U.S. patent application number 14/988625 was filed with the patent office on 2016-12-22 for carbon materials comprising enhanced electrochemical properties.
The applicant listed for this patent is BASF SE. Invention is credited to Alan T. Chang, Henry R. Costantino, Liam Cover, Aaron Marshall Feaver, Amalia L. Oppie, Yangyang Pan, William D. Scott.
Application Number | 20160372750 14/988625 |
Document ID | / |
Family ID | 46383486 |
Filed Date | 2016-12-22 |
United States Patent
Application |
20160372750 |
Kind Code |
A1 |
Chang; Alan T. ; et
al. |
December 22, 2016 |
CARBON MATERIALS COMPRISING ENHANCED ELECTROCHEMICAL PROPERTIES
Abstract
The present application is directed to carbon materials
comprising an optimized pore structure. The carbon materials
comprise enhanced electrochemical properties and find utility in
any number of electrical devices, for example, as electrode
material in ultracapacitors. Methods for making the disclosed
carbon materials are also disclosed.
Inventors: |
Chang; Alan T.; (Renton,
WA) ; Costantino; Henry R.; (Woodinville, WA)
; Feaver; Aaron Marshall; (Seattle, WA) ; Oppie;
Amalia L.; (Lynnwood, WA) ; Pan; Yangyang;
(Seattle, WA) ; Cover; Liam; (Seattle, WA)
; Scott; William D.; (Seattle, WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BASF SE |
Ludwigshafen |
|
DE |
|
|
Family ID: |
46383486 |
Appl. No.: |
14/988625 |
Filed: |
January 5, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
13336975 |
Dec 23, 2011 |
9269502 |
|
|
14988625 |
|
|
|
|
61427649 |
Dec 28, 2010 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
Y10T 428/249978
20150401; C01B 32/30 20170801; H01M 4/14 20130101; C01B 32/318
20170801; Y10T 428/249979 20150401; C01P 2006/14 20130101; H01M
10/054 20130101; H01M 10/0525 20130101; H01M 4/583 20130101; Y02E
60/13 20130101; H01G 11/44 20130101; C01P 2006/12 20130101; H01M
2/1606 20130101; H01M 10/06 20130101; Y10T 428/249953 20150401;
H01G 11/34 20130101; Y02E 60/10 20130101; C01P 2006/16 20130101;
H01G 11/24 20130101; H01M 4/133 20130101; Y02T 10/70 20130101; H01M
12/06 20130101 |
International
Class: |
H01M 4/583 20060101
H01M004/583; H01G 11/44 20060101 H01G011/44; H01G 11/24 20060101
H01G011/24; H01M 4/14 20060101 H01M004/14; C01B 31/08 20060101
C01B031/08; H01M 2/16 20060101 H01M002/16; H01M 10/06 20060101
H01M010/06; H01M 10/0525 20060101 H01M010/0525; H01M 12/06 20060101
H01M012/06; H01M 10/054 20060101 H01M010/054; H01G 11/34 20060101
H01G011/34; H01M 4/133 20060101 H01M004/133 |
Claims
1-75. (canceled)
76. A carbon material comprising a pore structure, the pore
structure comprising micropores, mesopores and a total pore volume,
wherein from 20% to 50% of the total pore volume resides in
micropores, from 50% to 80% of the total pore volume resides in
mesopores and less than 10% of the total pore volume resides in
pores greater than 20 nm.
77. The carbon material of claim 76, wherein from 20% to 40% of the
total pore volume resides in micropores and from 60% to 80% of the
total pore volume resides in mesopores.
78. The carbon material of claim 76, wherein from 25% to 35% of the
total pore volume resides in micropores and from 65% to 75% of the
total pore volume resides in mesopores.
79. The carbon material of claim 76, wherein about 30% of the total
pore volume resides in micropores and about 70% of the total pore
volume resides in mesopores.
80. The carbon material of claim 76, wherein from 30% to 50% of the
total pore volume resides in micropores and from 50% to 70% of the
total pore volume resides in mesopores.
81. The carbon material of claim 76, wherein from 35% to 45% of the
total pore volume resides in micropores and from 55% to 65% of the
total pore volume resides in mesopores.
82. The carbon material of claim 76, wherein about 40% of the total
pore volume resides in micropores and about 60% of the total pore
volume resides in mesopores.
83. The carbon material of claim 76, wherein less than 5% of the
total pore volume resides in pores greater than 20 nm.
84. The carbon material of claim 76, wherein the carbon material
comprises a BET specific surface area of at least 300
m.sup.2/g.
85. The carbon material of claim 76, wherein the carbon material
comprises a BET specific surface area of at least 500
m.sup.2/g.
86. The carbon material of claim 76, wherein the carbon material
comprises a pore volume of at least 0.50 cc/g.
87. The carbon material of claim 76, wherein the carbon material
comprises a pore volume of at least 0.60 cc/g.
88. The carbon material of claim 76, wherein the carbon material
comprises a pore volume of at least 0.70 cc/g.
89. An electrode comprising the carbon material of claim 76.
90. A device comprising the carbon material of claim 76.
91. The device of claim 90, wherein the device is an EDLC,
lithium/carbon battery, zinc/carbon, lithium air battery or lead
acid battery.
92. The device of claim 90, wherein the device is a lead/acid
battery comprising: a) at least one positive electrode comprising a
first active material in electrical contact with a first current
collector; b) at least one negative electrode comprising a second
active material in electrical contact with a second current
collector; and c) an electrolyte; wherein the positive electrode
and the negative electrode are separated by an inert porous
separator, and wherein at least one of the first or second active
materials comprises the carbon material.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] The present application claims priority to U.S. application
Ser. No. 13/336,975, filed Dec. 23, 2011; which claims the benefit
under 35 U.S.C. .sctn.119(e) of U.S. Provisional Patent Application
No. 61/427,649 filed on Dec. 28, 2010, the contents of which are
hereby incorporated in their entirety by reference.
BACKGROUND
[0002] Technical Field
[0003] The present invention generally relates to carbon materials
comprising an optimized pore structure, methods for making the same
and devices containing the same.
[0004] Description of the Related Art
[0005] Activated carbon is commonly employed in electrical storage
and distribution devices. The high surface area, conductivity and
porosity of activated carbon allows for the design of electrical
devices having higher energy density than devices employing other
materials. Electric double-layer capacitors (EDLCs or
"ultracapacitors") are an example of such devices. EDLCs often have
electrodes prepared from an activated carbon material and a
suitable electrolyte, and have an extremely high energy density
compared to more common capacitors. Typical uses for EDLCs include
energy storage and distribution in devices requiring short bursts
of power for data transmissions, or peak-power functions such as
wireless modems, mobile phones, digital cameras and other hand-held
electronic devices. EDLCs are also commonly use in electric
vehicles such as electric cars, trains, buses and the like.
[0006] Batteries are another common energy storage and distribution
device which often contain an activated carbon material (e.g., as
anode material, current collector, or conductivity enhancer). For
example, lithium/carbon batteries having a carbonaceous anode
intercalated with lithium represent a promising energy storage
device. Other types of carbon-containing batteries include lithium
air batteries, which use porous carbon as the current collector for
the air electrode, and lead acid batteries which often include
carbon additives in either the anode or cathode. Batteries are
employed in any number of electronic devices requiring low current
density electrical power (as compared to an EDLC's high current
density).
[0007] One known limitation of EDLCs and carbon-based batteries is
decreased performance at high-temperature, high voltage operation,
repeated charge/discharge cycles and/or upon aging. This decreased
performance has been attributed, at least in part, to electrolyte
impurity or impurities in the carbon electrode itself, causing
breakdown of the electrode at the electrolyte/electrode interface.
Thus, it has been suggested that EDLCs and/or batteries comprising
electrodes prepared from higher purity carbon materials could be
operated at higher voltages and for longer periods of time at
higher temperatures than existing devices.
[0008] In addition to purity, another known limitation of
carbon-containing electrical devices is the pore structure of the
activated carbon itself. While activated carbon materials typically
comprise high porosity, the pore size distribution is not optimized
for use in electrical energy storage and distribution devices. Such
optimization includes an idealized blend of both micropores and
mesopores. An idealized pore size distribution is expected to
maximize ion mobility (i.e., lower resistance), increase power
density and improve volumetric capacitance of electrodes prepared
from the optimized carbon materials.
[0009] Although the need for improved high purity carbon materials
comprising a pore structure optimized for high pulse power
electrochemical applications has been recognized, such carbon
materials are not commercially available and no reported
preparation method is capable of yielding the same. One common
method for producing high surface area activated carbon materials
is to pyrolyze an existing carbon-containing material (e.g.,
coconut fibers or tire rubber). This results in a char with
relatively low surface area which can subsequently be
over-activated to produce a material with the surface area and
porosity necessary for the desired application. Such an approach is
inherently limited by the existing structure of the precursor
material, and typically results in a carbon material having an
unoptimized pore structure and an ash content (e.g., metal
impurities) of 1% or higher.
[0010] Activated carbon materials can also be prepared by chemical
activation. For example, treatment of a carbon-containing material
with an acid, base or salt (e.g., phosphoric acid, potassium
hydroxide, sodium hydroxide, zinc chloride, etc.) followed by
heating results in an activated carbon material. However, such
chemical activation also produces an activated carbon material not
suitable for use in high performance electrical devices.
[0011] Another approach for producing high surface area activated
carbon materials is to prepare a synthetic polymer from
carbon-containing organic building blocks (e.g., a polymer gel). As
with the existing organic materials, the synthetically prepared
polymers are pyrolyzed and activated to produce an activated carbon
material. In contrast to the traditional approach described above,
the intrinsic porosity of the synthetically prepared polymer
results in higher process yields because less material is lost
during the activation step. However, known methods for preparing
carbon materials from synthetic polymers produce carbon materials
having unoptimized pore structures and unsuitable levels of
impurities. Accordingly, electrodes prepared from these materials
demonstrate unsuitable electrochemical properties.
[0012] While significant advances have been made in the field,
there continues to be a need in the art for improved high purity
carbon materials comprising an optimized pore structure for use in
electrical energy storage devices, as well as for methods of making
the same and devices containing the same. The present invention
fulfills these needs and provides further related advantages.
BRIEF SUMMARY
[0013] In general terms, the current invention is directed to novel
carbon materials comprising an optimized pore structure. The
optimized pore structure comprises a ratio of micropores to
mesopores which increases the power density and provides for high
ion mobility in electrodes prepared from the disclosed carbon
materials. In addition, electrodes prepared from the disclosed
carbon materials comprise low ionic resistance and high frequency
response. The electrodes thus comprise a higher power density and
increased volumetric capacitance compared to electrodes prepared
from other carbon materials. The high purity of the carbon
materials also contributes to improving the operation, life span
and performance of any number of electrical storage and/or
distribution devices
[0014] Accordingly, the novel carbon materials find utility in any
number of electrical energy storage devices, for example as
electrode material in ultracapacitors. Such devices containing the
disclosed carbon materials are useful in any number of
applications, including applications requiring high pulse power.
Because of the unique properties of the disclosed carbon materials,
the devices are also expected to have higher durability, and thus
an increased life span, compared to other known carbon-containing
electrochemical devices.
[0015] Accordingly, one embodiment of the present disclosure is
directed to a carbon material comprising a pore structure, the pore
structure comprising micropores, mesopores and a total pore volume,
wherein from 40% to 90% of the total pore volume resides in
micropores, from 10% to 60% of the total pore volume resides in
mesopores and less than 10% of the total pore volume resides in
pores greater than 20 nm.
[0016] In other embodiments, from 40% to 50% of the total pore
volume resides in micropores and from 50% to 60% of the total pore
volume resides in mesopores. For example, in some embodiments, from
43% to 47% of the total pore volume resides in micropores and from
53% to 57% of the total pore volume resides in mesopores. For
example, in a specific embodiment, about 45% of the total pore
volume resides in micropores and about 55% of the total pore volume
resides in mesopores. In another embodiment, less than 5% of the
total pore volume resides in pores greater than 20 nm.
[0017] In still other embodiments, from 40% to 85% of the total
pore volume of the carbon materials resides in micropores and from
15% to 40% of the total pore volume resides in mesopores. For
example, in some embodiments from 75% to 85% of the total pore
volume resides in micropores and from 15% to 25% of the total pore
volume resides in mesopores. In other embodiments from 65% to 75%
of the total pore volume resides in micropores and from 20% to 30%
of the total pore volume resides in mesopores. In some specific
embodiments, about 80% of the total pore volume resides in
micropores and about 20% of the total pore volume resides in
mesopores. In other specific embodiments, about 70% of the total
pore volume resides in micropores and about 30% of the total pore
volume resides in mesopores.
[0018] In other embodiments, the disclosure provides a carbon
material comprising a pore structure, the pore structure comprising
micropores, mesopores and a total pore volume, wherein from 20% to
50% of the total pore volume resides in micropores, from 50% to 80%
of the total pore volume resides in mesopores and less than 10% of
the total pore volume resides in pores greater than 20 nm.
[0019] In some embodiments, from 20% to 40% of the total pore
volume resides in micropores and from 60% to 80% of the total pore
volume resides in mesopores. In other embodiments, from 25% to 35%
of the total pore volume resides in micropores and from 65% to 75%
of the total pore volume resides in mesopores. For example, in some
embodiments about 30% of the total pore volume resides in
micropores and about 70% of the total pore volume resides in
mesopores.
[0020] In still other embodiments of the foregoing carbon material,
from 30% to 50% of the total pore volume resides in micropores and
from 50% to 70% of the total pore volume resides in mesopores. In
other embodiments, from 35% to 45% of the total pore volume resides
in micropores and from 55% to 65% of the total pore volume resides
in mesopores. For example, in some embodiments, about 40% of the
total pore volume resides in micropores and about 60% of the total
pore volume resides in mesopores.
[0021] In certain variations of any of the above embodiments, less
than 5% of the total pore volume resides in pores greater than 20
nm.
[0022] In other variations, the carbon material comprises a total
impurity content of less than 500 ppm of elements having atomic
numbers ranging from 11 to 92 as measured by proton induced x-ray
emission. For example, the carbon material may comprise a total
impurity content of less than 200 ppm, less than 100 ppm or even
less than 50 of elements having atomic numbers ranging from 11 to
92 as measured by proton induced x-ray emission.
[0023] In other embodiments, the ash content of the carbon material
is less than 0.03% as calculated from proton induced x-ray emission
data, for example, less than 0.01% or even less than 0.001% as
calculated from proton induced x-ray emission data.
[0024] In some embodiments, the carbon material comprises at least
95% carbon by weight as measured by combustion analysis and proton
induced x-ray emission.
[0025] In yet other embodiments, the carbon material comprises less
than 10 ppm iron as measured by proton induced x-ray emission, the
carbon material comprises less than 3 ppm nickel as measured by
proton induced x-ray emission, the carbon material comprises less
than 30 ppm sulfur as measured by proton induced x-ray emission,
the carbon material comprises less than 1 ppm chromium as measured
by proton induced x-ray emission, the carbon material comprises
less than 1 ppm copper as measured by proton induced x-ray emission
or the carbon material comprises less than 1 ppm zinc as measured
by proton induced x-ray emission.
[0026] In some certain embodiments, the carbon material comprises
less than 100 ppm sodium, less than 100 ppm silicon, less than 10
ppm sulfur, less than 25 ppm calcium, less than 10 ppm iron, less
than 2 ppm nickel, less than 1 ppm copper, less than 1 ppm
chromium, less than 50 ppm magnesium, less than 10 ppm aluminum,
less than 25 ppm phosphorous, less than 5 ppm chlorine, less than
25 ppm potassium, less than 2 ppm titanium, less than 2 ppm
manganese, less than 0.5 ppm cobalt and less than 5 ppm zinc as
measured by proton induced x-ray emission, and wherein all other
elements having atomic numbers ranging from 11 to 92 are undetected
by proton induced x-ray emission.
[0027] In other embodiments, the carbon material comprises less
than 50 ppm sodium, less than 50 ppm silicon, less than 30 ppm
sulfur, less than 10 ppm calcium, less than 10 ppm iron, less than
1 ppm nickel, less than 1 ppm copper, less than 1 ppm chromium and
less than 1 ppm zinc as measured by proton induced x-ray
emission.
[0028] In some embodiments, the carbon material comprises less than
3.0% oxygen, less than 0.1% nitrogen and less than 0.5% hydrogen as
determined by combustion analysis. For example, in further
embodiments, the carbon material comprises less than 1.0% oxygen as
determined by combustion analysis.
[0029] In other embodiments, the carbon material comprises a
pyrolyzed polymer cryogel or the carbon material comprises an
activated polymer cryogel.
[0030] In some specific embodiments, the carbon material comprises
a BET specific surface area of at least 500 m.sup.2/g, at least
1500 m.sup.2/g or at least 2000 m.sup.2/g.
[0031] In other embodiments, the carbon material comprises a pore
volume of at least 0.60 cc/g or a pore volume of at least 1.00
cc/g. In other embodiments, the carbon material comprises a pore
volume of at least 1.50 cc/g or a pore volume of at least 2.00
cc/g.
[0032] In yet other embodiments, the present disclosure provides an
electrode comprising a carbon material comprising a pore structure,
the pore structure comprising micropores, mesopores and a total
pore volume, wherein from 40% to 90% of the total pore volume
resides in micropores, from 10% to 60% of the total pore volume
resides in mesopores and less than 10% of the total pore volume
resides in pores greater than 20 nm.
[0033] In certain embodiments of the disclosed electrode, the
carbon material comprises a total impurity content of less than 500
ppm of elements having atomic numbers ranging from 11 to 92 as
measured by proton induced x-ray emission.
[0034] In still other embodiments, the present disclosure provides
a device comprising a carbon material comprising a pore structure,
the pore structure comprising micropores, mesopores and a total
pore volume, wherein from 40% to 90% of the total pore volume
resides in micropores, from 10% to 60% of the total pore volume
resides in mesopores and less than 10% of the total pore volume
resides in pores greater than 20 nm.
[0035] In some embodiments, the device is an electric double layer
capacitor EDLC. In other embodiments, the device is a battery, for
example a lithium/carbon battery, zinc/carbon, lithium air battery
or lead acid battery. For example, in some embodiments the device
is a lead/acid battery comprising:
[0036] a) at least one positive electrode comprising a first active
material in electrical contact with a first current collector;
[0037] b) at least one negative electrode comprising a second
active material in electrical contact with a second current
collector; and
[0038] c) an electrolyte;
[0039] wherein the positive electrode and the negative electrode
are separated by an inert porous separator, and wherein at least
one of the first or second active materials comprises the carbon
material.
[0040] In other certain embodiments, the device is an electric
double layer capacitor (EDLC) device comprising:
[0041] a) a positive electrode and a negative electrode wherein
each of the positive and the negative electrodes comprise the
carbon material;
[0042] b) an inert porous separator; and
[0043] c) an electrolyte;
[0044] wherein the positive electrode and the negative electrode
are separated by the inert porous separator.
[0045] In some aspects, the EDLC device comprises a gravimetric
power of at least 10 W/g, a volumetric power of at least 5 W/cc, a
gravimetric capacitance of at least 100 F/g or a volumetric
capacitance of at least 10.0 F/cc.
