Non-thermofusible phenol resin powder, method for producing the same, thermosetting resin composition, sealing material for semiconductor, and adhesive for semiconductor

• US 8,411,415 B2
• Filed: 03/14/2012
• Issued: 04/02/2013
• Est. Priority Date: 10/20/2006
• Status: Active Grant

• Current Assignee: Air Water Incorporated
• Original Assignee: Air Water Incorporated
• Inventors: Yoshinaga, Naoto, Wakayama, Yoshiharu, Ibaraki, Satoshi, Murage, Yoshimi, Shiomi, Niro, Kodani, Yoshinobu, Ikeda, Takaomi, Shimormura, Jun
• Primary Examiner(s): Fang, Shane
• Application Number:
  US13/420,566
• Publication Number:
  US 20120237830A1
• Time in Patent Office: 384 Days
• Field of Search: 429/231.8, 252/511, 361/502, 528/86
• US Class Current: 361/502
• CPC Class Codes: B01J 20/20 comprising free carbon; comprising carbon obtained by carbonising processes
• CPC Class Codes: B01J 20/28004 Sorbent size or size distribution, e.g. particle size
• CPC Class Codes: B01J 20/3078 Thermal treatment, e.g. calcining or pyrolizing
• CPC Class Codes: B29B 2009/125 Micropellets, microgranules, microparticles
• CPC Class Codes: B29B 9/12 characterised by structure or composition
• CPC Class Codes: C01B 13/0266 Carbon based materials
• CPC Class Codes: C01B 21/0461 Carbon based materials
• CPC Class Codes: C01B 2210/0046 Nitrogen
• CPC Class Codes: C08G 59/621 Phenols
• CPC Class Codes: C08G 8/10 with phenol
• CPC Class Codes: C08J 2361/06 of aldehydes with phenols
• CPC Class Codes: C08J 3/12 Powdering or granulating
• 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 11/38 Carbon pastes or blends; Binders or additives therein
• CPC Class Codes: H01G 11/42 Powders or particles, e.g. composition thereof
• CPC Class Codes: H01M 4/133 Electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
• CPC Class Codes: H01M 4/587 for inserting or intercalating light metals
• CPC Class Codes: Y02E 60/10 Energy storage using batteries
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors
• CPC Class Codes: Y10T 428/2982 Particulate matter [e.g., sphere, flake, etc.]

Abstract

Disclosed is a non-thermofusible phenol resin powder having an average particle diameter of not more than 20 μm and a single particle ratio of not less than 0.7. This non-thermofusible phenol resin powder preferably has a chlorine content of not more than 500 ppm. This non-thermofusible phenol resin powder is useful as an organic filler for sealing materials for semiconductors and adhesives for semiconductors. The non-thermofusible phenol resin powder is also useful as a precursor of functional carbon materials such as a molecular sieve carbon and a carbon electrode material.

Claims

1. A carbon powder for electrode having an average particle diameter of not more than 10 μ

m and a single particle ratio of at least 0.7, wherein

the coefficient of variation of a particle size distribution expressed in the following formula [1] is not more than 0.65;

coefficient of variation of particle size distribution=(d_84%−

d_16%)/(2×

average particle diameter) 

 

[1]

where d_84% and d_16% represent particle sizes exhibiting cumulative frequencies of 84% and 16% in a frequency distribution obtained by laser diffraction scattering respectively; and

wherein the carbon powder has a BET specific surface area of 1 to 500 m²/g.

2. The carbon powder for electrode according to claim 1, wherein the sphericity is at least 0.5.

3. A carbon powder for electrode mixture comprising at least two types of carbon powders for electrode according to claim 1 having different average particle diameters.

4. A method for producing the carbon powder for electrode according to claim 1, comprising:

(1) a phenol resin powder forming step of forming a phenol resin powder by reacting an aldehyde and a phenolic compound in an aqueous medium in the presence of an acidic catalyst having a molar concentration of at least 2.0 mol/L in a reaction liquid and a protective colloidal agent;

(2) a non-thermofusibilizing step of forming a non-thermofusible phenol resin powder by heating the reaction liquid containing said phenol resin powder;

(3) a separating step of separating said non-thermofusible phenol resin powder from the reaction liquid; and

(4) a firing step of firing the non-thermofusible phenol resin powder.

5. The method for producing a carbon powder for electrode according to claim 4, wherein

said acidic catalyst is hydrochloric acid, and said aldehyde is formaldehyde, paraformaldehyde or a mixture of these.

6. The method for producing a carbon powder for electrode according to claim 4, wherein

the feed molar ratio of said phenolic compound with respect to said aldehyde is not more than 0.9.

7. The method for producing a carbon powder for electrode according to claim 4, wherein

said protective colloidal agent is a water-soluble polysaccharide derivative.

8. The method for producing a carbon powder for electrode according to claim 4, wherein

said non-thermofusible phenol resin powder has a free phenol content of not more than 500 ppm.

9. A lithium ion battery or a lithium ion capacitor employing the carbon powder for electrode or the carbon powder for electrode mixture according to any one of claims 1 to 3.