Manufacturing methods for the production of carbon materials

• US 8,906,978 B2
• Filed: 10/07/2013
• Issued: 12/09/2014
• Est. Priority Date: 04/08/2009
• Status: Expired due to Fees

• Current Assignee: BASF SE
• Original Assignee: EnerG2 Technologies, Incorporated
• Inventors: Costantino, Henry R., Feaver, Aaron, Scott, William D.
• Primary Examiner(s): CAIN, EDWARD J
• Application Number:
  US14/047,935
• Publication Number:
  US 20140094572A1
• Time in Patent Office: 428 Days
• Field of Search: 521/61, 521/64, 521/181
• US Class Current: 521/181
• CPC Class Codes: B82Y 30/00 Nanotechnology for materials or surface science, e.g. nanocomposites
• CPC Class Codes: C01B 3/0021 Carbon, e.g. active carbon, carbon nanotubes, fullerenes; Treatment thereof
• CPC Class Codes: C01B 32/336 characterised by gaseous activating agents
• CPC Class Codes: C08G 8/22 Resorcinol
• CPC Class Codes: C08G 8/28 Chemically modified polycondensates
• CPC Class Codes: C08J 3/12 Powdering or granulating
• CPC Class Codes: C08K 5/04 Oxygen-containing compounds C08K5/0091 takes precedence
• CPC Class Codes: H01G 11/34 characterised by carbonisation or activation of carbon
• CPC Class Codes: H01M 4/96 Carbon-based electrodes
• CPC Class Codes: H01M 8/0234 Carbonaceous material
• CPC Class Codes: Y02E 60/13 Energy storage using capacitors
• CPC Class Codes: Y02E 60/32 Hydrogen storage
• CPC Class Codes: Y02E 60/50 Fuel cells
• CPC Class Codes: Y02P 70/50 Manufacturing or production processes characterised by the final manufactured product
• CPC Class Codes: Y10T 428/2982 Particulate matter [e.g., sphere, flake, etc.]

Abstract

The present application is generally directed to activated carbon materials and methods for making the same. The disclosed methods comprise rapidly freezing synthetically prepared polymer gel particles. The methods further comprise drying, pyrolyzing, and activating steps to obtain an activated carbon material of high porosity. The disclosed methods represent viable manufacturing processes for the preparation of activated carbon materials.

Claims

1. A polymer cryogel comprising less than about 100 ppm of organic extraction solvent, wherein the polymer cryogel has a tap density ranging from about 0.10 g/cc to about 0.60 g/cc.

2. The polymer cryogel of claim 1, wherein the polymer cryogel has a BET specific surface area ranging from about 100 m²/g to about 1000 m²/g.

3. The polymer cryogel of claim 1, wherein the polymer cryogel has a BET specific surface area of ranging from about 150 m²/g to about 700 m²/g.

4. The polymer cryogel of claim 1, wherein the polymer cryogel has a BET specific surface area ranging from about 400 m²/g to about 700 m²/g.

5. The polymer cryogel of claim 1, wherein the polymer cryogel has a tap density ranging from about 0.15 g/cc to about 0.25 g/cc.

6. The polymer cryogel of claim 3, wherein the polymer cryogel has a tap density ranging from about 0.15 g/cc to about 0.25 g/cc.

7. The polymer cryogel of claim 4, wherein the polymer cryogel has a tap density ranging from about 0.15 g/cc to about 0.25 g/cc.

8. The polymer cryogel of claim 1, wherein the polymer cryogel comprises less than 10 ppm of organic extraction solvent.

9. The polymer cryogel of claim 1, wherein the organic extraction solvent is t-butanol.

10. The polymer cryogel of claim 1, wherein the organic extraction solvent is acetone.