[0046] In other embodiments, the EDLC device comprises a
gravimetric capacitance of at least of at least 110 F/g as measured
by constant current discharge from 2.7 V to 0.1 V with a 5 second
time constant employing a 1.8 M solution of
tetraethylammonium-tetrafluroroborate in acetonitrile electrolyte
and a current density of 0.5 A/g. In still other embodiments, the
EDLC device comprises a volumetric capacitance of at least of at
least 15 F/cc as measured by constant current discharge from 2.7 V
to 0.1 V with a 5 second time constant employing a 1.8 M solution
of tetraethylammonium-tetrafluroroborate in acetonitrile
electrolyte and a current density of 0.5 A/g.
[0047] In still other embodiments of the foregoing EDLC device, the
EDLC device comprises a gravimetric capacitance of at least 13 F/cc
as measured by constant current discharge from 2.7 V to 0.1 V and
with at least 0.24 Hz frequency response and employing a 1.8 M
solution of tetraethylammonium-tetrafluroroborate in acetonitrile
electrolyte and a current density of 0.5 A/g. In some other
embodiments, the EDLC device comprises a gravimetric capacitance of
at least 17 F/cc as measured by constant current discharge from 2.7
V to 0.1 V and with at least 0.24 Hz frequency response and
employing a 1.8 M solution of tetraethylammonium-tetrafluroroborate
in acetonitrile electrolyte and a current density of 0.5 A/g.
[0048] In some embodiments of any of the foregoing devices, from
43% to 47% of the total pore volume resides in micropores and from
53% to 57% of the total pore volume resides in mesopores, and in
other embodiments from 83% to 77% of the total pore volume resides
in micropores and from 17% to 23% of the total pore volume resides
in mesopores.
[0049] In another variation of any of the foregoing devices, the
carbon material comprises a total impurity content of less than 500
ppm or less than 200 ppm, less than 100 ppm or even less than 50
ppm of elements having atomic numbers ranging from 11 to 92 as
measured by proton induced x-ray emission.
[0050] In other certain other embodiments of the foregoing devices,
the ash content of the carbon material is less than 0.03%, for
example less than 0.01% or even less than 0.001% as calculated from
proton induced x-ray emission data, while in other embodiments the
carbon material comprises at least 95% carbon as measured by
combustion analysis and proton induced x-ray emission.
[0051] In some specific embodiments of the foregoing devices, the
carbon material comprises less than 10 ppm iron as measured by
proton induced x-ray emission, less than 3 ppm nickel as measured
by proton induced x-ray emission, less than 30 ppm sulfur as
measured by proton induced x-ray emission, less than 1 ppm chromium
as measured by proton induced x-ray emission, less than 1 ppm
copper as measured by proton induced x-ray or less than 1 ppm zinc
as measured by proton induced x-ray emission. In other embodiments,
less than 5% of the total pore volume resides in pores greater than
20 nm.
[0052] In other embodiments of the foregoing devices, the carbon
material comprises an activated polymer cryogel. Other embodiments
in include variations wherein the carbon material comprises a BET
specific surface area of at least 500 m.sup.2/g, at least 1500
m.sup.2/g or at least 2000 m.sup.2/g.
[0053] In yet another embodiment, the present disclosure provides a
method for making a carbon material comprising a pore structure,
the pore structure comprising micropores, mesopores and a total
pore volume, wherein from 40% to 90% of the total pore volume
resides in micropores, from 10% to 60% of the total pore volume
resides in mesopores and less than 10% of the total pore volume
resides in pores greater than 20 nm, wherein the method comprises
reacting one or more polymer precursors under acidic conditions in
the presence of a volatile basic catalyst to obtain a polymer
gel.
[0054] In certain embodiments of the foregoing method, from 43% to
47% of the total pore volume resides in micropores and from 53% to
57% of the total pore volume resides in mesopores, and in other
embodiments, from 83% to 77% of the total pore volume resides in
micropores and from 17% to 23% of the total pore volume resides in
mesopores.
[0055] The disclosed method may also further comprise admixing the
one or more polymer precursors in a solvent comprising acetic acid
and water. Other variations include embodiments wherein the
volatile basic catalyst comprises ammonium carbonate, ammonium
bicarbonate, ammonium acetate, ammonium hydroxide, or combinations
thereof. In another embodiment, the one or more polymer precursors
comprise resorcinol and formaldehyde.
[0056] In some other further embodiments, the method further
comprises: [0057] (a) freeze drying the polymer gel to obtain a
polymer cryogel; [0058] (b) pyrolyzing the polymer cryogel to
obtain a pyrolyzed cryogel; and [0059] (c) activating the pyrolyzed
cryogel to obtain activated carbon material.
[0060] These and other aspects of the invention will be apparent
upon reference to the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0061] In the figures, identical reference numbers identify similar
elements. The sizes and relative positions of elements in the
figures are not necessarily drawn to scale and some of these
elements are arbitrarily enlarged and positioned to improve figure
legibility. Further, the particular shapes of the elements as drawn
are not intended to convey any information regarding the actual
shape of the particular elements, and have been solely selected for
ease of recognition in the figures.
[0062] FIG. 1 shows pore size distribution of two different batches
of dried polymer gel.
[0063] FIG. 2 is an overlay of the pore size distributions of
pyrolyzed carbon material and activated carbon material.
[0064] FIG. 3 is an overlay of pore size distribution by
incremental pore volume of 3 carbon materials according to the
present disclosure.
[0065] FIG. 4 demonstrates capacitance retention and stability over
time for various carbon materials.
[0066] FIGS. 5A and 5 show B resistance of various carbon materials
over time.
[0067] FIG. 6 is a Bode plot comparison of various carbon
materials.
[0068] FIG. 7 shows pore size distribution of various carbon
materials.
[0069] FIG. 8 shows two different batches of carbon material
according to the present disclosure.
[0070] FIG. 9 is an overlay of the pore size distribution of
various carbon materials.
[0071] FIG. 10 illustrates a prototype capacitor cell constructed
to test the carbon materials.
[0072] FIG. 11 depicts 30 minute leakage current values at four
different voltages for the two test capacitors.
[0073] FIG. 12 is a graph of constant current discharges of the
prototype capacitors containing the disclosed carbon material.
[0074] FIG. 13A is a complex plane representation of impedance data
from the capacitor fabricated using the disclosed carbon material
and organic electrolyte.
[0075] FIG. 13B is a Bode representation of impedance data for the
capacitor containing the disclosed carbon material and organic
electrolyte.
[0076] FIG. 13C presents impedance data represented as a series-RC
circuit.
[0077] FIG. 14 shows experimentally determined energy--power
relationship for a test capacitor fabricated using the disclosed
carbon materials and organic electrolyte.
[0078] FIG. 15 is an overlay of the pore size distributions of
flash frozen or slow frozen dried polymer gels.
[0079] FIG. 16 is an overlay of the pore size distribution of
carbon materials prepared from flash frozen or slow frozen dried
gels.
[0080] FIG. 17 is a graph showing activation weight loss and
surface areas for liquid nitrogen (LN) or shelf frozen (SF) polymer
gels.
[0081] FIG. 18 shows pore size distribution of exemplary carbon
samples.
[0082] FIG. 19 is a graph showing pore size distribution of dried
gel samples.
[0083] FIG. 20 presents pore size distributions of various carbon
samples.
DETAILED DESCRIPTION
[0084] In the following description, certain specific details are
set forth in order to provide a thorough understanding of various
embodiments. However, one skilled in the art will understand that
the invention may be practiced without these details. In other
instances, well-known structures have not been shown or described
in detail to avoid unnecessarily obscuring descriptions of the
embodiments. Unless the context requires otherwise, throughout the
specification and claims which follow, the word "comprise" and
variations thereof, such as, "comprises" and "comprising" are to be
construed in an open, inclusive sense, that is, as "including, but
not limited to." Further, headings provided herein are for
convenience only and do not interpret the scope or meaning of the
claimed invention.
[0085] Reference throughout this specification to "one embodiment"
or "an embodiment" means that a particular feature, structure or
characteristic described in connection with the embodiment is
included in at least one embodiment. Thus, the appearances of the
phrases "in one embodiment" or "in an embodiment" in various places
throughout this specification are not necessarily all referring to
the same embodiment. Furthermore, the particular features,
structures, or characteristics may be combined in any suitable
manner in one or more embodiments. Also, as used in this
specification and the appended claims, the singular forms "a,"
"an," and "the" include plural referents unless the content clearly
dictates otherwise. It should also be noted that the term "or" is
generally employed in its sense including "and/or" unless the
content clearly dictates otherwise.
DEFINITIONS
[0086] As used herein, and unless the context dictates otherwise,
the following terms have the meanings as specified below.
[0087] "Carbon material" refers to a material or substance
comprised substantially of carbon. Carbon materials include
ultrapure as well as amorphous and crystalline carbon materials.
Examples of carbon materials include, but are not limited to,
activated carbon, pyrolyzed dried polymer gels, pyrolyzed polymer
cryogels, pyrolyzed polymer xerogels, pyrolyzed polymer aerogels,
activated dried polymer gels, activated polymer cryogels, activated
polymer xerogels, activated polymer aerogels and the like.
[0088] "Amorphous" refers to a material, for example an amorphous
carbon material, whose constituent atoms, molecules, or ions are
arranged randomly without a regular repeating pattern. Amorphous
materials may have some localized crystallinity (i.e., regularity)
but lack long-range order of the positions of the atoms. Pyrolyzed
and/or activated carbon materials are generally amorphous.
[0089] "Crystalline" refers to a material whose constituent atoms,
molecules, or ions are arranged in an orderly repeating pattern.
Examples of crystalline carbon materials include, but are not
limited to, diamond and graphene.
[0090] "Synthetic" refers to a substance which has been prepared by
chemical means rather than from a natural source. For example, a
synthetic carbon material is one which is synthesized from
precursor materials and is not isolated from natural sources.
[0091] "Impurity" or "impurity element" refers to an undesired
foreign substance (e.g., a chemical element) within a material
which differs from the chemical composition of the base material.
For example, an impurity in a carbon material refers to any element
or combination of elements, other than carbon, which is present in
the carbon material. Impurity levels are typically expressed in
parts per million (ppm).
[0092] "PIXE impurity" or "PIXE element" is any impurity element
having an atomic number ranging from 11 to 92 (i.e., from sodium to
uranium). The phrases "total PIXE impurity content" and "total PIXE
impurity level" both refer to the sum of all PIXE impurities
present in a sample, for example, a polymer gel or a carbon
material. PIXE impurity concentrations and identities may be
determined by proton induced x-ray emission (PIXE).
[0093] "Ultrapure" refers to a substance having a total PIXE
impurity content of less than 0.050%. For example, an "ultrapure
carbon material" is a carbon material having a total PIXE impurity
content of less than 0.050% (i.e., 500 ppm).
[0094] "Ash content" refers to the nonvolatile inorganic matter
which remains after subjecting a substance to a high decomposition
temperature. Herein, the ash content of a carbon material is
calculated from the total PIXE impurity content as measured by
proton induced x-ray emission, assuming that nonvolatile elements
are completely converted to expected combustion products (i.e.,
oxides).
[0095] "Polymer" refers to a macromolecule comprised of two or more
structural repeating units.
[0096] "Synthetic polymer precursor material" or "polymer
precursor" refers to compounds used in the preparation of a
synthetic polymer. Examples of polymer precursors that can be used
in certain embodiments of the preparations disclosed herein
include, but are not limited to, aldehydes (i.e., HC(.dbd.O)R,
where R is an organic group), such as for example, methanal
(formaldehyde); ethanal (acetaldehyde); propanal (propionaldehyde);
butanal (butyraldehyde); glucose; benzaldehyde and cinnamaldehyde.
Other exemplary polymer precursors include, but are not limited to,
phenolic compounds such as phenol and polyhydroxy benzenes, such as
dihydroxy or trihydroxy benzenes, for example, resorcinol (i.e.,
1,3-dihydroxy benzene), catechol, hydroquinone, and phloroglucinol.
Mixtures of two or more polyhydroxy benzenes are also contemplated
within the meaning of polymer precursor.
[0097] "Monolithic" refers to a solid, three-dimensional structure
that is not particulate in nature.
[0098] "Sol" refers to a colloidal suspension of precursor
particles (e.g., polymer precursors), and the term "gel" refers to
a wet three-dimensional porous network obtained by condensation or
reaction of the precursor particles.
[0099] "Polymer gel" refers to a gel in which the network component
is a polymer; generally a polymer gel is a wet (aqueous or
non-aqueous based) three-dimensional structure comprised of a
polymer formed from synthetic precursors or polymer precursors.
[0100] "Sol gel" refers to a sub-class of polymer gel where the
polymer is a colloidal suspension that forms a wet
three-dimensional porous network obtained by reaction of the
polymer precursors.
[0101] "Polymer hydrogel" or "hydrogel" refers to a subclass of
polymer gel or gel wherein the solvent for the synthetic precursors
or monomers is water or mixtures of water and one or more
water-miscible solvent.
[0102] "RF polymer hydrogel" refers to a sub-class of polymer gel
wherein the polymer was formed from the catalyzed reaction of
resorcinol and formaldehyde in water or mixtures of water and one
or more water-miscible solvent.
[0103] "Acid" refers to any substance that is capable of lowering
the pH of a solution. Acids include Arrhenius, Bronsted and Lewis
acids. A "solid acid" refers to a dried or granular compound that
yields an acidic solution when dissolved in a solvent. The term
"acidic" means having the properties of an acid.
[0104] "Base" refers to any substance that is capable of raising
the pH of a solution. Bases include Arrhenius, Bronsted and Lewis
bases. A "solid base" refers to a dried or granular compound that
yields basic solution when dissolved in a solvent. The term "basic"
means having the properties of a base.
[0105] "Mixed solvent system" refers to a solvent system comprised
of two or more solvents, for example, two or more miscible
solvents. Examples of binary solvent systems (i.e., containing two
solvents) include, but are not limited to: water and acetic acid;
water and formic acid; water and propionic acid; water and butyric
acid and the like. Examples of ternary solvent systems (i.e.,
containing three solvents) include, but are not limited to: water,
acetic acid, and ethanol; water, acetic acid and acetone; water,
acetic acid, and formic acid; water, acetic acid, and propionic
acid; and the like. The present invention contemplates all mixed
solvent systems comprising two or more solvents.
[0106] "Miscible" refers to the property of a mixture wherein the
mixture forms a single phase over certain ranges of temperature,
pressure, and composition.
[0107] "Catalyst" is a substance which alters the rate of a
chemical reaction. Catalysts participate in a reaction in a cyclic
fashion such that the catalyst is cyclically regenerated. The
present disclosure contemplates catalysts which are sodium free.
The catalyst used in the preparation of a polymer gel (e.g., an
ultrapure polymer gel) as described herein can be any compound that
facilitates the polymerization of the polymer precursors to form an
ultrapure polymer gel. A "volatile catalyst" is a catalyst which
has a tendency to vaporize at or below atmospheric pressure.
Exemplary volatile catalysts include, but are not limited to,
ammoniums salts, such as ammonium bicarbonate, ammonium carbonate,
ammonium hydroxide, and combinations thereof.
[0108] "Solvent" refers to a substance which dissolves or suspends
reactants (e.g., ultrapure polymer precursors) and provides a
medium in which a reaction may occur. Examples of solvents useful
in the preparation of the gels, ultrapure polymer gels, ultrapure
synthetic carbon materials and ultrapure synthetic amorphous carbon
materials disclosed herein include, but are not limited to, water,
alcohols and mixtures thereof. Exemplary alcohols include ethanol,
t-butanol, methanol and mixtures thereof. Such solvents are useful
for dissolution of the synthetic ultrapure polymer precursor
materials, for example dissolution of a phenolic or aldehyde
compound. In addition, in some processes such solvents are employed
for solvent exchange in a polymer hydrogel (prior to freezing and
drying), wherein the solvent from the polymerization of the
precursors, for example, resorcinol and formaldehyde, is exchanged
for a pure alcohol. In one embodiment of the present application, a
cryogel is prepared by a process that does not include solvent
exchange.
[0109] "Dried gel" or "dried polymer gel" refers to a gel or
polymer gel, respectively, from which the solvent, generally water,
or mixture of water and one or more water-miscible solvents, has
been substantially removed.
[0110] "Pyrolyzed dried polymer gel" refers to a dried polymer gel
which has been pyrolyzed but not yet activated, while an "activated
dried polymer gel" refers to a dried polymer gel which has been
activated.
[0111] "Cryogel" refers to a dried gel that has been dried by
freeze drying.
[0112] "RF cryogel" refers to a dried gel that has been dried by
freeze drying wherein the gel was formed from the catalyzed
reaction of resorcinol and formaldehyde.
[0113] "Pyrolyzed cryogel" is a cryogel that has been pyrolyzed but
not yet activated.
[0114] "Activated cryogel" is a cryogel which has been activated to
obtain activated carbon material.
[0115] "Xerogel" refers to a dried gel that has been dried by air
drying, for example, at or below atmospheric pressure.
[0116] "Pyrolyzed xerogel" is a xerogel that has been pyrolyzed but
not yet activated.
[0117] "Activated xerogel" is a xerogel which has been activated to
obtain activated carbon material.
[0118] "Aerogel" refers to a dried gel that has been dried by
supercritical drying, for example, using supercritical carbon
dioxide.
[0119] "Pyrolyzed aerogel" is an aerogel that has been pyrolyzed
but not yet activated.
[0120] "Activated aerogel" is an aerogel which has been activated
to obtain activated carbon material.
[0121] "Organic extraction solvent" refers to an organic solvent
added to a polymer hydrogel after polymerization of the polymer
precursors has begun, generally after polymerization of the polymer
hydrogel is complete.
[0122] "Rapid multi-directional freezing" refers to the process of
freezing a polymer gel by creating polymer gel particles from a
monolithic polymer gel, and subjecting said polymer gel particles
to a suitably cold medium. The cold medium can be, for example,
liquid nitrogen, nitrogen gas, or solid carbon dioxide. During
rapid multi-directional freezing nucleation of ice dominates over
ice crystal growth. The suitably cold medium can be, for example, a
gas, liquid, or solid with a temperature below about -10.degree. C.
Alternatively, the suitably cold medium can be a gas, liquid, or
solid with a temperature below about -20.degree. C. Alternatively,
the suitably cold medium can be a gas, liquid, or solid with a
temperature below about -30.degree. C.
[0123] "Activate" and "activation" each refer to the process of
heating a raw material or carbonized/pyrolyzed substance at an
activation dwell temperature during exposure to oxidizing
atmospheres (e.g., carbon dioxide, oxygen, steam or combinations
thereof) to produce an "activated" substance (e.g., activated
cryogel or activated carbon material). The activation process
generally results in a stripping away of the surface of the
particles, resulting in an increased surface area. Alternatively,
activation can be accomplished by chemical means, for example, by
impregnation of carbon-containing precursor materials with
chemicals such as acids like phosphoric acid or bases like
potassium hydroxide, sodium hydroxide or salts like zinc chloride,
followed by carbonization. "Activated" refers to a material or
substance, for example a carbon material, which has undergone the
process of activation.
[0124] "Carbonizing", "pyrolyzing", "carbonization" and "pyrolysis"
each refer to the process of heating a carbon-containing substance
at a pyrolysis dwell temperature in an inert atmosphere (e.g.,
argon, nitrogen or combinations thereof) or in a vacuum such that
the targeted material collected at the end of the process is
primarily carbon. "Pyrolyzed" refers to a material or substance,
for example a carbon material, which has undergone the process of
pyrolysis.
[0125] "Dwell temperature" refers to the temperature of the furnace
during the portion of a process which is reserved for maintaining a
relatively constant temperature (i.e., neither increasing nor
decreasing the temperature). For example, the pyrolysis dwell
temperature refers to the relatively constant temperature of the
furnace during pyrolysis, and the activation dwell temperature
refers to the relatively constant temperature of the furnace during
activation.
