Emulsion and suspension polymerization processes, and improved electrochemical performance for carbon derived from same
First Claim
1. A method for making polymer particles in gel form via an emulsion or suspension process, the method comprising preparing a reactant mixture comprising a monomer component containing one or more phenolic compounds and one or more crosslinking compounds, and a carrier fluid, wherein:
- the carrier fluid contains less than 50 wt % cyclohexane, based on the total weight of the carrier fluid,the monomer component polymerizes to form the polymer particles in gel form,the carrier fluid comprises an acid, a base, a catalyst, or a combination thereof, at a concentration for each species of at least 50% of the saturation limit, anda volume average particle size (Dv,50) of the polymer particles in gel form is greater than or equal to 1 mm.
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Abstract
The present application is directed to methods for preparation of polymer particles in gel form and carbon materials made therefrom. The carbon materials comprise enhanced electrochemical properties and find utility in any number of electrical devices, for example, as electrode material in ultracapacitors or batteries. The methods herein can also be employed generally to improve emulsion and/or suspension polymerization processes by improved control of diffusion of acidic and basic species between the polymer and secondary phases.
39 Citations
20 Claims
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1. A method for making polymer particles in gel form via an emulsion or suspension process, the method comprising preparing a reactant mixture comprising a monomer component containing one or more phenolic compounds and one or more crosslinking compounds, and a carrier fluid, wherein:
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the carrier fluid contains less than 50 wt % cyclohexane, based on the total weight of the carrier fluid, the monomer component polymerizes to form the polymer particles in gel form, the carrier fluid comprises an acid, a base, a catalyst, or a combination thereof, at a concentration for each species of at least 50% of the saturation limit, and a volume average particle size (Dv,50) of the polymer particles in gel form is greater than or equal to 1 mm. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13)
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14. A method for making polymer particles in gel form via an emulsion or suspension process, the method comprising preparing a reactant mixture comprising a monomer component containing one or more phenolic compounds and one or more crosslinking compounds, and a carrier fluid, wherein:
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the monomer component polymerizes to form the polymer particles in gel form, the carrier fluid is free of or contains a surfactant at a concentration less than the critical micelle concentration, the carrier fluid comprises an acid, a base, a catalyst, or a combination thereof, at a concentration for each species of at least 50% of the saturation limit, and a volume average particle size (Dv,50) of the polymer particles in gel form is greater than or equal to 1 mm. - View Dependent Claims (15, 16, 17, 18, 19, 20)
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Specification