CN1461289A - 碳泡沫及其制造方法 - Google Patents
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Abstract
本发明描述了一种碳泡沫的制造方法,包括将含有至少一种可热解物质和至少一种不可热解物料的混合物热解,然后除去不可热解物料以获得碳泡沫。本发明还公开了通过此方法制造的碳泡沫。此外,本发明还描述了将此碳泡沫引入到各种最终应用,包括电极、热绝缘材料、聚合物等等中的用途。
Description
发明背景
本发明涉及碳泡沫(carbon foam)和碳泡沫的制造方法以及它们在各种产品如绝缘材料和电容器中的用途。
碳气溶胶已在各种应用中使用,所述应用包括热绝缘、用于聚合物或塑料的导电填料、电极和电化学电池。具有大表面积和高DBP值的碳气溶胶在很多这些应用和其它应用中是合意的。
已知有制造碳气溶胶的各种方法,包括使用沥青,使用有机凝胶与催化剂并将混合物反应,使用溶胶-凝胶聚合以形成高度交联网状结构的大表面积泡沫以及将聚丙烯腈溶解在经过加热的溶液中,所述的溶液含有存在于溶剂中的至少一种碱金属卤化物,最后形成液体凝胶。然后,将此液体凝胶加热,其中溶剂随被溶解的碱金属卤化物一同被除去,得到基本上由聚丙烯腈组成的多孔形式,然后将此多孔形式在高温下固化,以便将聚丙烯腈碳化形成碳泡沫。
尽管这种方法是有效的,但是在工业中总是期望开发出其它更便宜的碳泡沫的制造方法,所述方法优选能够在制造具有较大表面积以及高度结构性(high structure)的泡沫方面具有较大的适应性。
发明概述
本发明的一个特点是提供碳泡沫。
本发明的另一个特点是提供优选具有大表面积和高度结构性的碳泡沫。
本发明的再一个特点是提供碳泡沫的制造方法。
再有,本发明的另一个特点是将此碳泡沫引入到诸如热绝缘、弹性体或塑料补强、导电填料、电极等的应用中。
本发明的其它特点和优点一部分将记载在以下的描述中并且一部分将从这些描述中显而易见地得到,或者可以通过实践本发明而领悟到。本发明的目的和其它优点将通过以下书面描述和权利要求书中具体记载的组成要素和组合来实现和获得。
为实现这些优点和其它优点,并且达到本发明的目的(如本文所具体举例和一般描述的),本发明涉及一种碳泡沫的制造方法,该方法包括将含有至少一种可热解物质和至少一种不可热解物料的混合物热解,然后除去不可热解物料,获得碳泡沫。
本发明还涉及通过上述方法制造的碳泡沫。
本发明还涉及碳泡沫,该碳泡沫具有通过薄片或窗和/或支杆(strut)相邻接的网格(cell)。泡沫颗粒的直径一般为约5至约30微米并且网格的直径为约0.5至约3微米。一般来说,网格不是封闭的,但在它们之间有开孔。由于泡沫可以是刚性的(rigid),因此泡沫的片可以被折断并且物料中可以同时含有泡沫颗粒及其断片。
应当理解,前述的概括描述以及以下的详细描述仅仅是示例性的和解释性的,只是用于提供对本发明(如权利要求书所要求的)的进一步解释。
附图说明
图1是本发明的一种类型的碳泡沫颗粒的透射电子显微照片。
图2和3是本发明的碳泡沫颗粒的扫描电子显微照片。
发明详述
本发明涉及碳泡沫及这些碳泡沫的制造方法。本发明还涉及这些碳泡沫在各种最终应用中的用途。
本发明的碳泡沫优选通过将含有至少一种可热解物质和至少一种不可热解物料的混合物热解来制成。当将混合物热解后,将不可热解物料除去,获得碳泡沫。
然后,这种碳泡沫可以以泡沫状使用,或者可以将它们减径成碎片以形成颗粒,所述的颗粒优选是高度结构化的。
更详细地,参考上述方法,欲被热解的物质优选是有机物,例如有机化合物。实例包括,但不限于:碳水化合物类、煤(coal)和烃类。本质上说,所用的物质是当加热时能被裂解而非蒸发的物质。优选的可热解物质是糖、纤维素化合物类、煤等等。其它实例包括(但不限于)烃类和聚合物及其衍生物。
不可热解物料是可热解物质的反义词。换句话说,不可热解物料当加热时不裂解而是优选在整个热解步骤中能够保持它的状态。优选,不可热解物料是无机物料,例如盐。