[0126] "Pore" refers to an opening or depression in the surface, or
a tunnel in a carbon material, such as for example activated
carbon, pyrolyzed dried polymer gels, pyrolyzed polymer cryogels,
pyrolyzed polymer xerogels, pyrolyzed polymer aerogels, activated
dried polymer gels, activated polymer cryogels, activated polymer
xerogels, activated polymer aerogels and the like. A pore can be a
single tunnel or connected to other tunnels in a continuous network
throughout the structure.
[0127] "Pore structure" refers to the layout of the surface of the
internal pores within a carbon material, such as an activated
carbon material. Components of the pore structure include pore
size, pore volume, surface area, density, pore size distribution
and pore length. Generally the pore structure of an activated
carbon material comprises micropores and mesopores. For example, in
certain embodiments the ratio of micropores to mesopores is
optimized for enhanced electrochemical performance.
[0128] "Mesopore" generally refers to a pore having a diameter
ranging from 2 nanometers to 50 nanometers while the term
"micropore" refers to a pore having a diameter less than 2
nanometers.
[0129] "Surface area" refers to the total specific surface area of
a substance measurable by the BET technique. Surface area is
typically expressed in units of m.sup.2/g. The BET
(Brunauer/Emmett/Teller) technique employs an inert gas, for
example nitrogen, to measure the amount of gas adsorbed on a
material and is commonly used in the art to determine the
accessible surface area of materials.
[0130] "Connected" when used in reference to mesopores and
micropores refers to the spatial orientation of such pores.
[0131] "Effective length" refers to the portion of the length of
the pore that is of sufficient diameter such that it is available
to accept salt ions from the electrolyte.
[0132] "Electrode" refers to the positive or negative component of
a cell (e.g., capacitor, battery, etc.) including the active
material. Electrodes generally comprise one or more metal leads
through which electricity enters or leaves the electrode.
[0133] "Binder" refers to a material capable of holding individual
particles of a substance (e.g., a carbon material) together such
that after mixing a binder and the particles together the resulting
mixture can be formed into sheets, pellets, disks or other shapes.
In certain embodiments, an electrode may comprise the disclosed
carbon materials and a binder. Non-exclusive examples of binders
include fluoro polymers, such as, for example, PTFE
(polytetrafluoroethylene, Teflon), PFA (perfluoroalkoxy polymer
resin, also known as Teflon), FEP (fluorinated ethylene propylene,
also known as Teflon), ETFE (polyethylenetetrafluoroethylene, sold
as Tefzel and Fluon), PVF (polyvinyl fluoride, sold as Tedlar),
ECTFE (polyethylenechlorotrifluoroethylene, sold as Halar), PVDF
(polyvinylidene fluoride, sold as Kynar), PCTFE
(polychlorotrifluoroethylene, sold as Kel-F and CTFE),
trifluoroethanol and combinations thereof.
[0134] "Inert" refers to a material that is not active in the
electrolyte of an electrical energy storage device, that is it does
not absorb a significant amount of ions or change chemically, e.g.,
degrade.
[0135] "Conductive" refers to the ability of a material to conduct
electrons through transmission of loosely held valence
electrons.
[0136] "Current collector" refers to a part of an electrical energy
storage and/or distribution device which provides an electrical
connection to facilitate the flow of electricity in to, or out of,
the device. Current collectors often comprise metal and/or other
conductive materials and may be used as a backing for electrodes to
facilitate the flow of electricity to and from the electrode.
[0137] "Electrolyte" means a substance containing free ions such
that the substance is electrically conductive. Electrolytes are
commonly employed in electrical energy storage devices. Examples of
electrolytes include, but are not limited to, solvents such as
propylene carbonate, ethylene carbonate, butylene carbonate,
dimethyl carbonate, methyl ethyl carbonate, diethyl carbonate,
sulfolane, methylsulfolane, acetonitrile or mixtures thereof in
combination with solutes such as tetralkylammonium salts such as
TEA TFB (tetraethylammonium tetrafluoroborate), MTEATFB
(methyltriethylammonium tetrafluoroborate), EMITFB
(1-ethyl-3-methylimidazolium tetrafluoroborate),
tetraethylammonium, triethylammonium based salts or mixtures
thereof. In some embodiments, the electrolyte can be a water-based
acid or water-based base electrolyte such as mild aqueous sulfuric
acid or aqueous potassium hydroxide.
A. Carbon Materials Comprising Optimized Pore Size
Distributions
[0138] As noted above, one embodiment of the present disclosure is
a carbon material comprising an optimized pore size distribution.
The optimized pore size distribution contributes to the superior
performance of electrical devices comprising the carbon materials
relative to devices comprising other known carbon materials. For
example, in some embodiments, the carbon material comprises an
optimized blend of both micropores and mesopores and may also
comprise low surface functionality upon pryolysis and/or
activation. In other embodiments, the carbon material comprises a
total of less than 500 ppm of all elements having atomic numbers
ranging from 11 to 92, as measured by proton induced x-ray
emission. The high purity and optimized micropore/mesopore
distribution make the carbon materials ideal for use in electrical
storage and distribution devices, for example ultracapacitors.
[0139] The optimized pore size distributions, as well as the high
purity, of the disclosed carbon materials can be attributed to the
disclosed sol gel methods and subsequent post-polymerization
processing of the polymer gels (e.g., pyrolysis and/or activation).
Applicants have discovered that when one or more polymer
precursors, for example a phenolic compound and an aldehyde, are
co-polymerized under acidic conditions in the presence of a
volatile basic catalyst, an ultrapure polymer gel results. This is
in contrast to other reported methods for the preparation of
polymer gels which result in polymer gels comprising residual
levels of undesired impurities. Pyrolysis and/or activation of the
ultrapure polymer gels under the disclosed conditions results in an
ultrapure carbon material having an optimized pore size
distribution.
[0140] The properties of the disclosed carbon materials, as well as
methods for their preparation are discussed in more detail
below.
[0141] 1. Polymer Gels
[0142] Polymer gels are intermediates in the preparation of the
disclosed carbon materials. As such, the physical and chemical
properties of the polymer gels contribute to the properties of the
carbon materials.
[0143] In other embodiments, the polymer gel comprises a total of
less than 500 ppm of all other elements (i.e., excluding the
electrochemical modifier) having atomic numbers ranging from 11 to
92. For example, in some other embodiments the polymer gel
comprises less than 200 ppm, less than 100 ppm, less than 50 ppm,
less than 25 ppm, less than 10 ppm, less than 5 ppm or less than 1
ppm of all other elements having atomic numbers ranging from 11 to
92. In some embodiments, the electrochemical modifier content and
impurity content of the polymer gels can be determined by proton
induced x-ray emission (PUCE) analysis.
[0144] In some embodiments, the polymer gel is a dried polymer gel,
for example, a polymer cryogel. In other embodiments, the dried
polymer gel is a polymer xerogel or a polymer aerogel. In some
embodiments, the polymer gels are prepared from phenolic compounds
and aldehyde compounds, for example, in one embodiment, the polymer
gels can be produced from resorcinol and formaldehyde. In other
embodiments, the polymer gels are produced under acidic conditions,
and in other embodiments the polymer gels are produced in the
presence of the electrochemical modifier. In some embodiments,
acidity can be provided by dissolution of a solid acid compound, by
employing an acid as the reaction solvent or by employing a mixed
solvent system where one of the solvents is an acid. Preparation of
the polymer gels is described in more detail below.
[0145] The disclosed process comprises polymerization to form a
polymer gel in the presence of a basic volatile catalyst.
Accordingly, in some embodiments, the polymer gel comprises one or
more salts, for example, in some embodiments the one or more salts
are basic volatile salts. Examples of basic volatile salts include,
but are not limited to, ammonium carbonate, ammonium bicarbonate,
ammonium acetate, ammonium hydroxide, and combinations thereof.
Accordingly, in some embodiments, the present disclosure provides a
polymer gel comprising ammonium carbonate, ammonium bicarbonate,
ammonium acetate, ammonium hydroxide, or combinations thereof. In
further embodiments, the polymer gel comprises ammonium carbonate.
In other further embodiments, the polymer gel comprises ammonium
acetate.
[0146] The polymer gels may also comprise low ash content which may
contribute to the low ash content of a carbon material prepared
therefrom. Thus, in some embodiments, the ash content of the
polymer gel ranges from 0.1% to 0.001%. In other embodiments, the
ash content of the polymer gel is less than 0.1%, less than 0.08%,
less than 0.05%, less than 0.03%, less than 0.025%, less than
0.01%, less than 0.0075%, less than 0.005% or less than 0.001%.
[0147] In other embodiments, the polymer gel has a total PIXE
impurity content of all other elements of less than 500 ppm and an
ash content of less than 0.08%. In a further embodiment, the
polymer gel has a total PIXE impurity content of all other elements
of less than 300 ppm and an ash content of less than 0.05%. In
another further embodiment, the polymer gel has a total PIXE
impurity content of all other elements of less than 200 ppm and an
ash content of less than 0.02%. In another further embodiment, the
polymer gel has a total PIXE impurity content of all other elements
of less than 200 ppm and an ash content of less than 0.01%.
[0148] As noted above, polymer gels comprising impurities generally
yield carbon materials which also comprise impurities. Accordingly,
one aspect of the present disclosure is a polymer gel with low
levels of residual undesired impurities. The amount of individual
PIXE impurities present in the polymer gel can be determined by
proton induced x-ray emission. In some embodiments, the level of
sodium present in the polymer gel is less than 1000 ppm, less than
500 ppm, less than 100 ppm, less than 50 ppm, less than 10 ppm, or
less than 1 ppm. In some embodiments, the level of magnesium
present in the polymer gel is less than 1000 ppm, less than 100
ppm, less than 50 ppm, less than 10 ppm, or less than 1 ppm. As
noted above, in some embodiments other impurities such as hydrogen,
oxygen and/or nitrogen may be present in levels ranging from less
than 10% to less than 0.01%.
[0149] In some specific embodiments, the polymer gel comprises less
than 100 ppm sodium, less than 300 ppm silicon, less than 50 ppm
sulfur, less than 100 ppm calcium, less than 20 ppm iron, less than
10 ppm nickel, less than 40 ppm copper, less than 5 ppm chromium
and less than 5 ppm zinc. In other specific embodiments, the
polymer gel comprises less than 50 ppm sodium, less than 100 ppm
silicon, less than 30 ppm sulfur, less than 50 ppm calcium, less
than 10 ppm iron, less than 5 ppm nickel, less than 20 ppm copper,
less than 2 ppm chromium and less than 2 ppm zinc.
[0150] In other specific embodiments, the polymer gel comprises
less than 50 ppm sodium, less than 50 ppm silicon, less than 30 ppm
sulfur, less than 10 ppm calcium, less than 2 ppm iron, less than 1
ppm nickel, less than 1 ppm copper, less than 1 ppm chromium and
less than 1 ppm zinc.
[0151] In some other specific embodiments, the polymer gel
comprises less than 100 ppm sodium, less than 50 ppm magnesium,
less than 50 ppm aluminum, less than 10 ppm sulfur, less than 10
ppm chlorine, less than 10 ppm potassium, less than 1 ppm chromium
and less than 1 ppm manganese.
[0152] The disclosed method yields a polymer gel comprising a high
specific surface area. Without being bound by theory, it is
believed that the surface area of the polymer gel contributes, at
least in part, to the desirable surface area properties of the
carbon materials. The surface area can be measured using the BET
technique well-known to those of skill in the art. In one
embodiment of any of the aspects disclosed herein the polymer gel
comprises a BET specific surface area of at least 150 m.sup.2/g, at
least 250 m.sup.2/g, at least 400 m.sup.2/g, at least 500
m.sup.2/g, at least 600 m.sup.2/g or at least 700 m.sup.2/g.
[0153] In one embodiment, the polymer gel comprises a BET specific
surface area of 100 m.sup.2/g to 1000 m.sup.2/g. Alternatively, the
polymer gel comprises a BET specific surface area of between 150
m.sup.2/g and 900 m.sup.2/g. Alternatively, the polymer gel
comprises a BET specific surface area of between 400 m.sup.2/g and
800 m.sup.2/g.
[0154] In one embodiment, the polymer gel comprises a tap density
of from 0.10 g/cc to 0.60 g/cc. In one embodiment, the polymer gel
comprises a tap density of from 0.15 g/cc to 0.25 g/cc. In one
embodiment of the present disclosure, the polymer gel comprises a
BET specific surface area of at least 150 m.sup.2/g and a tap
density of less than 0.60 g/cc. Alternately, the polymer gel
comprises a BET specific surface area of at least 250 m.sup.2/g and
a tap density of less than 0.4 g/cc. In another embodiment, the
polymer gel comprises a BET specific surface area of at least 500
m.sup.2/g and a tap density of less than 0.30 g/cc.
[0155] In another embodiment of any of the aspects or variations
disclosed herein the polymer gel comprises a residual water content
of less than 15%, less than 13%, less than 10%, less than 5% or
less than 1%.
[0156] In one embodiment, the polymer gel comprises a fractional
pore volume of pores at or below 500 angstroms that comprises at
least 25% of the total pore volume, 50% of the total pore volume,
at least 75% of the total pore volume, at least 90% of the total
pore volume or at least 99% of the total pore volume. In another
embodiment, the polymer gel comprises a fractional pore volume of
pores at or below 20 nm that comprises at least 50% of the total
pore volume, at least 75% of the total pore volume, at least 90% of
the total pore volume or at least 99% of the total pore volume.
[0157] In some embodiments, the amount of nitrogen adsorbed per
mass of polymer gel at 0.11 relative pressure is at least 10% of
the total nitrogen adsorbed up to 0.99 relative pressure or at
least 20% of the total nitrogen adsorbed up to 0.99 relative
pressure. In another embodiment, the amount of nitrogen adsorbed
per mass of polymer gel at 0.11 relative pressure is between 10%
and 50% of the total nitrogen adsorbed up to 0.99 relative
pressure, is between 20% and 40% of the total nitrogen adsorbed up
to 0.99 relative pressure or is between 20% and 30% of the total
nitrogen adsorbed up to 0.99 relative pressure.
[0158] In one embodiment, the polymer gel comprises a fractional
pore surface area of pores at or below 100 nm that comprises at
least 50% of the total pore surface area, at least 75% of the total
pore surface area, at least 90% of the total pore surface area or
at least 99% of the total pore surface area. In another embodiment,
the polymer gel comprises a fractional pore surface area of pores
at or below 20 nm that comprises at least 50% of the total pore
surface area, at least 75% of the total pore surface area, at least
90% of the total pore surface or at least 99% of the total pore
surface area.
[0159] As described in more detail below, methods for preparing the
disclosed carbon materials may include pyrolysis of a polymer gel.
In some embodiments, the pyrolyzed polymer gels have a surface area
from about 100 to about 1200 m.sup.2/g. In other embodiments, the
pyrolyzed polymer gels have a surface area from about 500 to about
800 m.sup.2/g. In other embodiments, the pyrolyzed polymer gels
have a surface area from about 500 to about 700 m.sup.2/g.
[0160] In other embodiments, the pyrolyzed polymer gels have a tap
density from about 0.1 to about 1.0 g/cc. In other embodiments, the
pyrolyzed polymer gels have a tap density from about 0.3 to about
0.6 g/cc. In other embodiments, the pyrolyzed polymer gels have a
tap density from about 0.3 to about 0.5 g/cc.
[0161] The polymer gels can be prepared by the polymerization of
one or more polymer precursors in an appropriate solvent system
under catalytic conditions. The electrochemical modifier can be
incorporated into the gel either during or after the polymerization
process. Accordingly, in one embodiment the polymer gel is prepared
by admixing one or more miscible solvents, one or more phenolic
compounds, one or more aldehydes, one or more catalysts and an
electrochemical modifier. For example in a further embodiment the
polymer gel is prepared by admixing water, acetic acid, resorcinol,
formaldehyde, ammonium acetate and lead acetate. Preparation of
polymers gels, and carbon materials, from the same is discussed in
more detail below.
[0162] 2. Carbon Materials
[0163] The present disclosure is directed to a carbon material
comprising an optimized pore structure. While not wishing to be
bound by theory, it is believed that, in addition to the pore
structure, the purity profile, surface area and other properties of
the carbon materials are a function of its preparation method, and
variation of the preparation parameters may yield carbon materials
having different properties. Accordingly, in some embodiments, the
carbon material is a pyrolyzed dried polymer gel, for example, a
pyrolyzed polymer cryogel, a pyrolyzed polymer xerogel or a
pyrolyzed polymer aerogel. In other embodiments, the carbon
material is pyrolyzed and activated (e.g., a synthetic activated
carbon material). For example, in further embodiments the carbon
material is an activated dried polymer gel, an activated polymer
cryogel, an activated polymer xerogel or an activated polymer
aerogel.
[0164] As noted above, activated carbon particles are widely
employed as an energy storage material. In this regard, a
critically important characteristic is high power density, which is
possible with electrodes that have low ionic resistance that yield
high frequency response. It is important to achieve a low ionic
resistance, for instance in situations with device ability to
respond to cyclic performance is a constraint. The disclosed carbon
material solves the problem of how to optimize an electrode
formulation and maximize the power performance of electrical energy
storage and distribution devices. Devices comprising the carbon
materials exhibit long-term stability, fast response time and high
pulse power performance.
[0165] The disclosed methods produce carbon materials comprising
specific micropore structure, which is typically described in terms
of fraction (percent) of total pore volume residing in either
micropores or mesopores or both. Accordingly, in some embodiments
the pore structure of the carbon materials comprises from 10% to
90% micropores. In some other embodiments the pore structure of the
carbon materials comprises from 20% to 80% micropores. In other
embodiments, the pore structure of the carbon materials comprises
from 30% to 70% micropores. In other embodiments, the pore
structure of the carbon materials comprises from 40% to 60%
micropores. In other embodiments, the pore structure of the carbon
materials comprises from 40% to 50% micropores. In other
embodiments, the pore structure of the carbon materials comprises
from 43% to 47% micropores. In certain embodiments, the pore
structure of the carbon materials comprises about 45%
micropores.
[0166] In some other embodiments the pore structure of the carbon
materials comprises from 20% to 50% micropores. In still other
embodiments the pore structure of the carbon materials comprises
from 20% to 40% micropores, for example from 25% to 35% micropores
or 27% to 33% micropores. In some other embodiments, the pore
structure of the carbon materials comprises from 30% to 50%
micropores, for example from 35% to 45% micropores or 37% to 43%
micropores. In some certain embodiments, the pore structure of the
carbon materials comprises about 30% micropores or about 40%
micropores.
[0167] In some other embodiments the pore structure of the carbon
materials comprises from 40% to 90% micropores. In still other
embodiments the pore structure of the carbon materials comprises
from 45% to 90% micropores, for example from 55% to 85% micropores.
In some other embodiments, the pore structure of the carbon
materials comprises from 65% to 85% micropores, for example from
75% to 85% micropores or 77% to 83% micropores. In yet other
embodiments the pore structure of the carbon materials comprises
from 65% to 75% micropores, for example from 67% to 73% micropores.
In some certain embodiments, the pore structure of the carbon
materials comprises about 80% micropores or about 70%
micropores.
