wherein synthesizing the polymeric precursors comprises:

hydrolyzing the metal alkoxide.

6. The method of claim 1, wherein synthesizing the polymeric precursors comprises aminolyzing a metal amide.

7. The method of claim 1, further comprising, after fabricating the fibrous material:

curing the fibrous material.

8. The method of claim 7, wherein curing comprises one of radiation curing and thermal curing.

9. The method of claim 1, wherein fabricating the fibrous material comprises:

one of extruding and spinning the polymeric precursors.

10. The method of claim 9, wherein extruding comprises extruding the fibrous material into lengths of fiber on the order of about 10 to 100 microns.

11. The method of claim 1, wherein fabricating the body comprises weaving the fibrous material.

12. The method of claim 1, wherein fabricating the body comprises dispersing the fibrous material in a binder.

13. The method of claim 12, wherein the binder is cellulose.

14. The method of claim 1, further comprising:

fabricating the body of the fibrous material into an electrode.

15. A method comprising:

fabricating a fibrous material by one of a sol-gel and a aminolysis process; and

fabricating the fibrous material into an electrode body.

16. The method of claim 15, wherein fabricating a fibrous material comprises:

synthesizing a polymeric precursor from a unit having the general formula;

17. The method of claim 15, wherein fabricating a fibrous material comprises:

synthesizing a polymeric precursor form a unit having the general formula;

18. The method of claim 17, wherein fabricating the fibrous material comprises:

one of spinning and extruding the polymeric precursors.

19. The method of claim 18, wherein extruding comprises extruding the fibrous material into lengths of fiber on the order of about 10 to 100 microns.

20. The method of claim 18, further comprising, after one of spinning and extruding, curing.

21. The method of claim 20, wherein curing comprises one of radiation curing and thermal curing.

22. The method of claim 15, wherein fabricating the electrode body comprises weaving the fibrous material.

23. The method of claim 15, wherein fabricating the electrode body comprises dispersing the fibrous material in a binder.

24. The method of claim 23, wherein the binder is cellulose.

25. The method of claim 23, further comprising, after dispersing:

modifying the fibrous material to an electrode body comprised of moieties of the metal, M, and a heteroatom, Y, selected from the group consisting of oxygen, nitrogen, carbon, and boron.

26. The method of claim 25, wherein modifying comprises sintering by the introduction into the body of fibrous material of a gas species.