热解步骤可以在能够导致可热解物质被热解或者至少部分被热解的任何温度下发生。取决于形成碳泡沫时所发生的热解的程度,碳泡沫可以显示出各种性能。低度热解或不完全热解通常产生不导电的碳泡沫,而经过完全热解或近乎完全热解的物料通常是电导性的。此外,热解得越完全,通常所形成的碳泡沫的导电性越高。因此,本发明中,可以通过控制热解的程度,来使碳泡沫的性能“调整”至合意的性能。作为另一个实例,热解温度决定着热解后物料的化学和物理组成。例如,如果将糖在350℃至400℃下热解,所得的物料是褐色的并且含有约2%的氢。它基本上是非导电的。如果将糖加热至700℃,泡沫变成黑色并且是电导性的并且如果进一步加热至1100℃,导电性进一步增加。
热解温度范围的实例包括(但不限于)约200℃至约1600℃,并且更优选约400℃至约1600℃。肯定地说,其它温度范围也是可以的,取决于所用可热解物质的类型。鉴于目前的应用和常规试验,一旦确定了可热解物质,确定必要的热解温度属于本领域技术人员力所能及的范围。
含有至少一种可热解物质和至少一种不可热解物料的混合物优选是细的分散体。这种混合物可以通过使用常规混合装置将可热解物质与不可热解物质混合来获得。优选,该混合物是可热解物质与不可热解物质的均相混合物,以便获得均相泡沫。这种混合物可以通过使用标准研磨技术将可热解物质与不可热解物质一起研磨来制备。例如,可以使用高强度研磨,如球磨。还可以使用钢丸磨或砂磨机。
混合也可以通过使用加拿大专利申请CA 2,230,443和US专利5,328,501中描述的机械和/或化学技术,例如高能量研磨等等来完成,上述两篇文献被全文引入本文作为参考。
或者,混合可以通过将可热解物质和不可热解物料溶解于能够溶解此两种物料的溶剂中来获得。将此混合物溶于一种或多种溶剂后,可以让此溶液沉淀,以便除去溶剂并且形成细分散的混合物。此方法可以通过将溶液雾化并且允许液滴干燥来实现,其中所述的溶液含有被溶解了的可热解物质和不可热解物料。
制备混合物的另一种方法可以包括将一种流体与可热解物质和不可热解物料混合,制成面糊或面团状物料。然后,可以将此面团或面糊在密闭式混合机如班伯里密炼机或其它能够提供两成分均相混合物的设备中研磨。可以使用其它技术来将可热解物质与不可热解物料混合。
当获得混合物之后,可以将此混合物如上所述地热解。热解可以通过使用能够实现达到使混合物热解所必要的温度的任何常规设备来进行。这种设备包括(但不限于)旋转和固定床式窑(kilns)。
混合物经热解后,可以将由于其性能而没有被热解的不可热解物料除去。这种物料的去除可以通过任何技术来完成,例如将不可热解物料溶解。或者,可以将不可热解物料蒸发掉或熔融掉,或可以通过使不可热解物料升华来去除。当除去不可热解物料后,便获得了碳泡沫,其具有碳成形的网格的网状结构。
本发明所形成的碳泡沫优选具有含有网格的碳泡沫,其中所述的网格的相邻之间的边界为薄片、窗和/或支杆。泡沫颗粒的跨度一般为约5至约30微米并且网格的厚度为约0.5至约3微米。一般来说,网格不是封闭的,但它们之间具有开孔。泡沫可以是刚性的,并且片可以被折断。因此,此物料可以同时含有泡沫颗粒及其断片。
在一个实施方案中,本发明的碳泡沫具有的BET表面积优选为约100至约500m2/g,并且更优选约270至约350m2/g。本发明的其它碳泡沫可以具有其它BET表面积,取决于形成碳泡沫所用的起始物料和热解的程度。碳泡沫还可以具有约100cc/100g至约500cc/100g的DBP吸附度。同样,碳泡沫可以具有其它DBP吸附度,取决于形成碳泡沫所用的起始物料以及热解的程度。本发明的碳泡沫优选具有不同于气溶胶的壁或窗,气溶胶仅仅具有非常小的支杆。在本发明的碳泡沫中,窗优选固定到支杆上。
接下来,使用各种技术将本发明碳泡沫化学改性或进行表面处理,例如将有机基团连接到碳泡沫的表面上。这种技术和基团包括(但不限于)美国专利5,900,029;5,895,522;5,885,335;5,851,280;5,837,045;5,803,959;5,672,198;5,571,311;5,630,868;5,707,432;5,803,959;5,554,739;5,698,016;5,713,988;WO 96/18688;WO 97/47697;WO 97/47699和US专利申请系列号09/317,287;60/116,500;60/135,558;60/163,716和60/163,857中所述的;所有均整体引入本文作为参考。
优选,不可热解物料是可被水溶解的,由此使得去除不可热解物料的步骤变得经济和容易。例如,如果不可热解物料是盐,则通过水便通常可以达到去除的目的。