[0168] The mesoporosity of the carbon materials contributes to high
ion mobility and low resistance. In some embodiments, the pore
structure of the carbon materials comprises from 10% to 90%
mesopores. In some other embodiments, the pore structure of the
carbon materials comprises from 20% to 80% mesopores. In other
embodiments, the pore structure of the carbon materials comprises
from 30% to 70% mesopores. In other embodiments, the pore structure
of the carbon materials comprises from 40% to 60% mesopores. In
other embodiments, the pore structure of the carbon materials
comprises from 50% to 60% mesopores. In other embodiments, the pore
structure of the carbon materials comprises from 53% to 57%
mesopores. In other embodiments, the pore structure of the carbon
materials comprises about 55% mesopores.
[0169] In some other embodiments the pore structure of the carbon
materials comprises from 50% to 80% mesopores. In still other
embodiments the pore structure of the carbon materials comprises
from 60% to 80% mesopores, for example from 65% to 75% mesopores or
67% to 73% mesopores. In some other embodiments, the pore structure
of the carbon materials comprises from 50% to 70% mesopores, for
example from 55% to 65% mesopores or 57% to 53% mesopores. In some
certain embodiments, the pore structure of the carbon materials
comprises about 30% mesopores or about 40% mesopores.
[0170] In some other embodiments the pore structure of the carbon
materials comprises from 10% to 60% mesopores. In some other
embodiments the pore structure of the carbon materials comprises
from 10% to 55% mesopores, for example from 15% to 45% mesopores or
from 15% to 40% mesopores. In some other embodiments, the pore
structure of the carbon materials comprises from 15% to 35%
mesopores, for example from 15% to 25% mesopores or from 17% to 23%
mesopores. In some other embodiments, the pore structure of the
carbon materials comprises from 25% to 35% mesopores, for example
from 27% to 33% mesopores. In some certain embodiments, the pore
structure of the carbon materials comprises about 20% mesopores and
in other embodiments the carbon materials comprise about 30%
mesopores.
[0171] The optimized blend of micropores and mesopores within the
carbon materials contributes to the enhanced electrochemical
performance of the same. Thus, in some embodiments the pore
structure of the carbon materials comprises from 10% to 90%
micropores and from 10% to 90% mesopores. In some other embodiments
the pore structure of the carbon materials comprises from 20% to
80% micropores and from 20% to 80% mesopores. In other embodiments,
the pore structure of the carbon materials comprises from 30% to
70% micropores and from 30% to 70% mesopores. In other embodiments,
the pore structure of the carbon materials comprises from 40% to
60% micropores and from 40% to 60% mesopores. In other embodiments,
the pore structure of the carbon materials comprises from 40% to
50% micropores and from 50% to 60% mesopores. In other embodiments,
the pore structure of the carbon materials comprises from 43% to
47% micropores and from 53% to 57% mesopores. In other embodiments,
the pore structure of the carbon materials comprises about 45%
micropores and about 55% mesopores.
[0172] In still other embodiments, the pore structure of the carbon
materials comprises from 40% to 90% micropores and from 10% to 60%
mesopores. In other embodiments, the pore structure of the carbon
materials comprises from 45% to 90% micropores and from 10% to 55%
mesopores. In other embodiments, the pore structure of the carbon
materials comprises from 40% to 85% micropores and from 15% to 40%
mesopores. In yet other embodiments, the pore structure of the
carbon materials comprises from 55% to 85% micropores and from 15%
to 45% mesopores, for example from 65% to 85% micropores and from
15% to 35% mesopores. In other embodiments, the pore structure of
the carbon materials comprises from 65% to 75% micropores and from
15% to 25% mesopores, for example from 67% to 73% micropores and
from 27% to 33% mesopores In some other embodiments, the pore
structure of the carbon materials comprises from 75% to 85%
micropores and from 15% to 25% mesopores, for example from 83% to
77% micropores and from 17% to 23% mesopores. In other certain
embodiments, the pore structure of the carbon materials comprises
about 80% micropores and about 20% mesopores, or in other
embodiments, the pore structure of the carbon materials comprises
about 70% micropores and about 30% mesopores.
[0173] In still other embodiments, the pore structure comprises
from 20% to 50% micropores, and from 50% to 80% mesopores. For
example, in some embodiments, from 20% to 40% of the total pore
volume resides in micropores and from 60% to 80% of the total pore
volume resides in mesopores. In other embodiments, from 25% to 35%
of the total pore volume resides in micropores and from 65% to 75%
of the total pore volume resides in mesopores. For example, in some
embodiments about 30% of the total pore volume resides in
micropores and about 70% of the total pore volume resides in
mesopores.
[0174] In still other embodiments, from 30% to 50% of the total
pore volume resides in micropores and from 50% to 70% of the total
pore volume resides in mesopores. In other embodiments, from 35% to
45% of the total pore volume resides in micropores and from 55% to
65% of the total pore volume resides in mesopores. For example, in
some embodiments, about 40% of the total pore volume resides in
micropores and about 60% of the total pore volume resides in
mesopores.
[0175] In other variations of any of the foregoing carbon
materials, the carbon materials do not have a substantial volume of
pores greater than 20 nm. For example, in certain embodiments the
carbon materials comprise less than 50%, less than 40%, less than
30%, less than 25%, less than 20%, less than 15%, less than 10%,
less than 5%, less than 2.5% or even less than 1% of the total pore
volume in pores greater than 20 nm.
[0176] The porosity of the carbon materials contributes to their
enhanced electrochemical performance. Accordingly, in one
embodiment the carbon material comprises a pore volume residing in
pores less than 20 angstroms of at least 1.8 cc/g, at least 1.2, at
least 0.6, at least 0.30 cc/g, at least 0.25 cc/g, at least 0.20
cc/g or at least 0.15 cc/g. In other embodiments, the carbon
material comprises a pore volume residing in pores greater than 20
angstroms of at least 4.00 cc/g, at least 3.75 cc/g, at least 3.50
cc/g, at least 3.25 cc/g, at least 3.00 cc/g, at least 2.75 cc/g,
at least 2.50 cc/g, at least 2.25 cc/g, at least 2.00 cc/g, at
least 1.90 cc/g, 1.80 cc/g, 1.70 cc/g, 1.60 cc/g, 1.50 cc/g, 1.40
cc/g, at least 1.30 cc/g, at least 1.20 cc/g, at least 1.10 cc/g,
at least 1.00 cc/g, at least 0.85 cc/g, at least 0.80 cc/g, at
least 0.75 cc/g, at least 0.70 cc/g, at least 0.65 cc/g, or at
least 0.5 cc/g.
[0177] In other embodiments, the carbon material comprises a pore
volume of at least 4.00 cc/g, at least 3.75 cc/g, at least 3.50
cc/g, at least 3.25 cc/g, at least 3.00 cc/g, at least 2.75 cc/g,
at least 2.50 cc/g, at least 2.25 cc/g, at least 2.00 cc/g, at
least 1.90 cc/g, 1.80 cc/g, 1.70 cc/g, 1.60 cc/g, 1.50 cc/g, 1.40
cc/g, at least 1.30 cc/g, at least 1.20 cc/g, at least 1.10 cc/g,
at least 1.00 cc/g, at least 0.85 cc/g, at least 0.80 cc/g, at
least 0.75 cc/g, at least 0.70 cc/g, at least 0.65 cc/g or at least
0.50 cc/g for pores ranging from 20 angstroms to 300 angstroms.
[0178] In yet other embodiments, the carbon materials comprise a
total pore volume of at least 4.00 cc/g, at least 3.75 cc/g, at
least 3.50 cc/g, at least 3.25 cc/g, at least 3.00 cc/g, at least
2.75 cc/g, at least 2.50 cc/g, at least 2.25 cc/g, at least 2.00
cc/g, at least 1.90 cc/g, 1.80 cc/g, 1.70 cc/g, 1.60 cc/g, 1.50
cc/g, 1.40 cc/g, at least 1.30 cc/g, at least 1.20 cc/g, at least
1.10 cc/g, at least 1.00 cc/g, at least 0.85 cc/g, at least 0.80
cc/g, at least 0.75 cc/g, at least 0.70 cc/g, at least 0.65 cc/g,
at least 0.60 cc/g, at least 0.55 cc/g, at least 0.50 cc/g, at
least 0.45 cc/g, at least 0.40 cc/g, at least 0.35 cc/g, at least
0.30 cc/g, at least 0.25 cc/g or at least 0.20 cc/g.
[0179] In yet other embodiments, the carbon materials comprise a
pore volume residing in pores of less than 20 angstroms of at least
0.2 cc/g and a pore volume residing in pores of between 20 and 300
angstroms of at least 0.8 cc/g. In yet other embodiments, the
carbon materials comprise a pore volume residing in pores of less
than 20 angstroms of at least 0.5 cc/g and a pore volume residing
in pores of between 20 and 300 angstroms of at least 0.5 cc/g. In
yet other embodiments, the carbon materials comprise a pore volume
residing in pores of less than 20 angstroms of at least 0.6 cc/g
and a pore volume residing in pores of between 20 and 300 angstroms
of at least 2.4 cc/g. In yet other embodiments, the carbon
materials comprise a pore volume residing in pores of less than 20
angstroms of at least 1.5 cc/g and a pore volume residing in pores
of between 20 and 300 angstroms of at least 1.5 cc/g.
[0180] In certain embodiments a mesoporous carbon material having
low pore volume in the micropore region (e.g., less than 60%, less
than 50%, less than 40%, less than 30%, less than 20%
microporosity) is provided. For example, the mesoporous carbon can
be a polymer gel that has been pyrolyzed, but not activated. In
some embodiments, the pyrolyzed mesoporous carbon comprises a
specific surface area of at least 400 m.sup.2/g, at least 500
m.sup.2/g, at least 600 m.sup.2/g, at least 675 m.sup.2/g or at
least 750 m.sup.2/g. In other embodiments, the mesoporous carbon
material comprises a total pore volume of at least 0.50 cc/g, at
least 0.60 cc/g, at least 0.70 cc/g, at least 0.80 cc/g or at least
0.90 cc/g. In yet other embodiments, the mesoporous carbon material
comprises a tap density of at least 0.30 g/cc, at least 0.35 g/cc,
at least 0.40 g/cc, at least 0.45 g/cc, at least 0.50 g/cc or at
least 0.55 g/cc.
[0181] The carbon material comprises low total PIXE impurities
(excluding the electrochemical modifier). Thus, in some embodiments
the total PIXE impurity content (excluding the electrochemical
modifier) of all other PIXE elements in the carbon material (as
measured by proton induced x-ray emission) is less than 1000 ppm.
In other embodiments, the total PIXE impurity content (excluding
the electrochemical modifier) of all other PIXE elements in the
carbon material is less than 800 ppm, less than 500 ppm, less than
300 ppm, less than 200 ppm, less than 150 ppm, less than 100 ppm,
less than 50 ppm, less than 25 ppm, less than 10 ppm, less than 5
ppm or less than 1 ppm. In further embodiments of the foregoing,
the carbon material is a pyrolyzed dried polymer gel, a pyrolyzed
polymer cryogel, a pyrolyzed polymer xerogel, a pyrolyzed polymer
aerogel, an activated dried polymer gel, an activated polymer
cryogel, an activated polymer xerogel or an activated polymer
aerogel.
[0182] In addition to low content of undesired PIXE impurities, the
disclosed carbon materials may comprise high total carbon content.
In addition to carbon, the carbon material may also comprise
oxygen, hydrogen, nitrogen and the electrochemical modifier. In
some embodiments, the material comprises at least 75% carbon, 80%
carbon, 85% carbon, at least 90% carbon, at least 95% carbon, at
least 96% carbon, at least 97% carbon, at least 98% carbon or at
least 99% carbon on a weight/weight basis. In some other
embodiments, the carbon material comprises less than 10% oxygen,
less than 5% oxygen, less than 3.0% oxygen, less than 2.5% oxygen,
less than 1% oxygen or less than 0.5% oxygen on a weight/weight
basis. In other embodiments, the carbon material comprises less
than 10% hydrogen, less than 5% hydrogen, less than 2.5% hydrogen,
less than 1% hydrogen, less than 0.5% hydrogen or less than 0.1%
hydrogen on a weight/weight basis. In other embodiments, the carbon
material comprises less than 5% nitrogen, less than 2.5% nitrogen,
less than 1% nitrogen, less than 0.5% nitrogen, less than 0.25%
nitrogen or less than 0.01% nitrogen on a weight/weight basis. The
oxygen, hydrogen and nitrogen content of the disclosed carbon
materials can be determined by combustion analysis. Techniques for
determining elemental composition by combustion analysis are well
known in the art.
[0183] The total ash content of the carbon material may, in some
instances, have an effect on the electrochemical performance of the
carbon material. Accordingly, in some embodiments, the ash content
of the carbon material ranges from 0.1% to 0.001% weight percent
ash, for example in some specific embodiments the ash content of
the carbon material is less than 0.1%, less than 0.08%, less than
0.05%, less than 0.03%, than 0.025%, less than 0.01%, less than
0.0075%, less than 0.005% or less than 0.001%.
[0184] In other embodiments, the carbon material comprises a total
PIXE impurity content of less than 500 ppm and an ash content of
less than 0.08%. In further embodiments, the carbon material
comprises a total PIXE impurity content of less than 300 ppm and an
ash content of less than 0.05%. In other further embodiments, the
carbon material comprises a total PIXE impurity content of less
than 200 ppm and an ash content of less than 0.05%. In other
further embodiments, the carbon material comprises a total PIXE
impurity content of less than 200 ppm and an ash content of less
than 0.025%. In other further embodiments, the carbon material
comprises a total PIXE impurity content of less than 100 ppm and an
ash content of less than 0.02%. In other further embodiments, the
carbon material comprises a total PIXE impurity content of less
than 50 ppm and an ash content of less than 0.01%.
[0185] The amount of individual PIXE impurities present in the
disclosed carbon materials can be determined by proton induced
x-ray emission. Individual PIXE impurities may contribute in
different ways to the overall electrochemical performance of the
disclosed carbon materials. Thus, in some embodiments, the level of
sodium present in the carbon material is less than 1000 ppm, less
than 500 ppm, less than 100 ppm, less than 50 ppm, less than 10
ppm, or less than 1 ppm. As noted above, in some embodiments other
impurities such as hydrogen, oxygen and/or nitrogen may be present
in levels ranging from less than 10% to less than 0.01%.
[0186] In some embodiments, the carbon material comprises undesired
PIXE impurities near or below the detection limit of the proton
induced x-ray emission analysis. For example, in some embodiments
the carbon material comprises less than 50 ppm sodium, less than 15
ppm magnesium, less than 10 ppm aluminum, less than 8 ppm silicon,
less than 4 ppm phosphorous, less than 3 ppm sulfur, less than 3
ppm chlorine, less than 2 ppm potassium, less than 3 ppm calcium,
less than 2 ppm scandium, less than 1 ppm titanium, less than 1 ppm
vanadium, less than 0.5 ppm chromium, less than 0.5 ppm manganese,
less than 0.5 ppm iron, less than 0.25 ppm cobalt, less than 0.25
ppm nickel, less than 0.25 ppm copper, less than 0.5 ppm zinc, less
than 0.5 ppm gallium, less than 0.5 ppm germanium, less than 0.5
ppm arsenic, less than 0.5 ppm selenium, less than 1 ppm bromine,
less than 1 ppm rubidium, less than 1.5 ppm strontium, less than 2
ppm yttrium, less than 3 ppm zirconium, less than 2 ppm niobium,
less than 4 ppm molybdenum, less than 4 ppm, technetium, less than
7 ppm rubidium, less than 6 ppm rhodium, less than 6 ppm palladium,
less than 9 ppm silver, less than 6 ppm cadmium, less than 6 ppm
indium, less than 5 ppm tin, less than 6 ppm antimony, less than 6
ppm tellurium, less than 5 ppm iodine, less than 4 ppm cesium, less
than 4 ppm barium, less than 3 ppm lanthanum, less than 3 ppm
cerium, less than 2 ppm praseodymium, less than 2 ppm, neodymium,
less than 1.5 ppm promethium, less than 1 ppm samarium, less than 1
ppm europium, less than 1 ppm gadolinium, less than 1 ppm terbium,
less than 1 ppm dysprosium, less than 1 ppm holmium, less than 1
ppm erbium, less than 1 ppm thulium, less than 1 ppm ytterbium,
less than 1 ppm lutetium, less than 1 ppm hafnium, less than 1 ppm
tantalum, less than 1 ppm tungsten, less than 1.5 ppm rhenium, less
than 1 ppm osmium, less than 1 ppm iridium, less than 1 ppm
platinum, less than 1 ppm silver, less than 1 ppm mercury, less
than 1 ppm thallium, less than 1 ppm lead, less than 1.5 ppm
bismuth, less than 2 ppm thorium, or less than 4 ppm uranium.
[0187] In some specific embodiments, the carbon material comprises
less than 100 ppm sodium, less than 300 ppm silicon, less than 50
ppm sulfur, less than 100 ppm calcium, less than 20 ppm iron, less
than 10 ppm nickel, less than 140 ppm copper, less than 5 ppm
chromium and less than 5 ppm zinc as measured by proton induced
x-ray emission. In other specific embodiments, the carbon material
comprises less than 50 ppm sodium, less than 30 ppm sulfur, less
than 100 ppm silicon, less than 50 ppm calcium, less than 10 ppm
iron, less than 5 ppm nickel, less than 20 ppm copper, less than 2
ppm chromium and less than 2 ppm zinc.
[0188] In other specific embodiments, the carbon material comprises
less than 50 ppm sodium, less than 50 ppm silicon, less than 30 ppm
sulfur, less than 10 ppm calcium, less than 2 ppm iron, less than 1
ppm nickel, less than 1 ppm copper, less than 1 ppm chromium and
less than 1 ppm zinc.
[0189] In some other specific embodiments, the carbon material
comprises less than 100 ppm sodium, less than 50 ppm magnesium,
less than 50 ppm aluminum, less than 10 ppm sulfur, less than 10
ppm chlorine, less than 10 ppm potassium, less than 1 ppm chromium
and less than 1 ppm manganese.
[0190] In some embodiments, the carbon materials comprise less than
10 ppm iron. In other embodiments, the carbon materials comprise
less than 3 ppm nickel. In other embodiments, the carbon materials
comprise less than 30 ppm sulfur. In other embodiments, the carbon
materials comprise less than 1 ppm chromium. In other embodiments,
the carbon materials comprise less than 1 ppm copper. In other
embodiments, the carbon materials comprise less than 1 ppm
zinc.
[0191] The disclosed carbon materials also comprise a high surface
area. While not wishing to be bound by theory, it is thought that
such high surface area may contribute, at least in part, to their
superior electrochemical performance. Accordingly, in some
embodiments, the carbon material comprises a BET specific surface
area of at least 100 m.sup.2/g, at least 300 m.sup.2/g, at least
500 m.sup.2/g, at least 1000 m.sup.2/g, at least 1500 m.sup.2/g, at
least 2000 m.sup.2/g, at least 2400 m.sup.2/g, at least 2500
m.sup.2/g, at least 2750 m.sup.2/g or at least 3000 m.sup.2/g. In
other embodiments, the BET specific surface area ranges from about
100 m.sup.2/g to about 3000 m.sup.2/g, for example from about 500
m.sup.2/g to about 1000 m.sup.2/g, from about 1000 m.sup.2/g to
about 1500 m.sup.2/g, from about 1500 m.sup.2/g to about 2000
m.sup.2/g, from about 2000 m.sup.2/g to about 2500 m.sup.2/g or
from about 2500 m.sup.2/g to about 3000 m.sup.2/g. For example, in
some embodiments of the foregoing, the carbon material is
activated.
