Porous carbon material, composite material reinforced with carbon material, porous carbon material precursor, porous carbon material precursor production method, and porous carbon material production method

• US 10,131,770 B2
• Filed: 02/13/2015
• Issued: 11/20/2018
• Est. Priority Date: 02/26/2014
• Status: Active Grant

• Current Assignee: Toray Industries Incorporated
• Original Assignee: Toray Industries Incorporated
• Inventors: Mihara, Takaaki, Tanaka, Kentaro, Takeuchi, Kosaku, Horiguchi, Tomoyuki
• Primary Examiner(s): Cain, Edward J
• Application Number:
  US15/121,424
• Publication Number:
  US 20160362541A1
• Time in Patent Office: 1,376 Days
• CPC Class Codes: B29B 7/002 Methods chemical aspects C08J3/00
• CPC Class Codes: B29C 55/005 characterised by the choice of materials
• CPC Class Codes: B29K 2033/20 PAN, i.e. polyacrylonitrile
• CPC Class Codes: B29K 2039/06 Polymers of N-vinyl-pyrrolidones
• CPC Class Codes: B29L 2031/731 Filamentary material, i.e. comprised of a single element, e.g. filaments, strands, threads, fibres cables B29L2031/707
• 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: C01B 32/306 with molecular sieve properties
• CPC Class Codes: C01B 32/366 by physical processes, e.g. by irradiation, by using electric current passing through carbonaceous feedstock or by using recyclable inert heating bodies
• CPC Class Codes: C01B 32/382 Making shaped products, e.g. fibres, spheres, membranes or foam
• CPC Class Codes: C01P 2002/70 defined by measured X-ray, neutron or electron diffraction data
• CPC Class Codes: C01P 2004/03 obtained by SEM
• CPC Class Codes: C04B 2235/422 Carbon
• CPC Class Codes: C04B 2235/48 Organic compounds becoming part of a ceramic after heat treatment, e.g. carbonising phenol resins
• CPC Class Codes: C04B 35/565 based on silicon carbide
• CPC Class Codes: C04B 35/83 Carbon fibres in a carbon matrix
• CPC Class Codes: C04B 38/0022 obtained by a chemical conversion or reaction other than those relating to the setting or hardening of cement-like material or to the formation of a sol or a gel, e.g. by carbonising or pyrolysing preformed cellular materials based on polymers, organo-metallic or organo-silicon precursors
• CPC Class Codes: C04B 38/0051 characterised by the pore size, pore shape or kind of porosity
• CPC Class Codes: C04B 38/068 Carbonaceous materials, e.g. coal, carbon, graphite, hydrocarbons
• CPC Class Codes: C08K 2201/016 Additives defined by their aspect ratio
• CPC Class Codes: C08K 7/24 inorganic
• CPC Class Codes: C08L 2203/12 : used for fibers
• CPC Class Codes: C08L 33/20 : Homopolymers or copolymers of acrylonitrile C08L55/02 takes precedence
• CPC Class Codes: C08L 39/06 : Homopolymers or copolymers of N-vinyl-pyrrolidones
• CPC Class Codes: D01D 5/247 : Discontinuous hollow structure or microporous structure
• CPC Class Codes: D01F 1/08 : for forming hollow filaments
• CPC Class Codes: D01F 6/54 : of polymers of unsaturated nitriles
• CPC Class Codes: D01F 6/56 : of polymers of cyclic compounds with one carbon-to-carbon double bond in the side chain
• CPC Class Codes: D01F 9/22 : from polyacrylonitriles

Abstract

A carbon material having a continuous porous structure oriented to the stretching axis is provided, which carbon material can be used as a structural material excellent in interfacial adhesion. The porous carbon material has a continuous porous structure in at least a portion thereof, in which the continuous porous structure has an orientation degree measured by a small-angle X-ray scattering method or an X-ray CT method of 1.10 or more.