本发明的碳泡沫,当形成后,可以用作任何其它常规的碳泡沫。例如,可以按照美国专利5,300,272;6,033,506;5,945,084和5,476,878中描述的方式使用此碳泡沫,所有均引入本文作为参考。
如果需要,可以将碳泡沫减径成断片和/或颗粒。碳泡沫的减径可以通过任何技术来实现,例如将碳泡沫磨碎成高度结构化的颗粒和/或断片。磨碎的碳泡沫可以用作填料或任何其它用于碳基颗粒的用途。
如上所述,碳泡沫可以用于各种应用中,包括热绝缘、聚合物、高弹体、电容器、电池电极(battery electrodes)、燃料电池、电化学电池或超电容器中的电极等等。碳泡沫或其断片还可以用作聚合物中的导电填料或高弹体中的补强填料。鉴于目前的应用和在这些应用中使用碳泡沫的技术,碳泡沫在这些应用中使用的方式和用量对本领域技术人员来说是常规的和已知的。
本发明通过以下实施例将会进一步得到阐明,这些实施例仅仅是本发明的示例。
BET表面积通过使用ASTM第09.01卷的方法D 4820来测定并且DBP通过使用ASTM第09.01卷的方法D2414来测定。
实施例
实施例1
在本实施例中,使用糖作为可热解物质且使用氯化钠作为不可热解物料。所用的盐与糖的重量比为10∶1或5∶1,将配料在钢丸磨(shot mill)中混合在一起。将混合物研磨30分钟。
在第二组实验中,将相同比例的盐和糖溶解在水中,然后喷雾干燥。
将经过研磨的混合物和喷雾干燥的混合物都在初始温度为350至400℃的温度下煅烧30分钟。据证实,此温度足以引起糖的部分热解。煅烧在氮气的惰性气氛下进行。
在各自的情况中,然后将裂解的混合物用水洗涤,除去盐并且留下裂解的糖。然后,将物料在氮气气氛中于两种不同温度700℃和1100℃下进一步煅烧30分钟。
测定所得碳泡沫的表面积和DBP。所得碳泡沫的BET表面积为270至290平方米每克并且DBP吸附度为370cc′s每100克。此外,图1显示了透射电子显微照片并且图2和3是一些在1100℃下煅烧的颗粒的扫描电子显微照片,放大率如显微照片中所示。
实施例2
将盐和煤一起在Szegvari超细磨碎机中使用500g 3/16″不锈钢钢丸和500g 3/8″陶瓷珠以最高速度设定点磨碎30分钟。在超细磨碎机中使用100g盐和20g或10g煤,形成5∶1或10∶1重量比的盐和煤。研磨后所得颗粒粒度分布为约1至40微米。平均颗粒粒度为约6微米。然后,将磨碎的盐和煤样品在管式炉中用30分钟的时间从室温加热至700℃,随后在氮气气氛中于700℃下放置1小时。然后用1升水洗涤此样品并且通过6微米滤器真空过滤,除去任何盐。此操作进行两次。然后将样品在120℃下干燥。使用ASTM第09.01卷的方法D4820测定BET表面积。
样品#
描述
BET表面积(M 2 /gCB)
1 单独的煤 1.5
2 5∶1盐/煤 82.7
3 10∶1盐/煤 236.1
然后通过将管式炉加热至700℃,然后使用与舟皿(boat)相连的不锈钢线将样品牵引到加热炉中,以此将样品闪式加热。
样品#
描述
BET表面积(M 2 /gCB)
4 单独的煤 2.2
5 5∶1盐/煤 165
6 10∶1盐/煤 280正如从样品中看到的,使用盐可明显地增加表面积。快速加热可进一步增加表面积。
这些实施例中形成的碳泡沫对用于各种最终应用是可接受的,例如在聚合物配混料(polymer compound)、热绝缘材料、电极、电容器等等中。此碳泡沫可以代替在这些最终应用中常规的填料、颜料或颗粒。
依据本文所公开的具体说明和本发明的实践,本发明的其它实施方案对本领域技术人员来说是显而易见的。目前的具体说明和实施例应当认为仅仅是示例性的,而本发明的实际范围和实质由权利要求书及其等效内容来限定。
Claims (39)
1.一种碳泡沫的制造方法,包括将含有至少一种可热解物质和至少一种不可热解物料的混合物热解;并且在热解之后,除去所述的不可热解物料以获得碳泡沫。
2.权利要求1的方法,还包括将所述的碳泡沫磨碎成颗粒。
3.权利要求1的方法,其中所述的可热解物质是有机化合物。
4.权利要求1的方法,其中所述的可热解物质包括至少一种碳水化合物。
5.权利要求1的方法,其中所述的可热解物质是糖或纤维素。
6.权利要求1的方法,其中所述的可热解物质包括至少一种含烃物料。
7.权利要求1的方法,其中所述的可热解物质包括煤。
8.权利要求1的方法,其中所述的不可热解物料是无机物料。