[0192] In still other examples, the carbon material comprises less
than 100 ppm sodium, less than 100 ppm silicon, less than 10 ppm
sulfur, less than 25 ppm calcium, less than 1 ppm iron, less than 2
ppm nickel, less than 1 ppm copper, less than 1 ppm chromium, less
than 50 ppm magnesium, less than 10 ppm aluminum, less than 25 ppm
phosphorous, less than 5 ppm chlorine, less than 25 ppm potassium,
less than 2 ppm titanium, less than 2 ppm manganese, less than 0.5
ppm cobalt and less than 5 ppm zinc as measured by proton induced
x-ray emission, and wherein all other elements having atomic
numbers ranging from 11 to 92 are undetected by proton induced
x-ray emission.
[0193] In another embodiment, the carbon material comprises a tap
density between 0.1 and 1.0 g/cc, between 0.2 and 0.8 g/cc, between
0.3 and 0.5 g/cc or between 0.4 and 0.5 g/cc. In another
embodiment, the carbon material has a total pore volume of at least
0.1 cm.sup.3/g, at least 0.2 cm.sup.3/g, at least 0.3 cm.sup.3/g,
at least 0.4 cm3/g, at least 0.5 cm.sup.3/g, at least 0.7
cm.sup.3/g, at least 0.75 cm.sup.3/g, at least 0.9 cm.sup.3/g, at
least 1.0 cm.sup.3/g, at least 1.1 cm.sup.3/g, at least 1.2
cm.sup.3/g, at least 1.3 cm.sup.3/g, at least 1.4 cm.sup.3/g, at
least 1.5 cm.sup.3/g or at least 1.6 cm.sup.3/g.
[0194] The pore size distribution of the disclosed carbon materials
is one parameter that may have an effect on the electrochemical
performance of the carbon materials. For example, the carbon
materials may comprise mesopores with a short effective length
(i.e., less than 10 nm, less than 5, nm or less than 3 nm as
measured by TEM) which decreases ion diffusion distance and may be
useful to enhance ion transport and maximize power.
[0195] In another embodiment, the carbon material comprises a
fractional pore surface area of pores between 20 and 300 angstroms
that comprises at least 40% of the total pore surface area, at
least 50% of the total pore surface area, at least 70% of the total
pore surface area or at least 80% of the total pore surface area.
In another embodiment, the carbon material comprises a fractional
pore surface area of pores at or below 20 nm that comprises at
least 20% of the total pore surface area, at least 30% of the total
pore surface area, at least 40% of the total pore surface area or
at least 50% of the total pore surface area.
[0196] In another embodiment, the carbon material comprises pores
predominantly in the range of 1000 angstroms or lower, for example
100 angstroms or lower, for example 50 angstroms or lower.
Alternatively, the carbon material comprises micropores in the
range of 0-20 angstroms and mesopores in the range of 20-300
angstroms. The ratio of pore volume or pore surface in the
micropore range compared to the mesopore range can be in the range
of 95:5 to 5:95. Alternatively, the ratio of pore volume or pore
surface in the micropore range compared to the mesopore range can
be in the range of 20:80 to 60:40.
[0197] In other embodiments, the carbon materials are mesoporous
and comprise monodisperse mesopores. As used herein, the term
"monodisperse" when used in reference to a pore size refers
generally to a span (further defined as (Dv90-Dv10)/Dv, 50 where
Dv10, Dv50 and Dv90 refer to the pore size at 10%, 50% and 90% of
the distribution by volume of about 3 or less, typically about 2 or
less, often about 1.5 or less.
[0198] Yet in other embodiments, the carbons materials comprise a
pore volume of at least 1 cc/g, at least 2 cc/g, at least 3 cc/g,
at least 4 cc/g or at least 7 cc/g. In one particular embodiment,
the carbon materials comprise a pore volume of from 1 cc/g to 7
cc/g.
[0199] In other embodiments, the carbon materials comprise at least
50% of the total pore volume residing in pores with a diameter
ranging from 50 .ANG. to 5000 .ANG.. In some instances, the carbon
materials comprise at least 50% of the total pore volume residing
in pores with a diameter ranging from 50 .ANG. to 500 .ANG.. Still
in other instances, the carbon materials comprise at least 50% of
the total pore volume residing in pores with a diameter ranging
from 500 .ANG. to 1000 .ANG.. Yet in other instances, the carbon
materials comprise at least 50% of the total pore volume residing
in pores with a diameter ranging from 1000 .ANG. to 5000 .ANG..
[0200] In some embodiments, the mean particle diameter for the
carbon materials ranges from 1 to 1000 microns. In other
embodiments the mean particle diameter for the carbon materials
ranges from 1 to 100 microns. Still in other embodiments the mean
particle diameter for the carbon materials ranges from 1 to 50
microns. Yet in other embodiments, the mean particle diameter for
the carbon materials ranges from 5 to 15 microns or from 1 to 5
microns. Still in other embodiments, the mean particle diameter for
the carbon materials is about 10 microns. Still in other
embodiments, the mean particle diameter for the carbon materials is
less than 4, is less than 3, is less than 2, is less than 1
microns.
[0201] In some embodiments, the carbon materials exhibit a mean
particle diameter ranging from 1 nm to 10 nm. In other embodiments,
the mean particle diameter ranges from 10 nm to 20 nm. Yet in other
embodiments, the mean particle diameter ranges from 20 nm to 30 nm.
Still in other embodiments, the mean particle diameter ranges from
30 nm to 40 nm. Yet still in other embodiments, the mean particle
diameter ranges from 40 nm to 50 nm. In other embodiments, the mean
particle diameter ranges from 50 nm to 100 nm.
[0202] In another embodiment of the present disclosure, the carbon
material is prepared by a method disclosed herein, for example, in
some embodiments the carbon material is prepared by a method
comprising pyrolyzing a dried polymer gel as disclosed herein. In
some embodiments, the pyrolyzed polymer gel is further activated to
obtain an activated carbon material. Carbon materials comprising an
electrochemical modifier can be prepared by any number of methods
described in more detail below.
B. Preparation of Carbon Materials Comprising Optimized Pore Size
Distributions
[0203] Methods for preparing carbon materials which comprise
electrochemical modifiers and which comprise high surface area,
high porosity and low levels of undesirable impurities are not
known in the art. Current methods for preparing carbon materials of
high surface area and high porosity result in carbon materials
having high levels of undesirable impurities. Electrodes prepared
by incorporating an electrochemical modifier into these carbon
materials have poor electrical performance as a result of the
residual impurities. Accordingly, in one embodiment the present
disclosure provides a method for preparing carbon materials
comprising an electrochemical modifier, wherein the carbon
materials comprise a high surface area, high porosity and low
levels of undesirable impurities. In some embodiments, the methods
comprise preparation of a polymer gel by a sol gel process followed
by pyrolysis of the dried polymer gel and optional activation of
the pyrolyzed polymer gel. The sol gel process provides significant
flexibility such that an electrochemical modifier can be
incorporated at any number of steps. In other embodiments, carbon
materials from other sources (e.g., carbon nanotubes, carbon
fibers, etc.) can be impregnated with an electrochemical modifier.
In one embodiment, a method for preparing a polymer gel comprising
an electrochemical modifier is provided. In another embodiment,
methods for preparing pyrolyzed polymer gels comprising
electrochemical modifiers or activated carbon materials comprising
electrochemical modifiers is provided. Details of the variable
process parameters of the various embodiments of the disclosed
methods are described below.
[0204] 1. Preparation of Polymer Gels
[0205] The polymer gels may be prepared by a sol gel process. For
example, the polymer gel may be prepared by co-polymerizing one or
more polymer precursors in an appropriate solvent. In one
embodiment, the one or more polymer precursors are co-polymerized
under acidic conditions. In some embodiments, a first polymer
precursor is a phenolic compound and a second polymer precursor is
an aldehyde compound. In one embodiment, of the method the phenolic
compound is phenol, resorcinol, catechol, hydroquinone,
phloroglucinol, or a combination thereof; and the aldehyde compound
is formaldehyde, acetaldehyde, propionaldehyde, butyraldehyde,
benzaldehyde, cinnamaldehyde, or a combination thereof. In a
further embodiment, the phenolic compound is resorcinol, phenol or
a combination thereof, and the aldehyde compound is formaldehyde.
In yet further embodiments, the phenolic compound is resorcinol and
the aldehyde compound is formaldehyde.
[0206] The sol gel polymerization process is generally performed
under catalytic conditions. Accordingly, in some embodiments,
preparing the polymer gel comprises co-polymerizing one or more
polymer precursors in the presence of a catalyst. In some
embodiments, the catalyst comprises a basic volatile catalyst. For
example, in one embodiment, the basic volatile catalyst comprises
ammonium carbonate, ammonium bicarbonate, ammonium acetate,
ammonium hydroxide, or combinations thereof. In a further
embodiment, the basic volatile catalyst is ammonium carbonate. In
another further embodiment, the basic volatile catalyst is ammonium
acetate.
[0207] The molar ratio of catalyst to phenolic compound may have an
effect on the final properties of the polymer gel as well as the
final properties of the carbon materials, for example. Thus, in
some embodiments such catalysts are used in the range of molar
ratios of 5:1 to 2000:1 phenolic compound:catalyst. In some
embodiments, such catalysts can be used in the range of molar
ratios of 20:1 to 200:1 phenolic compound:catalyst. For example in
other embodiments, such catalysts can be used in the range of molar
ratios of 5:1 to 100:1 phenolic compound:catalyst.
[0208] The reaction solvent is another process parameter that may
be varied to obtain the desired properties (e.g., surface area,
porosity, purity, etc.) of the polymer gels and carbon materials.
In some embodiments, the solvent for preparation of the polymer gel
is a mixed solvent system of water and a miscible co-solvent. For
example, in certain embodiments the solvent comprises a water
miscible acid. Examples of water miscible acids include, but are
not limited to, propionic acid, acetic acid, and formic acid. In
further embodiments, the solvent comprises a ratio of
water-miscible acid to water of 99:1, 90:10, 75:25, 50:50, 25:75,
10:90 or 1:90. In other embodiments, acidity is provided by adding
a solid acid to the reaction solvent.
[0209] In some other embodiments of the foregoing, the solvent for
preparation of the polymer gel is acidic. For example, in certain
embodiments the solvent comprises acetic acid. For example, in one
embodiment, the solvent is 100% acetic acid. In other embodiments,
a mixed solvent system is provided, wherein one of the solvents is
acidic. For example, in one embodiment of the method the solvent is
a binary solvent comprising acetic acid and water. In further
embodiments, the solvent comprises a ratio of acetic acid to water
of 99:1, 90:10, 75:25, 50:50, 25:75, 20:80, 10:90 or 1:90. In other
embodiments, acidity is provided by adding a solid acid to the
reaction solvent.
[0210] Some embodiments of the disclosed method do not comprise a
solvent exchange step (e.g., exchange t-butanol for water) prior to
drying (e.g., lyophilization). For example, in one embodiment of
any of the methods described herein, before freezing, the polymer
gel or polymer gel particles are rinsed with water. In one
embodiment, the average diameter of the polymer gel particles prior
to freezing is less than 25 mm, for example, between 0.001 mm and
25 mm; alternately, the average diameter of the polymer gel
particles prior to freezing is between 0.01 mm and 15 mm, for
example, between 1.0 mm and 15 mm. In some examples, the polymer
gel particles are between 1 mm and 10 mm. In further embodiments,
the polymer gel particles are frozen via immersion in a medium
having a temperature of below about -10.degree. C., for example,
below about -20.degree. C., or alternatively below about
-30.degree. C. For example, the medium may be liquid nitrogen or
ethanol (or other organic solvent) in dry ice or ethanol cooled by
another means. In some embodiments, drying under vacuum comprises
subjecting the frozen particles to a vacuum pressure of below about
3000 mTorr. Alternatively, drying under vacuum comprises subjecting
the frozen particles to a vacuum pressure of below about 1000
mTorr. Alternatively, drying under vacuum comprises subjecting the
frozen particles to a vacuum pressure of below about 300 mTorr.
Alternatively, drying under vacuum comprises subjecting the frozen
particles to a vacuum pressure of below about 100 mTorr.
[0211] Other methods of rapidly freezing the polymer gel particles
are also envisioned. For example, in another embodiment the polymer
gel is rapidly frozen by co-mingling or physical mixing of polymer
gel particles with a suitable cold solid, for example, dry ice
(solid carbon dioxide). Another envisioned method comprises using a
blast freezer with a metal plate at -60.degree. C. to rapidly
remove heat from the polymer gel particles scattered over its
surface. Another method of rapidly cooling water in a polymer gel
particle is to snap freeze the particle by pulling a high vacuum
very rapidly (the degree of vacuum is such that the temperature
corresponding to the equilibrium vapor pressure allows for
freezing). Yet another method for rapid freezing comprises admixing
a polymer gel with a suitably cold gas. In some embodiments the
cold gas may have a temperature below about -10.degree. C. In some
embodiments the cold gas may have a temperature below about
-20.degree. C. In some embodiments the cold gas may have a
temperature below about -30.degree. C. In yet other embodiments,
the gas may have a temperature of about -196.degree. C. For
example, in some embodiments, the gas is nitrogen. In yet other
embodiments, the gas may have a temperature of about -78.degree. C.
For example, in some embodiments, the gas is carbon dioxide.
[0212] In other embodiments, the polymer gel particles are frozen
on a lyophilizer shelf at a temperature of -20.degree. C. or lower.
For example, in some embodiments the polymer gel particles are
frozen on the lyophilizer shelf at a temperature of -30.degree. C.
or lower. In some other embodiments, the polymer gel monolith is
subjected to a freeze thaw cycle (from room temperature to
-20.degree. C. or lower and back to room temperature), physical
disruption of the freeze-thawed gel to create particles, and then
further lyophilization processing. For example, in some
embodiments, the polymer gel monolith is subjected to a freeze thaw
cycle (from room temperature to -30.degree. C. or lower and back to
room temperature), physical disruption of the freeze-thawed gel to
create particles, and then further lyophilization processing.
[0213] In some embodiments of the methods described herein, the
molar ratio of phenolic precursor to catalyst is from about 5:1 to
about 2000:1 or the molar ratio of phenolic precursor to catalyst
is from about 20:1 to about 200:1. In further embodiments, the
molar ratio of phenolic precursor to catalyst is from about 25:1 to
about 100:1. In further embodiments, the molar ratio of phenolic
precursor to catalyst is from about 25:1 to about 50:1. In further
embodiments, the molar ratio of phenolic precursor to catalyst is
from about 100:1 to about 5:1.
[0214] In the specific embodiment wherein one of the polymer
precursors is resorcinol and another polymer precursor is
formaldehyde, the resorcinol to catalyst ratio can be varied to
obtain the desired properties of the resultant polymer gel and
carbon materials. In some embodiments of the methods described
herein, the molar ratio of resorcinol to catalyst is from about
10:1 to about 2000:1 or the molar ratio of resorcinol to catalyst
is from about 20:1 to about 200:1. In further embodiments, the
molar ratio of resorcinol to catalyst is from about 25:1 to about
100:1. In further embodiments, the molar ratio of resorcinol to
catalyst is from about 25:1 to about 50:1. In further embodiments,
the molar ratio of resorcinol to catalyst is from about 100:1 to
about 5:1.
[0215] Polymerization to form a polymer gel can be accomplished by
various means described in the art and may include addition of an
electrochemical modifier. For instance, polymerization can be
accomplished by incubating suitable polymer precursor materials,
and optionally an electrochemical modifier, in the presence of a
suitable catalyst for a sufficient period of time. The time for
polymerization can be a period ranging from minutes or hours to
days, depending on the temperature (the higher the temperature the
faster, the reaction rate, and correspondingly, the shorter the
time required). The polymerization temperature can range from room
temperature to a temperature approaching (but lower than) the
boiling point of the starting solution. For example, the
temperature can range from about 20.degree. C. to about 90.degree.
C. In the specific embodiment wherein one polymer precursor is
resorcinol and one polymer precursor is formaldehyde, the
temperature can range from about 20.degree. C. to about 100.degree.
C., typically from about 25.degree. C. to about 90.degree. C. In
some embodiments, polymerization can be accomplished by incubation
of suitable synthetic polymer precursor materials in the presence
of a catalyst for at least 24 hours at about 90.degree. C.
Generally polymerization can be accomplished in between about 6 and
about 24 hours at about 90.degree. C., for example between about 18
and about 24 hours at about 90.degree. C.
[0216] The polymer precursor materials as disclosed herein include
(a) alcohols, phenolic compounds, and other mono- or polyhydroxy
compounds and (b) aldehydes, ketones, and combinations thereof.
Representative alcohols in this context include straight chain and
branched, saturated and unsaturated alcohols. Suitable phenolic
compounds include polyhydroxy benzene, such as a dihydroxy or
trihydroxy benzene. Representative polyhydroxy benzenes include
resorcinol (i.e., 1,3-dihydroxy benzene), catechol, hydroquinone,
and phloroglucinol. Mixtures of two or more polyhydroxy benzenes
can also be used. Phenol (monohydroxy benzene) can also be used.
Representative polyhydroxy compounds include sugars, such as
glucose, and other polyols, such as mannitol. Aldehydes in this
context include: straight chain saturated aldeydes such as methanal
(formaldehyde), ethanal (acetaldehyde), propanal (propionaldehyde),
butanal (butyraldehyde), and the like; straight chain unsaturated
aldehydes such as ethenone and other ketenes, 2-propenal
(acrylaldehyde), 2-butenal (crotonaldehyde), 3 butenal, and the
like; branched saturated and unsaturated aldehydes; and
aromatic-type aldehydes such as benzaldehyde, salicylaldehyde,
hydrocinnamaldehyde, and the like. Suitable ketones include:
straight chain saturated ketones such as propanone and 2 butanone,
and the like; straight chain unsaturated ketones such as propenone,
2 butenone, and 3-butenone (methyl vinyl ketone) and the like;
branched saturated and unsaturated ketones; and aromatic-type
ketones such as methyl benzyl ketone (phenylacetone), ethyl benzyl
ketone, and the like. The polymer precursor materials can also be
combinations of the precursors described above.
[0217] In some embodiments, one polymer precursor is an
alcohol-containing species and another polymer precursor is a
carbonyl-containing species. The relative amounts of
alcohol-containing species (e.g., alcohols, phenolic compounds and
mono- or poly-hydroxy compounds or combinations thereof) reacted
with the carbonyl containing species (e.g. aldehydes, ketones or
combinations thereof) can vary substantially. In some embodiments,
the ratio of alcohol-containing species to aldehyde species is
selected so that the total moles of reactive alcohol groups in the
alcohol-containing species is approximately the same as the total
moles of reactive carbonyl groups in the aldehyde species.
Similarly, the ratio of alcohol-containing species to ketone
species may be selected so that the total moles of reactive alcohol
groups in the alcohol containing species is approximately the same
as the total moles of reactive carbonyl groups in the ketone
species. The same general 1:1 molar ratio holds true when the
carbonyl-containing species comprises a combination of an aldehyde
species and a ketone species.
[0218] The total solids content in the solution or suspension prior
to polymer gel formation can be varied. The weight ratio of
resorcinol to water is from about 0.05 to 1 to about 0.70 to 1.