Claims

1. A porous carbon material having a continuous porous structure in at least a portion thereof, in which the continuous porous structure has an orientation degree measured by a small-angle X-ray scattering method or an X-ray CT method of 1.10 or more, wherein the continuous porous structure is continuous three-dimensionally when a longitudinal section or cross section of the porous carbon material or a surface of pulverized porous carbon material is observed by a scanning secondary electron microscope and when the longitudinal section or cross section of the porous carbon material or surface of pulverized porous carbon material is tilted.

2. The porous carbon material according to claim 1, wherein a structural period of a major axis side thereof is from 5 nm to 5 μ

m, and a structural period of a minor axis side thereof is from 10 nm to 20 μ

m.

3. The porous carbon material according to claim 1, having a dense layer at least in a portion of a surface thereof.

4. A composite material reinforced with a carbon material, which is obtained by compositing the porous carbon material according to claim 1 with a resin.

5. The porous carbon material according to claim 1, which is in a form of a fiber.

6. The porous carbon material according to claim 1, which is in a form of a film.

7. The porous carbon material according to claim 1, which is in a form of a particle.

8. The porous carbon material according to claim 5, wherein an aspect ratio calculated by fiber length/fiber diameter is 2 or more.

9. A process for producing a porous-carbon-material precursor, the process comprising:

step 1;

a step in which a carbonizable resin and an eliminable resin are brought into a compatibly mixed state to obtain a resin mixture;

step 2;

a step in which the resin mixture obtained in the step 1 is molded and caused to undergo phase separation, thereby obtaining a precursor material having a co-continuous phase separation structure in which the phases in which the carbonizable resin and the eliminable resin constituting the resin mixture occupy 50% by weight or more undergo phase separation in succession with each other; and

step 3;

a step in which the precursor material obtained in the step 2 is subjected to stretching.

10. The process for producing a porous-carbon-material precursor according to claim 9, wherein, in the step 1, from 10 to 90% by weight of the carbonizable resin and from 90 to 10% by weight of the eliminable resin are brought into a compatibly mixed state.

11. The process for producing a porous-carbon-material precursor according to claim 9, wherein, in the step 3, the stretching is performed multiple times.

12. The process for producing a porous-carbon-material precursor according to claim 9, further comprising a step of removing the eliminable resin after the step 3.

13. A process for producing a porous carbon material, the process comprising:

step 1;

a step in which a carbonizable resin and an eliminable resin are brought into a compatibly mixed state to obtain a resin mixture;

step 2;

a step in which the resin mixture obtained in the step 1 is molded and caused to undergo phase separation, thereby obtaining a precursor material having a co-continuous phase separation structure;

step 3;

a step in which the precursor material obtained in the step 2 is subjected to stretching to obtain a porous-carbon-material precursor; and

step 5′

;

a carbonization treatment step in which the porous-carbon-material precursor obtained in the step 3 is carbonized and the eliminable resin is removed therefrom.

14. A process for producing a porous carbon material, the process comprising:

step 1;

a step in which a carbonizable resin and an eliminable resin are brought into a compatibly mixed state to obtain a resin mixture;

step 2;

a step in which the resin mixture obtained in the step 1 is molded and caused to undergo phase separation, thereby obtaining a precursor material having a co-continuous phase separation structure;

step 3;

a step in which the precursor material obtained in the step 2 is subjected to stretching to obtain a porous-carbon-material precursor;

step 4;

a step in which the eliminable resin is removed from the porous-carbon-material precursor obtained in the step 3; and

step 5;

a carbonization treatment step in which the porous-carbon-material precursor from which the eliminable resin has been removed obtained in the step 4 is carbonized.

15. A porous-carbon-material precursor having a co-continuous phase separation structure in at least a portion thereof, in which the co-continuous phase separation structure has an orientation degree measured by a small-angle X-ray scattering method or an X-ray CT method of 1.10 or more.