9.权利要求1的方法,其中所述的不可热解物料是盐。
10.权利要求1的方法,其中所述的热解在约300℃至约1600℃的温度下发生。
11.权利要求1的方法,其中将所述的混合物快速加热。
12.权利要求1的方法,其中所述的混合物是细分散体。
13.权利要求1的方法,其中所述的混合物通过将所述的可热解物质和不可热解物料研磨来获得。
14.权利要求1的方法,其中所述的混合物通过将至少一种可热解物质与至少一种不可热解物料一起溶解于溶剂中、然后从所述的溶剂中沉淀出可热解物质和不可热解物料来获得。
15.权利要求1的方法,其中所述的不可热解物料的去除是通过溶解不可热解物料来完成的。
16.权利要求1的方法,其中所述的不可热解物料的去除是通过蒸发、通过熔融、通过升华或其组合来完成的。
17.通过权利要求1的方法形成的碳泡沫。
18.一种具有网格的碳泡沫,所述的网格通过薄片、窗、支杆或其组合相邻接,其中所述的碳泡沫所具有的BET表面积为约100至约500m2/g。
19.权利要求18的碳泡沫,其中所述的碳泡沫具有约100cc/100g至约500cc/100g的DBP吸收度。
20.权利要求18的碳泡沫,其中所述的碳泡沫颗粒的直径为约5至约30微米,并且所述的网格的直径为约0.5至约3微米。
21.权利要求18的碳泡沫,其中所述的网格之间具有开孔。
22.权利要求18的碳泡沫,其中所述的碳泡沫是刚性的。
23.一种含有权利要求18的碳泡沫和/或其断片的热绝缘材料。
24.一种含有权利要求18的碳泡沫和/或其断片的聚合物配混料。
25.一种含有权利要求18的碳泡沫和/或其断片的高弹体配混料。
26.一种含有权利要求18的碳泡沫的电极。
27.一种含有权利要求18的碳泡沫的电容器电极。
28.一种含有权利要求18的碳泡沫的电池电极。
29.一种含有权利要求18的碳泡沫的燃料电池电极。
30.权利要求17的碳泡沫,其中所述的碳泡沫颗粒的直径为约5至约30微米并且所述的网格的直径为约0.5至约3微米。
31.权利要求17的碳泡沫,其中所述的网格之间具有开孔。
32.权利要求17的碳泡沫,其中所述的碳泡沫是刚性的。
33.一种含有权利要求17的碳泡沫和/或其断片的热绝缘材料。
34.一种含有权利要求17的碳泡沫和/或其断片的聚合物配混料。
35.一种含有权利要求17的碳泡沫和/或其断片的高弹体配混料。
36.一种含有权利要求17的碳泡沫的电极。
37.一种含有权利要求17的碳泡沫的电容器电极。
38.一种含有权利要求17的碳泡沫的电池电极。
39.一种含有权利要求17的碳泡沫的燃料电池电极。
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US09/805,264 US6500401B2 (en) | 2000-07-20 | 2001-03-13 | Carbon foams and methods of making the same |
US09/805,264 | 2001-03-13 |
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EP (1) | EP1303466A2 (zh) |
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CN101146674B (zh) * | 2005-01-26 | 2012-07-18 | 南方研究院 | 复合材料及其制造方法和用途 |
CN102745668A (zh) * | 2012-07-23 | 2012-10-24 | 上海理工大学 | 一种具有核壳结构的碳泡沫材料及其制备方法 |
CN102745668B (zh) * | 2012-07-23 | 2014-07-23 | 上海理工大学 | 一种具有核壳结构的碳泡沫材料及其制备方法 |
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WO2002008151A2 (en) | 2002-01-31 |
US6500401B2 (en) | 2002-12-31 |
US20020028385A1 (en) | 2002-03-07 |
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