Alternatively, the ratio of resorcinol to water is from about 0.15
to 1 to about 0.6 to 1. Alternatively, the ratio of resorcinol to
water is from about 0.15 to 1 to about 0.35 to 1. Alternatively,
the ratio of resorcinol to water is from about 0.25 to 1 to about
0.5 to 1. Alternatively, the ratio of resorcinol to water is from
about 0.3 to 1 to about 0.4 to 1.
[0219] Examples of solvents useful in the preparation of the
polymer gels disclosed herein include but are not limited to water
or alcohols such as, for example, ethanol, t butanol, methanol or
combinations thereof as well as aqueous mixtures of the same. Such
solvents are useful for dissolution of the polymer precursor
materials, for example dissolution of the phenolic compound. In
addition, in some processes such solvents are employed for solvent
exchange in the polymer gel (prior to freezing and drying), wherein
the solvent from the polymerization of the precursors, for example,
resorcinol and formaldehyde, is exchanged for a pure alcohol. In
one embodiment of the present application, a polymer gel is
prepared by a process that does not include solvent exchange.
[0220] Suitable catalysts in the preparation of the polymer gels
include volatile basic catalysts that facilitate polymerization of
the precursor materials into a monolithic polymer. The catalyst can
also comprise various combinations of the catalysts described
above. In embodiments comprising phenolic compounds, such catalysts
can be used in the range of molar ratios of 5:1 to 200:1 phenolic
compound:catalyst. For example, in some specific embodiments such
catalysts can be used in the range of molar ratios of 25:1 to 100:1
phenolic compound:catalyst.
[0221] 2. Creation of Polymer Gel Particles
[0222] A monolithic polymer gel can be physically disrupted to
create smaller particles according to various techniques known in
the art. The resultant polymer gel particles generally have an
average diameter of less than about 30 mm, for example, in the size
range of about 1 mm to about 25 mm, or between about 1 mm to about
5 mm or between about 0.5 mm to about 10 mm. Alternatively, the
size of the polymer gel particles can be in the range below about 1
mm, for example, in the size range of about 10 to 1000 microns.
Techniques for creating polymer gel particles from monolithic
material include manual or machine disruption methods, such as
sieving, grinding, milling, or combinations thereof. Such methods
are well-known to those of skill in the art. Various types of mills
can be employed in this context such as roller, bead, and ball
mills and rotary crushers and similar particle creation equipment
known in the art.
[0223] In a specific embodiment, a roller mill is employed. A
roller mill has three stages to gradually reduce the size of the
gel particles. The polymer gels are generally very brittle and are
not damp to the touch. Consequently they are easily milled using
this approach; however, the width of each stage must be set
appropriately to achieve the targeted final mesh. This adjustment
is made and validated for each combination of gel recipe and mesh
size. Each gel is milled via passage through a sieve of known mesh
size. Sieved particles can be temporarily stored in sealed
containers.
[0224] In one embodiment, a rotary crusher is employed. The rotary
crusher has a screen mesh size of about 118.sup.th inch. In another
embodiment, the rotary crusher has a screen mesh size of about
318.sup.th inch. In another embodiment, the rotary crusher has a
screen mesh size of about 518.sup.th inch. In another embodiment,
the rotary crusher has a screen mesh size of about 318.sup.th
inch.
[0225] Milling can be accomplished at room temperature according to
methods well known to those of skill in the art. Alternatively,
milling can be accomplished cryogenically, for example by
co-milling the polymer gel with solid carbon dioxide (dry ice)
particles. In this embodiment, the two steps of (a) creating
particles from the monolithic polymer gel and (b) rapid,
multidirectional freezing of the polymer gel are accomplished in a
single process.
[0226] 3. Rapid Freezing of Polymer Gels
[0227] After the polymer gel particles are formed from the
monolithic polymer gel, freezing of the polymer gel particles may
be accomplished rapidly and in a multi-directional fashion as
described in more detail above. Freezing slowly and in a
unidirectional fashion, for example by shelf freezing in a
lyophilizer, results in dried material having a very low surface
area. Similarly, snap freezing (i.e., freezing that is accomplished
by rapidly cooling the polymer gel particles by pulling a deep
vacuum) also results in a dried material having a low surface area.
As disclosed herein rapid freezing in a multidirectional fashion
can be accomplished by rapidly lowering the material temperature to
at least about -10.degree. C. or lower, for example, -20.degree. C.
or lower, or for example, to at least about -30.degree. C. or
lower. Rapid freezing of the polymer gel particles creates a fine
ice crystal structure within the particles due to widespread
nucleation of ice crystals, but leaves little time for ice crystal
growth. This provides a high specific surface area between the ice
crystals and the hydrocarbon matrix, which is necessarily excluded
from the ice matrix.
[0228] The concept of extremely rapid freezing to promote
nucleation over crystal growth can also be applied to mixed solvent
systems. In one embodiment, as the mixed solvent system is rapidly
cooled, the solvent component that predominates will undergo
crystallization at its equilibrium melting temperature, with
increased concentration of the co-solvent(s) and concomitant
further freezing point depression. As the temperature is further
lowered, there is increased crystallization of the predominant
solvent and concentration of co-solvent(s) until the eutectic
composition is reached, at which point the eutectic composition
undergoes the transition from liquid to solid without further
component concentration or product cooling until complete freezing
is achieved. In the specific case of water and acetic acid (which
as pure substances exhibit freezing points of 0.degree. C. and
17.degree. C., respectively), the eutectic composition is comprised
of approximately 59% acetic acid and 41% water and freezes at about
-27.degree. C. Accordingly, in one embodiment, the mixed solvent
system is the eutectic composition, for example, in one embodiment
the mixed solvent system comprises 59% acetic acid and 41%
water.
[0229] 4. Drying of Polymer Gels
[0230] In one embodiment, the frozen polymer gel particles
containing a fine ice matrix are lyophilized under conditions
designed to avoid collapse of the material and to maintain fine
surface structure and porosity in the dried product. Generally
drying is accomplished under conditions where the temperature of
the product is kept below a temperature that would otherwise result
in collapse of the product pores, thereby enabling the dried
material to retain an extremely high surface area.
[0231] The structure of the final carbon material is reflected in
the structure of the dried polymer gel which in turn is established
by the polymer gel properties. These features can be created in the
polymer gel using a sol-gel processing approach as described
herein, but if care is not taken in removal of the solvent, then
the structure is not preserved. It is of interest to both retain
the original structure of the polymer gel and modify its structure
with ice crystal formation based on control of the freezing
process. In some embodiments prior to drying, the aqueous content
of the polymer gel is in the range of about 50% to about 99%. In
certain embodiments upon drying, the aqueous content of the polymer
cryogel is about 10%, alternately less than about 5% or less than
about 2.5%.
[0232] A lyophilizer chamber pressure of about 2250 microns results
in a primary drying temperature in the drying product of about
-10.degree. C. Drying at about 2250 micron chamber pressure or
lower case provides a product temperature during primary drying
that is no greater than about -10.degree. C. As a further
illustration, a chamber pressure of about 1500 microns results in a
primary drying temperature in the drying product of about
-15.degree. C. Drying at about 1500 micron chamber pressure or
lower provides a product temperature during primary drying that is
no greater than about -15.degree. C. As yet a further illustration,
a chamber pressure of about 750 microns results in a primary drying
temperature in the drying product of about -20.degree. C. Drying at
750 micron chamber pressure or lower provides a product temperature
during primary drying that is no greater than about -20.degree. C.
As yet a further illustration, a chamber pressure of about 300
microns results in a primary drying temperature in the drying
product of about -30.degree. C. Drying at 300 micron chamber
pressure or lower provides a product temperature during primary
drying that is no greater than about -30.degree. C.
[0233] 5. Pyrolysis and Activation of Polymer Gels
[0234] The polymer gels described above, can be further processed
to obtain carbon materials. Such processing includes, for example,
pyrolysis and/or activation. Generally, in the pyrolysis process,
dried polymer gels are weighed and placed in a rotary kiln. The
temperature ramp is set at 5.degree. C. per minute, the dwell time
and dwell temperature are set; cool down is determined by the
natural cooling rate of the furnace. The entire process is usually
run under an inert atmosphere, such as a nitrogen environment.
Pyrolyzed samples are then removed and weighed. Other pyrolysis
processes are well known to those of skill in the art.
[0235] In some embodiments, pyrolysis dwell time (the period of
time during which the sample is at the desired temperature) is from
about 0 minutes to about 120 minutes, from about 0 minutes to about
60 minutes, from about 0 minutes to about 30 minutes, from about 0
minutes to about 10 minutes, from about 0 to 5 minutes or from
about 0 to 1 minute.
[0236] Pyrolysis may also be carried out more slowly than described
above. For example, in one embodiment the pyrolysis is carried out
in about 120 to 480 minutes. In other embodiments, the pyrolysis is
carried out in about 120 to 240 minutes.
[0237] In some embodiments, pyrolysis dwell temperature ranges from
about 500.degree. C. to 2400.degree. C. In some embodiments,
pyrolysis dwell temperature ranges from about 650.degree. C. to
1800.degree. C. In other embodiments pyrolysis dwell temperature
ranges from about 700.degree. C. to about 1200.degree. C. In other
embodiments pyrolysis dwell temperature ranges from about
850.degree. C. to about 1050.degree. C. In other embodiments
pyrolysis dwell temperature ranges from about 800.degree. C. to
about 900.degree. C.
[0238] In some embodiments, the pyrolysis dwell temperature is
varied during the course of pyrolysis. In one embodiment, the
pyrolysis is carried out in a rotary kiln with separate, distinct
heating zones. The temperature for each zone is sequentially
decreased from the entrance to the exit end of the rotary kiln
tube. In one embodiment, the pyrolysis is carried out in a rotary
kiln with separate distinct heating zones, and the temperature for
each zone is sequentially increased from entrance to exit end of
the rotary kiln tube.
[0239] Activation time and activation temperature both have a large
impact on the performance of the resulting activated carbon
material, as well as the manufacturing cost thereof. Increasing the
activation temperature and the activation dwell time results in
higher activation percentages, which generally correspond to the
removal of more material compared to lower temperatures and shorter
dwell times. Activation temperature can also alter the pore
structure of the carbon where lower temperatures result in more
microporous carbon and higher temperatures result in mesoporosity.
This is a result of the activation gas diffusion limited reaction
that occurs at higher temperatures and reaction kinetic driven
reactions that occur at lower temperature. Higher activation
percentage often increases performance of the final activated
carbon, but it also increases cost by reducing overall yield.
Improving the level of activation corresponds to achieving a higher
performance product at a lower cost.
[0240] Pyrolyzed polymer gels may be activated by contacting the
pyrolyzed polymer gel with an activating agent. Many gases are
suitable for activating, for example gases which contain oxygen.
Non-limiting examples of activating gases include carbon dioxide,
carbon monoxide, steam, oxygen and combinations thereof. Activating
agents may also include corrosive chemicals such as acids, bases or
salts (e.g., phosphoric acid, acetic acid, citric acid, formic
acid, oxalic acid, uric acid, lactic acid, potassium hydroxide,
sodium hydroxide, zinc chloride, etc.). Other activating agents are
known to those skilled in the art.
[0241] In some embodiments, the activation time is between 1 minute
and 48 hours. In other embodiments, the activation time is between
1 minute and 24 hours. In other embodiments, the activation time is
between 5 minutes and 24 hours. In other embodiments, the
activation time is between 1 hour and 24 hours. In further
embodiments, the activation time is between 12 hours and 24 hours.
In certain other embodiments, the activation time is between 30 min
and 4 hours. In some further embodiments, the activation time is
between 1 hour and 2 hours.
[0242] Pyrolyzed polymer gels may be activated using any number of
suitable apparatuses known to those skilled in the art, for
example, fluidized beds, rotary kilns, elevator kilns, roller
hearth kilns, pusher kilns, etc. In one embodiment of the
activation process, samples are weighed and placed in a rotary
kiln, for which the automated gas control manifold is set to ramp
at a 20.degree. C. per minute rate. Carbon dioxide is introduced to
the kiln environment for a period of time once the proper
activation temperature has been reached. After activation has
occurred, the carbon dioxide is replaced by nitrogen and the kiln
is cooled down. Samples are weighed at the end of the process to
assess the level of activation. Other activation processes are well
known to those of skill in the art. In some of the embodiments
disclosed herein, activation temperatures may range from
800.degree. C. to 1300.degree. C. In another embodiment, activation
temperatures may range from 800.degree. C. to 1050.degree. C. In
another embodiment, activation temperatures may range from about
850.degree. C. to about 950.degree. C. One skilled in the art will
recognize that other activation temperatures, either lower or
higher, may be employed.
[0243] The degree of activation is measured in terms of the mass
percent of the pyrolyzed dried polymer gel that is lost during the
activation step. In one embodiment of the methods described herein,
activating comprises a degree of activation from 5% to 90%; or a
degree of activation from 10% to 80%; in some cases activating
comprises a degree of activation from 40% to 70%, or a degree of
activation from 45% to 65%.
C. Characterization of Polymer Gels and Carbon Materials
[0244] The structural properties of the final carbon material and
intermediate polymer gels may be measured using Nitrogen sorption
at 77K, a method known to those of skill in the art. The final
performance and characteristics of the finished carbon material is
important, but the intermediate products (both dried polymer gel
and pyrolyzed, but not activated, polymer gel), can also be
evaluated, particularly from a quality control standpoint, as known
to those of skill in the art. The Micromeretics ASAP 2020 is used
to perform detailed micropore and mesopore analysis, which reveals
a pore size distribution from 0.35 nm to 50 nm in some embodiments.
The system produces a nitrogen isotherm starting at a pressure of
10.sup.-7 atm, which enables high resolution pore size
distributions in the sub 1 nm range. The software generated reports
utilize a Density Functional Theory (DFT) method to calculate
properties such as pore size distributions, surface area
distributions, total surface area, total pore volume, and pore
volume within certain pore size ranges.
[0245] The impurity content of the carbon materials can be
determined by any number of analytical techniques known to those of
skill in the art. One particular analytical method useful within
the context of the present disclosure is proton induced x-ray
emission (PIXE). This technique is capable of measuring the
concentration of elements having atomic numbers ranging from 11 to
92 at low ppm levels. Accordingly, in one embodiment the
concentration of impurities present in the carbon materials is
determined by PIXE analysis.
D. Devices Comprising the Carbon Materials
[0246] 1. EDLCs
[0247] The disclosed carbon materials can be used as electrode
material in any number of electrical energy storage and
distribution devices. One such device is an ultracapacitor.
Ultracapacitors comprising carbon materials are described in detail
in co-owned U.S. Pat. No. 7,835,136 which is hereby incorporated in
its entirety.
[0248] EDLCs use electrodes immersed in an electrolyte solution as
their energy storage element. Typically, a porous separator
immersed in and impregnated with the electrolyte ensures that the
electrodes do not come in contact with each other, preventing
electronic current flow directly between the electrodes. At the
same time, the porous separator allows ionic currents to flow
through the electrolyte between the electrodes in both directions
thus forming double layers of charges at the interfaces between the
electrodes and the electrolyte.
[0249] When electric potential is applied between a pair of
electrodes of an EDLC, ions that exist within the electrolyte are
attracted to the surfaces of the oppositely-charged electrodes, and
migrate towards the electrodes. A layer of oppositely-charged ions
is thus created and maintained near each electrode surface.
Electrical energy is stored in the charge separation layers between
these ionic layers and the charge layers of the corresponding
electrode surfaces. In fact, the charge separation layers behave
essentially as electrostatic capacitors. Electrostatic energy can
also be stored in the EDLCS through orientation and alignment of
molecules of the electrolytic solution under influence of the
electric field induced by the potential. This mode of energy
storage, however, is secondary.
[0250] EDLCS comprising the disclosed carbon material can be
employed in various electronic devices where high power is desired.
Accordingly, in one embodiment an electrode comprising the carbon
materials is provided. In another embodiment, the electrode
comprises activated carbon material. In a further embodiment, an
ultracapacitor comprising an electrode comprising the carbon
materials is provided. In a further embodiment of the foregoing,
the ultrapure synthetic carbon material comprises an optimized
balance of micropores and mesopores and described above.
[0251] The disclosed carbon materials find utility in any number of
electronic devices, for example wireless consumer and commercial
devices such as digital still cameras, notebook PCs, medical
devices, location tracking devices, automotive devices, compact
flash devices, mobiles phones, PCMCIA cards, handheld devices, and
digital music players. Ultracapacitors are also employed in heavy
equipment such as: excavators and other earth moving equipment,
forklifts, garbage trucks, cranes for ports and construction and
transportation systems such as buses, automobiles and trains.
[0252] Accordingly, in certain embodiments the present disclosure
provides an electrical energy storage device comprising any of the
foregoing carbon materials, for example a carbon material
comprising a pore structure, the pore structure comprising
micropores, mesopores and a total pore volume, wherein from 20% to
80% of the total pore volume resides in micropores and from 20% to
80% of the total pore volume resides in mesopores and less than 10%
of the total pore volume resides in pores greater than 20 nm.
[0253] In some embodiments, the device is an electric double layer
capacitor (EDLC) device comprising:
[0254] a) a positive electrode and a negative electrode wherein
each of the positive and the negative electrodes comprise the
carbon material;
[0255] b) an inert porous separator; and
[0256] c) an electrolyte;
[0257] wherein the positive electrode and the negative electrode
are separated by the inert porous separator.
[0258] In one embodiment, an ultracapacitor device comprising the
carbon material comprises a gravimetric power of at least 5 W/g, at
least 10 W/g, at least 15 W/g, at least 20 W/g, at least 25 W/g, at
least 30 W/g, at least 35 W/g, at least 50 W/g. In another
embodiment, an ultracapacitor device comprising the carbon material
comprises a volumetric power of at least 2 W/g, at least 4 W/cc, at
least 5 W/cc, at least 10 W/cc, at least 15 W/cc or at least 20
W/cc. In another embodiment, an ultracapacitor device comprising
the carbon material carbon material comprises a gravimetric energy
of at least 2.5 Wh/kg, at least 5.0 Wh/kg, at least 7.5 Wh/kg, at
least 10 Wh/kg, at least 12.5 Wh/kg, at least 15.0 Wh/kg, at least
17.5. Wh/kg, at least 20.0 Wh/kg, at least 22.5 wh/kg or at least
25.0 Wh/kg. In another embodiment, an ultracapacitor device
comprising the carbon material comprises a volumetric energy of at
least 1.5 Wh/liter, at least 3.0 Wh/liter, at least 5.0 Wh/liter,
at least 7.5 Wh/liter, at least 10.0 Wh/liter, at least 12.5
Wh/liter, at least 15 Wh/liter, at least 17.5 Wh/liter or at least
20.0 Wh/liter.
[0259] In some embodiments of the foregoing, the gravimetric power,
volumetric power, gravimetric energy and volumetric energy of an
ultracapacitor device comprising the carbon material are measured
by constant current discharge from 2.7 V to 1.89 V employing a 1.0
M solution of tetraethylammonium-tetrafluroroborate in acetonitrile
(1.0 M TEATFB in AN) electrolyte and a 0.5 second time
constant.
[0260] In one embodiment, an ultracapacitor device comprising the
carbon material comprises a gravimetric power of at least 10 W/g, a
volumetric power of at least 5 W/cc, a gravimetric capacitance of
at least 100 F/g (@0.5 A/g) and a volumetric capacitance of at
least 10 F/cc (@0.5 A/g). In one embodiment, the aforementioned
ultracapacitor device is a coin cell double layer ultracapacitor
comprising the carbon material, a conductivity enhancer, a binder,
an electrolyte solvent, and an electrolyte salt. In further
embodiments, the aforementioned conductivity enhancer is a carbon
black and/or other conductivity enhancer known in the art. In
further embodiments, the aforementioned binder is Teflon and or
other binder known in the art. In further aforementioned
embodiments, the electrolyte solvent is acetonitrile or propylene
carbonate, or other electrolyte solvent(s) known in the art. In
further aforementioned embodiments, the electrolyte salt is
tetraethylaminotetrafluroborate or triethylmethyl
aminotetrafluroborate or other electrolyte salt known in the art,
or liquid electrolyte known in the art.
[0261] In one embodiment, an ultracapacitor device comprising the
carbon material comprises a gravimetric power of at least 15 W/g, a
volumetric power of at least 10 W/cc, a gravimetric capacitance of
at least 110 F/g (@0.5 A/g) and a volumetric capacitance of at
least 15 F/cc (@0.5 A/g). In one embodiment, the aforementioned
ultracapacitor device is a coin cell double layer ultracapacitor
comprising the carbon material, a conductivity enhancer, a binder,
an electrolyte solvent, and an electrolyte salt. In further
embodiments, the aforementioned conductivity enhancer is a carbon
black and/or other conductivity enhancer known in the art. In
further embodiments, the aforementioned binder is Teflon and or
other binder known in the art. In further aforementioned
embodiments, the electrolyte solvent is acetonitrile or propylene
carbonate, or other electrolyte solvent(s) known in the art. In
further aforementioned embodiments, the electrolyte salt is
tetraethylaminotetrafluroborate or triethylmethyl
aminotetrafluroborate or other electrolyte salt known in the art,
or liquid electrolyte known in the art.
[0262] In one embodiment, an ultracapacitor device comprising the
carbon material comprises a gravimetric capacitance of at least 90
F/g, at least 95 F/g, at least 100 F/g, at least 105 F/g, at least
110 F/g, at least 115 F/g, at least 120 F/g, at least 125 F/g, or
at least 130 F/g. In another embodiment, an ultracapacitor device
comprising the carbon material comprises a volumetric capacitance
of at least 5 F/cc, at least 10 F/cc, at least 15 F/cc, at least 20
F/cc, or at least 25 F/cc. In some embodiments of the foregoing,
the gravimetric capacitance and volumetric capacitance are measured
by constant current discharge from 2.7 V to 0.1 V with a 5-second
time constant and employing a 1.8 M solution of
tetraethylammonium-tetrafluroroborate in acetonitrile (1.8 M TEATFB
in AN) electrolyte and a current density of 0.5 A/g, 1.0 A/g, 4.0
A/g or 8.0 A/g.
[0263] In one embodiment, the present disclosure provides
ultracapacitors comprising a carbon material as disclosed herein,
wherein the percent decrease in original capacitance (i.e.,
capacitance before being subjected to voltage hold) of the
ultracapacitor comprising the carbon material after a voltage hold
period is less than the percent decrease in original capacitance of
an ultracapacitor comprising known carbon materials. In one
embodiment, the percent of original capacitance remaining for an
ultracapacitor comprising the carbon material after a voltage hold
at 2.7 V for 24 hours at 65.degree. C. is at least 90%, at least
80%, at least 70%, at least 60%, at least 50%, at least 40%, at
least 30% at least 20% or at least 10%. In further embodiments of
the foregoing, the percent of original capacitance remaining after
the voltage hold period is measured at a current density of 0.5
A/g, 1 A/g, 4 A/g or 8 A/g.
[0264] In another embodiment, the present disclosure provides
ultracapacitors comprising a carbon material as disclosed herein,
wherein the percent decrease in original capacitance of the
ultracapacitor comprising the carbon material after repeated
voltage cycling is less than the percent decrease in original
capacitance of an ultracapacitor comprising known carbon materials
subjected to the same conditions. For example, in one embodiment,
the percent of original capacitance remaining for an ultracapacitor
comprising the carbon material is more than the percent of original
capacitance remaining for an ultracapacitor comprising known carbon
materials after 1000, 2000, 4000, 6000, 8000, or 1000 voltage
cycling events comprising cycling between 2 V and 1V at a current
density of 4 A/g. In another embodiment, the percent of original
capacitance remaining for an ultracapacitor comprising the carbon
material after 1000, 2000, 4000, 6000, 8000, or 1000 voltage
cycling events comprising cycling between 2 V and 1V at a current
density of 4 A/g, is at least 90%, at least 80%, at least 70%, at
least 60%, at least 50%, at least 40%, at least 30% at least 20% or
at least 10%.
[0265] In still other embodiments, the EDLC device comprises a
gravimetric capacitance of at least of at least 13 F/cc as measured
by constant current discharge from 2.7 V to 0.1 V and with at least
0.24 Hz frequency response and employing a 1.8 M solution of
tetraethylammonium-tetrafluroroborate in acetonitrile electrolyte
and a current density of 0.5 A/g. Other embodiments include and
EDLC device, wherein the EDLC device comprises a gravimetric
capacitance of at least of at least 17 F/cc as measured by constant
current discharge from 2.7 V to 0.1 V and with at least 0.24 Hz
frequency response and employing a 1.8 M solution of
tetraethylammonium-tetrafluroroborate in acetonitrile electrolyte
and a current density of 0.5 A/g.
[0266] As noted above, the carbon material can be incorporated into
ultracapacitor devices. In some embodiments, the carbon material is
milled to an average particle size of about 10 microns using a
jetmill according to the art. While not wishing to be bound by
theory, it is believed that this fine particle size enhances
particle-to-particle conductivity, as well as enabling the
production of very thin sheet electrodes. The jetmill essentially
grinds the carbon against itself by spinning it inside a disc
shaped chamber propelled by high-pressure nitrogen. As the larger
particles are fed in, the centrifugal force pushes them to the
outside of the chamber; as they grind against each other, the
particles migrate towards the center where they eventually exit the
grinding chamber once they have reached the appropriate
dimensions.
[0267] In further embodiments, after jet milling the carbon is
blended with a fibrous Teflon binder (3% by weight) to hold the
particles together in a sheet. The carbon Teflon mixture is kneaded
until a uniform consistency is reached. Then the mixture is rolled
into sheets using a high-pressure roller-former that results in a
final thickness of 50 microns. These electrodes are punched into
discs and heated to 195.degree. C. under a dry argon atmosphere to
remove water and/or other airbourne contaminants. The electrodes
are weighed and their dimensions measured using calipers.
[0268] The carbon electrodes of the EDLCs are wetted with an
appropriate electrolyte solution. Examples of solvents for use in
electrolyte solutions for use in the devices of the present
application include but are not limited to propylene carbonate,
ethylene carbonate, butylene carbonate, dimethyl carbonate, methyl
ethyl carbonate, diethyl carbonate, sulfolane, methylsulfolane and
acetonitrile. Such solvents are generally mixed with solute,
including, tetralkylammonium salts such as TEATFB
(tetraethylammonium tetrafluoroborate); TEMATFB
(tri-ethyl,methylammonium tetrafluoroborate); EMITFB
(1-ethyl-3-methylimidazolium tetrafluoroborate),
tetramethylammonium or triethylammonium based salts. Further the
electrolyte can be a water based acid or base electrolyte such as
mild sulfuric acid or potassium hydroxide.
[0269] In some embodiments, the electrodes are wetted with a 1.0 M
solution of tetraethylammonium-tetrafluroroborate in acetonitrile
(1.0 M TEATFB in AN) electrolyte. In other embodiments, the
electrodes are wetted with a 1.0 M solution of
tetraethylammonium-tetrafluroroborate in propylene carbonate (1.0 M
TEATFB in PC) electrolyte. These are common electrolytes used in
both research and industry and are considered standards for
assessing device performance. In other embodiments, the symmetric
carbon-carbon (C--C) capacitors are assembled under an inert
atmosphere, for example, in an Argon glove box, and a NKK porous
membrane 30 micron thick serves as the separator. Once assembled,
the samples may be soaked in the electrolyte for about 20 minutes
or more depending on the porosity of the sample.
[0270] In some embodiments, the capacitance and power output are
measured using cyclic voltametry (CV), chronopotentiometry (CP) and
impedance spectroscopy at various voltages (ranging from 1.0-2.5 V
maximum voltage) and current levels (from 1-10 mA) on a Biologic
VMP3 electrochemical workstation. In this embodiment, the
capacitance may be calculated from the discharge curve of the
potentiogram using the formula:
C = I .times. .DELTA. t .DELTA. V Equation 1 ##EQU00001##
where I is the current (A) and .DELTA.V is the voltage drop,
.DELTA.t is the time difference. Because in this embodiment the
test capacitor is a symmetric carbon-carbon (C--C) electrode, the
specific capacitance is determined from:
C.sub.s=2C/m.sub.e Equation 2
where m.sub.e is the mass of a single electrode. The specific
energy and power may be determined using:
E s = 1 4 CV max 2 m e Equation 3 P s = E s / 4 ESR Equation 4
##EQU00002##
where C is the measured capacitance V.sub.max is the maximum test
voltage and ESR is the equivalent series resistance obtained from
the voltage drop at the beginning of the discharge. ESR can
alternately be derived from impedance spectroscopy.
[0271] 2. Batteries
[0272] The disclosed carbon materials also find utility as
electrodes in a any number of types of batteries. One such battery
is the metal air battery, for example lithium air batteries.
Lithium air batteries generally comprise an electrolyte interposed
between positive electrode and negative electrodes. The positive
electrode generally comprises a lithium compound such as lithium
oxide or lithium peroxide and serves to oxidize or reduce oxygen.
The negative electrode generally comprises a carbonaceous substance
which absorbs and releases lithium ions. As with supercapacitors,
batteries such as lithium air batteries which comprise the
disclosed carbon materials are expected to be superior to batteries
comprising known carbon materials. Accordingly, in one embodiment
the present invention provides a metal air battery, for example a
lithium air battery, comprising a carbon material as disclosed
herein.
[0273] Any number of other batteries, for example, zinc-carbon
batteries, lithium/carbon batteries, lead acid batteries and the
like are also expected to perform better with the carbon materials.
One skilled in the art will recognize other specific types of
carbon containing batteries which will benefit from the disclosed
carbon materials. Accordingly, in another embodiment the present
invention provides a battery, in particular a zinc/carbon, a
lithium/carbon batteries or a lead acid battery comprising a carbon
material as disclosed herein.
[0274] One embodiment is directed to a lead acid battery comprising
the disclosed carbon materials, for example a lead/acid battery
comprising:
[0275] a) at least one positive electrode comprising a first active
material in electrical contact with a first current collector;
[0276] b) at least one negative electrode comprising a second
active material in electrical contact with a second current
collector; and
[0277] c) an electrolyte;
[0278] wherein the positive electrode and the negative electrode
are separated by an inert porous separator, and wherein at least
one of the first or second active materials comprises the carbon
material.
[0279] Active materials within the scope of the present disclosure
include materials capable of storing and/or conducting electricity.
The active material can be any active material known in the art and
useful in lead acid batteries, for example the active material may
comprise lead, lead (II) oxide, lead (IV) oxide, or combinations
thereof and may be in the form of a paste.
[0280] Another embodiment of any of the above devices, the carbon
material comprises the same micropore to mesopore distribution but
at a lower surface area range. This embodiment is prepared by
synthesizing the same base high purity polymer structure that
yields the same optimized micropore to mesopore volume distribution
with low surface functionality upon pyrolysis (but no activation).
The result of lower surface area optimized pore structure in a
battery application like lead acid batteries is a maximization of
an electrode formulation with a highly conductive network. It is
also theorized that high mesopore volume may be an excellent
structure to allow high ion mobility in many other energy storage
systems such as lead acid, lithium ion, etc.
EXAMPLES
[0281] The carbon materials disclosed in the following Examples
were prepared according to the methods disclosed herein. Chemicals
were obtained from commercial sources at reagent grade purity or
better and were used as received from the supplier without further
purification.
[0282] Unless indicated otherwise, the following conditions were
generally employed for preparation of the carbon materials and
precursors. Phenolic compound and aldehyde were reacted in the
presence of a catalyst in a binary solvent system (e.g., water and
acetic acid). The molar ratio of phenolic compound to aldehyde was
typically 0.5 to 1. The reaction was allowed to incubate in a
sealed container at temperatures of up to 85 C for up to 24 h. The
resulting polymer hydrogel contained water, but no organic solvent;
and was not subjected to solvent exchange of water for an organic
solvent, such as t-butanol. The polymer hydrogel monolith was then
physically disrupted, for example by grinding, to form polymer
hydrogel particles having an average diameter of less than about 5
mm. Unless stated otherwise, the particles were then rapidly
frozen, generally by immersion in a cold fluid (e.g., liquid
nitrogen or ethanol/dry ice) and lyophilized. Generally, the
lyophilizer shelf was pre-cooled to -30.degree. C. before loading a
tray containing the frozen polymer hydrogel particles on the
lyophilizer shelf. The chamber pressure for lyophilization was
typically in the range of 50 to 1000 mTorr and the shelf
temperature was in the range of +10 to +25.degree. C.
Alternatively, the shelf temperature can be set lower, for example
in the range of 0 to +10.degree. C. Alternatively, the shelf
temperature can be set higher, for example in the range of 25 to
+100.degree. C. Chamber pressure can be held in the range of 50 to
3000 mTorr. For instance, the chamber pressure can be controlled in
the range of 150 to 300 mTorr.
[0283] The dried polymer hydrogel was typically pyrolyzed by
heating in a nitrogen atmosphere at temperatures ranging from
700-1200.degree. C. for a period of time as specified in the
examples. Activation conditions generally comprised heating a
pyrolyzed polymer hydrogel in a CO.sub.2 atmosphere at temperatures
ranging from 800-1000.degree. C. for a period of time as specified
in the examples. Specific pyrolysis and activation conditions were
as described in the following examples.
Example 1
Preparation of Dried Polymer Gel
[0284] A polymer gel was prepared by polymerization of resorcinol
and formaldehyde (0.5:1) in a water/acetic acid solvent (75:25) in
the presence of ammonium acetate catalyst. The resorcinol to
solvent ration (R/S) was 0.3, and the resorcinol to catalyst ratio
(R/C) was 25. The reaction mixture was placed at elevated
temperature (incubation at 45.degree. C. for about 6 h followed by
incubation at 85.degree. C. for about 24 h) to allow for gellation
to create a polymer gel. Polymer gel particles were created from
the polymer gel and passed through a 4750 micron mesh sieve. The
sieved particles were flash frozen by immersion in liquid nitrogen,
loaded into a lyophilization tray at a loading of 3 to 7
g/in.sup.2, and lyophilized at approximately 50 mTorr. The time to
dry (as inferred from time for product to reach within 2.degree. C.
of shelf temperature) varied with product loading on the
lyophilizer shelf.
[0285] The mass loss on drying the polymer gel was 73.4%. The
surface area of the dried polymer gel was determined to be 752
m.sup.2/g, the total pore volume was 1.40 cc/g and the tap density
was 0.22 g/cc. The pore size distribution of two different batches
of dried polymer gel is shown in FIG. 1.
Example 2
Preparation of Pyrolyzed Carbon Material from Dried Polymer Gel
[0286] Dried polymer gel prepared according to Example 2 was
pyrolyzed by passage through a rotary kiln at 850.degree. C. with a
nitrogen gas flow of 200 L/h. The weight loss upon pyrolysis was
determined to be 56.2%
[0287] The surface area of the pyrolyzed dried polymer gel was
examined by nitrogen surface analysis using a surface area and
porosity analyzer. The measured specific surface area using the
standard BET approach was 726 m.sup.2/g, the total pore volume was
0.71 cc/g and the tap density was 0.42 g/cc. Carbon materials
comprising different properties (e.g., surface area, pore
structure, etc.) can be prepared by altering the pyrolysis
conditions (e.g., temperature, time, etc.) described above.
Example 3
Production of Activated Carbon
[0288] Pyrolyzed carbon material prepared according to Example 2
was activated a batch rotary kiln at 900.degree. C. under a
CO.sub.2 for 660 min, resulting in a total weight loss of
64.8%.
[0289] The surface area of the activated carbon was examined by
nitrogen surface analysis using a surface area and porosity
analyzer. The measured specific surface area using the BET approach
was 1989 m.sup.2/g, the total pore volume was 1.57 cc/g and the tap
density was 0.28 g/cc.
[0290] FIG. 2 shows an overlay of the pore size distributions of
the pyrolyzed carbon material of Example 2 and the activated carbon
material of Example 3. Note that the pore size distribution for the
activated carbon was measured on a micromeritics ASAP2020, a
micropore-capable analyzer with a higher resolution (lower pore
size volume detection) than the Tristar 3020 that was used to
measure the pore size distribution for the pyrolyzed carbon.
[0291] From the DFT cumulative volume plot for the activated carbon
material of Example 3, it was determined that the 44% of the pore
volume resides in micropores and 56% of the pore volume resides in
mesopores. Carbon materials comprising different properties (e.g.,
surface area, pore structure, etc.) can be prepared by altering the
activation conditions (e.g., temperature, time, etc.) described
above.
Example 4
Micronization of Activated Carbon Via Jet Milling
[0292] Activated carbon prepared according to Example 3 was jet
milled using a Jet Pulverizer Micron Master 2 inch diameter jet
mill. The conditions comprised about 0.7 lbs of activated carbon
per hour, nitrogen gas flow about 20 scf per min and about 100 psi
pressure. The average particle size after jet milling was about 8
to 10 microns.
Example 5
Purity Analysis of Activated Carbon & Comparison Carbons
[0293] Carbon samples prepared according to the general procedures
herein were examined for their impurity content via proton induced
x-ray emission (PIXE). PIXE is an industry-standard, highly
sensitive and accurate measurement for simultaneous elemental
analysis by excitation of the atoms in a sample to produce
characteristic X-rays which are detected and their intensities
identified and quantified. PIXE is capable of detection of all
elements with atomic numbers ranging from 11 to 92 (i.e., from
sodium to uranium).
[0294] The PIXE impurities (Imp.) detected in carbon materials as
disclosed herein as well as other commercial carbon materials for
comparison purposes is presented in Table 1. Carbon 1 is a
pyrolyzed (but not activated) carbon material. Carbons 2 and 3 are
pyrolyzed and activated carbon materials. Carbon 4 is an activated
carbon denoted "MSP-20" obtained from Kansai Coke and Chemicals
Co., Ltd. (Kakogawa, Japan), Carbon 5 is an activated carbon
denoted "YP-50F(YP-17D)" obtained from Kuraray Chemical Co. (Osaka,
Japan).
[0295] As seen in Table 1, the carbon materials according to the
instant disclosure have a lower PIXE impurity content and lower ash
content as compared to other known activated carbon samples.
TABLE-US-00001 TABLE 1 Purity Analysis of Activated Carbon &
Comparison Carbons Impurity Concentration (PPM) Impurity Carbon 1
Carbon 2 Carbon 3 Carbon 4 Carbon 5 Na ND* ND ND 353.100 ND Mg ND
ND ND 139.000 ND Al ND ND ND 63.850 38.941 Si ND ND ND 34.670
513.517 P ND ND ND ND 59.852 S 12.191 10.390 18.971 90.110 113.504
Cl ND ND ND 28.230 9.126 K ND ND ND 44.210 76.953 Ca 10.651 3.071
16.571 ND 119.804 Cr ND ND ND 4.310 3.744 Mn ND ND ND ND 7.552 Fe
2.672 2.144 3.140 3.115 59.212 Ni ND ND ND 36.620 2.831 Cu ND ND ND
7.927 17.011 Zn ND ND ND ND 2.151 Total 25.514 15.605 38.682
805.142 1024.198 (% Ash) (0.006) (0.003) (0.009) (0.13) (0.16) *ND
= not detected by PIXE analysis
Example 6
Preparation and Properties of Various Carbon Samples
[0296] As noted above, the disclosed carbon materials comprise a
higher density through optimization of the micropore and mesopore
structure. Specifically, the carbon material exhibits two regions
of pore structures (1) micropores, <20 .ANG., (2) mesopores
between 20 .ANG. and 200 .ANG.. There is a relative lack of pore
structure between these two populations, and a relative lack of
pore structure above 200 .ANG.. High pulse power EDLC systems
require low resistance performance from carbon electrodes and from
the total cell system. This high pulse power performance electrode
carbon is characterized by fast response time as measured using
impedance spectroscopy. The fast response time is attributed to
purity and pore volume that provide high ion mobility and low ion
resistance within the porous structure.
[0297] To demonstrate the utility of the carbon materials, various
carbon samples were prepared by following the general procedures
described in Examples 1-4. The physiochemical properties of three
different types of carbon samples (Carbons 1-3) prepared according
to the above procedures are tabulated in Table 1 below. The pore
size distribution of the carbon samples is depicted in FIG. 3.
TABLE-US-00002 TABLE 1 Physiochemical Characteristics of Carbons
1-3 Ratio N.sub.2 PV Total Pore Tap adsorbed meso/ SSA Volume
Density (P/Po)95/(P/ PV total Sample (m.sup.2/g) (cc/g) (g/cc) Po)5
(%) Purity Carbon 1 600-800 0.6-0.8 0.35-0.45 2.5-3.5 70-80%*
<200 ppm impurities Ash <0.1% Carbon 2 1550-2100 1.2-1.6
0.25-0.35 2.0-2.5 52-60% <200 ppm impurities Ash <0.1% Carbon
3 2100-2800 1.5-2.7 0.19-0.28 2.0-2.5 52-60% <200 ppm impurities
Ash <0.1% *Calculation from DFT model on Tristar mesopore
analysis as opposed to ASAP2020 micropore analysis for Carbon 2
& 3.
Example 7
Electrochemical Properties of Various Carbon Samples
[0298] The carbon samples were analyzed for their electrochemical
performance, specifically as an electrode material in EDLC coin
cell devices. Specific details regarding fabrication of electrodes,
EDLCs and their testing are described below.
[0299] Capacitor electrodes comprised 99 parts by weight carbon
particles (average particle size 5-15 microns) and 1 part by weight
Teflon. The carbon and Teflon were masticated in a mortar and
pestle until the Teflon was well distributed and the composite had
some physical integrity. After mixing, the composite was rolled out
into a flat sheet, approximately 50 microns thick. Electrode disks,
approximately 1.59 cm in diameter, were punched out of the sheet.
The electrodes were placed in a vacuum oven attached to a dry box
and heated for 12 hours at 195.degree. C. This removed water
adsorbed from the atmosphere during electrode preparation. After
drying, the electrodes were allowed to cool to room temperature,
the atmosphere in the oven was filled with argon and the electrodes
were moved into the dry box where the capacitors were made.
[0300] A carbon electrode was placed into a cavity formed by a 1
inch (2.54 cm) diameter carbon-coated aluminum foil disk and a 50
micron thick polyethylene gasket ring which had been heat sealed to
the aluminum. A second electrode was then prepared in the same way.
Two drops of electrolyte comprising 1.8 M tetraethylene ammonium
tetrafluoroborate in acetonitrile were added to each electrode.
Each electrode was covered with a 0.825 inch diameter porous
polypropylene separator. The two electrode halves were sandwiched
together with the separators facing each other and the entire
structure was hot pressed together.
[0301] When complete, the capacitor was ready for electrical
testing with a potentiostat/function generator/frequency response
analyzer. Capacitance was measured by a constant current discharge
method, comprising applying a current pulse for a known duration
and measuring the resulting voltage profile. By choosing a given
time and ending voltage, the capacitance was calculated from the
following C=It/.DELTA.V, where C=capacitance, I=current, t=time to
reached the desired voltage and .DELTA.V=the voltage difference
between the initial and final voltages. The specific capacitance
based on the weight and volume of the two carbon electrodes was
obtained by dividing the capacitance by the weight and volume
respectively. This data is reported in Table 11 for discharge
between 2.7 and 1.89V.
[0302] The data in Table 2 shows that the carbons of this
disclosure demonstrate high power with improved volumetric
capacitance over a commercially available carbon that was deemed
not viable for market due to its low density capacitance, but noted
for its high turn on frequency character--a character expanded by
carbons of this disclosure to both exhibit higher turn on frequency
characteristics and higher volumetric capacitance performance.
TABLE-US-00003 TABLE 2 Electrochemical Characteristics of Certain
Carbon Materials Gravimetric Volumetric Capacitance Capacitance
Volumetric Gravimetric (F/g) (F/cc) Power Power Sample (@ 0.5 A/g)
(@ 0.5 A/g) (W/cc) (W/g) Carbon 2 105-120 12-17 4-10 8-15 Carbon 3
115-125 10-14 6-10 15-30 Commercial 105** 7.5 2 7.8 Carbon A**
**Measured in 2.0 V (see Example 10)
[0303] Carbon 2 was measured for stability testing at 2.7 voltage
hold at 65.degree. C. from zero to 128 hours. The higher stability
nature of this carbon is depicted in Table 3 as a high capacitance
retention over stress testing compared to two commercially
available carbon materials (Commercial carbons B and C) used as
industry standard stable carbon in EDLC applications. Carbon 4 is
predominantly microporous carbon (see curve denoted "NC2-1D" in
FIG. 7).
TABLE-US-00004 TABLE 3 Electrochemical Stability as a function of %
Capacitance Retention over Time Capacitance % Retention of F/cc at
0.5 A/g, 2.7 V hold at 65.degree. C. after several time points
(0-128 h) t = 0 h t = 24 h t = 48 h t = 128 h Sample (%) (%) (%)
(%) Carbon 2 100 89.9 87.5 82.2 Carbon 4 100 84.6 79.3 68.3
Commercial 100 90.9 84.9 63.0 Carbon B Commercial 100 89.3 85.4
75.3 Carbon C
[0304] Graphically, FIG. 4 shows that Carbon 2 exhibits higher
stability at 128 hours compared to carbons 4 and carbons B and C
and extrapolation in the charted trend points towards this carbon
being a higher stability carbon than other carbons in Table 3.
[0305] Resistance directly relates to power calculations. The lower
the resistance, the higher the power performance. Resistance 1
refers to direct current discharge initial IR drop calculation.
This is shown in FIGS. 5A and 5B for various carbon materials.
[0306] Stress testing showed that the resistances of Carbon 2 over
time remain low, which is a contrast to other carbons in Table 3.
Low resistance directly relates to higher power performance.
[0307] A Bode plot (FIG. 6) was generated to depict the high
frequency response of typical of the disclosed carbon materials. In
this plot, Carbon 2 is designated NC2-3. The shift to the right and
higher frequency range on the Bode plot indicates higher frequency
response and power performance.
[0308] FIG. 7 shows how NC2-3 occupies a unique range of pore size
distribution compared to two comparator carbons.
Example 8
Electrochemical Properties of Other Carbon Samples
[0309] Another carbon sample (Carbon 2) was prepared according to
the general procedures described in the Examples. EDLC coin cells
comprising the carbon material were prepared and their
electrochemical properties analyzed using 1M TEABF.sub.4/ACN
electrolyte. The results are tabulated in Tables 4, 5 and 6
below.
TABLE-US-00005 TABLE 4 Capacitance and Current Density of Carbon 2
Current density 0.5 A/g 1 A/g 4 A/g 8 A/g Capacitance 13.8 13.5
11.6 9.2 (F/cc) Capacitance 113.1 110.4 94.7 75.6 (F/g)
[0310] Table 5 summarizes the resistance data for Carbon 2.
Resistance 1 refers to direct current discharge initial IR drop
calculation method. Resistance 2 refers to direct current discharge
final voltage relaxation calculation method. Resistance 3 refers to
ESR taken at 2V EIS curve at reactance intercept which usually
occurs near 400 kHz for the coin cells.
TABLE-US-00006 TABLE 5 Resistance of the Carbon 2 Material Current
density 0.5 A/g 1 A/g 4 A/g 8 A/g Resistance 1 4.0 3.8 3.1 2.7
(ohm) Resistance 2 5.0 4.8 4.3 4.4 (ohm) Resistance 3 0.53
(ohm)
[0311] Table 6 summarizes the power data for EDLCs comprising the
carbon material. This power data is calculated from 2V EIS curve.
Power number calculated from -45 deg phase angle.
TABLE-US-00007 TABLE 6 Power Data for the Carbon 2 Material Power
density Power density (W/cc) (W/g) FOM Power value 5.0 10.3
Example 9
Properties of Other Carbon Samples
[0312] Additional carbon samples were prepared according to the
general procedures described above.
TABLE-US-00008 TABLE 7 Electrochemical Data for the Carbon
Materials Gravimetric Volumetric Gravimetric Power Sample
Capacitance (F/g) Capacitance (F/cc) (W/g) 5 118 12 57 6 127 11
61
TABLE-US-00009 TABLE 8 Physical Properties for the Carbon Materials
Specific Surface Total Pore Volume Sample Area (m.sup.2/g) (cc/g) 7
2113 2.03 8 1989 1.57
[0313] The pore size distribution of these carbon samples is shown
in FIGS. 8 and 9. FIG. 8 shows that two different batches of carbon
material exhibit similar pore structure, while FIG. 9 shows that
the carbon materials according to the present disclosure comprise a
high volume of mesopore compared to other known carbon materials.
Without being bound by theory, Applicants believe this mesoporosity
contributes, at least in part, to the enhanced electrochemical
properties of the carbon materials.
Example 10
Properties and Performance of Capacitor Electrodes Comprising the
Carbon Materials
[0314] A carbon material prepared according to the general
procedures described above was evaluated for its properties and
performance as an electrode in a symmetric electrochemical
capacitor with a carbonate-based organic electrolyte. A
comprehensive set of property and performance measurements was
performed on test capacitors fabricated with this material.
[0315] The sample was very granular and included relatively large
particles. As a result, the capacitor's electrodes formed for the
evaluation were porous and had very low density (0.29 g/cm.sup.3).
The electrode fabricated using the carbon material exhibited a high
value of specific capacitance (105 F/g) but because of the very low
electrode density the volumetric capacitance was only 30 F/cc.
Using the mass or volume of the dry electrodes only, the test
devices had Figure of Merit (FOM) values (see Miller, "Pulse Power
Performance of Electrochemical Capacitors: Technical Status of
Present Commercial Devices," Proc. 8th International Seminar on
Double Layer Capacitors and Similar Energy Storage Devices,
Deerfield Beach, Fla. (Dec. 7-9, 1998)) around 7.8 W/g and 2 W/ml
for operation at 2 V. These values would be reduced by packaging
with electrolyte but increased by operation at higher voltages. In
comparison, the maximum reported FOM value for commercial capacitor
products using organic electrolyte (1998) was 3.6 W/g and 4.1 W/ml.
The disclosed carbon material compares very favorably to the
commercial devices on a weight basis, primarily because of the
relatively high "turn-on" frequency (0.17 Hz). It is anticipated
that the volumetric performance of the carbon materials can be
improved by reducing the particle size by grinding or other
processing.
[0316] The carbon sample was labeled 9AC16. The sample was dried at
60.degree. C. then mixed with a Teflon binder at 3.0% by weight.
This mixture was thoroughly blended and formed into
0.003''-thick-electrodes. The sample appeared to have a significant
fraction of larger particles which led to a porous and low density
electrode. In some instances, 0.002'' thick electrodes are used for
evaluation but the sample could not be formed into this thin a
sheet with the integrity required for subsequent handling, and
thus, the thicker electrodes were prepared. The sheet material was
punched using a steel die to make discs 0.625'' in diameter. Four
electrode discs of each material were weighed to an accuracy of 0.1
mg. The average mass and density of a pair of electrodes is shown
in Table 9.
TABLE-US-00010 TABLE 9 Electrode masses and volumes for test
capacitors fabricated using the Carbon Materials. Combined Average
mass thickness Volume of two of two of two Electrode electrodes
electrodes electrodes Density ID (mg) (inches) (cm.sup.3)
(g/cm.sup.3) 9AC16 8.7 0.006 0.003 0.29
[0317] The electrodes were dried under vacuum conditions
(mechanical roughing pump) at 195.degree. C. for 14 hours as the
last preparation step.
[0318] After cooling, the vacuum container containing the
electrodes (still under vacuum) was transferred into the drybox.
All subsequent assembly work was performed in the drybox. The
electrode discs were soaked in the organic electrolyte for 10
minutes then assembled into cells. The electrolyte was an equal
volume mixture of propylene carbonate (PC) and dimethylcarbonate
(DMC) that contained 1.0 M of tetraethylammoniumtetrafluoroborate
(TEATFB) salt.
[0319] Two layers of an open cell foam type separator material were
used to prepare the test cells. The double separator was
.about.0.004'' thick before it is compressed in the test cell.
Initially test cells were fabricated using the normal single layer
of separator but these cells had high leakage currents, presumably
because of particulates in the electrodes piercing the thin
separator. The conductive faceplates of the test cell were aluminum
metal with a special surface treatment to prevent oxidation (as
used in the lithium-ion battery industry). The thermoplastic edge
seal material was selected for electrolyte compatibility and low
moisture permeability and applied using an impulse heat sealer
located directly within the drybox.
[0320] Two substantially identical test cells were fabricated. The
assembled cells were removed from the drybox for testing. Metal
plates were clamped against each conductive face-plate and used as
current collectors. The cross section of the assembled device is
shown in FIG. 10. The electrodes were each 0.003'' thick, and the
separator 0.004'' thick (a double layer of 0.002'' thick material).
Electrodes had a diameter of 0.625''. Capacitor cells were
conditioned at 1.0 V for ten minutes, measured for properties, then
conditioned at 2.0 V for 10 minutes and measured for
properties.
[0321] The following test equipment was used for testing the
capacitor cells:
1. Frequency Response Analyzer (FRA), Solartron model 1250
Potentiostat/Galvanostat, PAR 273
2. Digital Multimeter, Keithley Model 197
[0322] 3. Capacitance test box S/N 005, 500 ohm setting
4. RCL Meter, Philips PM6303
5. Power Supply, Hewlett-Packard Model E3610A
6. Balance, Mettler H10
7. Micrometer, Brown/Sharp
[0323] 8. Leakage current apparatus 9. Battery/capacitor tester,
Arbin Model EVTS
[0324] All measurements were performed at room temperature. The
test capacitors were conditioned at 1.0 V then shorted and the
following measurements were made: 1 kHz equivalent series
resistance (ESR) using the RCL meter, charging capacitance at 1.0 V
with a 500 ohm series resistance using the capacitance test box,
leakage current at 0.5 and 1.0 V after 30 minutes using the leakage
current apparatus, and electrochemical impedance spectroscopy (EIS)
measurements using the electrochemical interface and FRA at 1.0 V
bias voltage. Then the test capacitors were conditioned at 2.0 V
then shorted and the following measurements were made: 1 kHz
equivalent series resistance (ESR) using the RCL meter, charging
capacitance at 2.0 V with a 500 ohm series resistance, leakage
current at 1.5 and 2.0 V after 30 minutes using the leakage current
apparatus, and EIS measurements at 2.0 V bias voltage. Finally
charge/discharge measurements were made using the Arbin. These
measurements included constant current charge/discharge cycles
between 0.1 and 2.0 V at currents of 1, 5, and 15 mA and constant
current charge/constant power discharges between 2.0 V and 0.5 V at
power levels from 0.01 W to 0.2 W.
[0325] Tables 10 and 11 list test data for the capacitors
fabricated with organic electrolyte. The two samples are almost
identical in their charge storage properties, though they vary
somewhat in density.
TABLE-US-00011 TABLE 10 Test results of two substantially identical
prototype capacitors constructed with the disclosed carbon
materials. Test capacitors #1 and #2 (data not shown) were
fabricated with one layer of separator and were unsuitable for
testing because of high leakage currents. 1 kHz 30 min leakage
current ESR @ 1.0 V (.mu.A) ID (.OMEGA.) C500 (F) 0.5 V 1.0 V 9AC16
#3 3.457 0.21 1.7 7.4 9AC16 #4 3.558 0.20 5.1 15.0 C500--500
.OMEGA. charging capacitance
TABLE-US-00012 TABLE 11 Test results after initial 1.0 V
measurements of prototype capacitors constructed with the disclosed
carbon material. Specific capacitance is on a dry-weight basis. 30
min 1 kHz leakage current ESR @ 2.0 V (.mu.A) F/g F/cc ID (.OMEGA.)
C500 (F) 1.5 V 2.0 V @ 2.0 V @ 2.0 V 9AC16 #3 3.296 0.23 11.8 53
106 30 9AC16 #4 3.522 0.22 23.7 70 102 29 C500--500 .OMEGA.
charging capacitance
[0326] FIG. 11 shows 30 minute leakage current values at four
different voltages for the two test capacitors. A log-linear
relationship between voltage and leakage current is typical for
electrochemical capacitors and occurs when leakage current is
dominated by charge transfer reactions associated with impurities.
The test capacitors exhibit close to a log-linear relationship
between leakage current and voltage. This relationship is typical
for electrochemical capacitors and occurs when leakage current is
charge transfer reactions associated with impurities. The leakage
current values are within the normal range typically measured for
carbon electrode samples
[0327] FIG. 12 shows constant current discharge behavior of the
capacitors containing the disclosed carbon materials when
discharged at three current values. The discharge rate at 5 mA
corresponds to a current density of .about.2.5 mA/cm.sup.2.
[0328] FIG. 13a shows impedance data in a complex-plane
representation for a test capacitor at voltages of 1.0 and 2.0 V.
The behavior is very similar at both bias voltages. There is
essentially no voltage dependence to the response, which is
expected. An ideal RC circuit would be represented by a straight
vertical line that intersects the real axis at the value of the
resistance. Shown is an intersection with the real axis at
.about.3.3.OMEGA.. The line rises for a short distance at an angle
of -45 degrees. This type behavior is seen in devices having porous
electrodes, and may be due to distributed charge storage. After
that the lines are not quite vertical, which is usually due to a
parallel charging path such as a leakage current. Nevertheless, the
non-ideal characteristics are very minor for this sample.
[0329] FIG. 13b shows the same impedance data in a Bode
representation, which is the magnitude of the impedance |Z| and the
phase angle versus frequency. Capacitive behavior is evident by the
-1 slope at lower frequencies and the phase angles approaching -90
degrees. Note the phase angle is close to zero at high frequencies
and approaches -90 degrees at low frequencies.
[0330] FIG. 13c shows the same data in yet another
representation--assuming the device can be represented by a
series-RC circuit. The capacitance is calculated as -1/(2.pi.fZ''),
where f is the frequency in Hz, Z'' is the reactance, and
.pi.=3.1415. As shown, the capacitance increases from a minimum at
.about.200 Hz in a monotonic fashion as the frequency is reduced,
reaching saturation of .about.0.24-0.25 F at frequencies below
.about.0.1 Hz. The series resistance has a minimum value at about 1
kHz and increases as the frequency is reduced. This type behavior
is characteristic of a porous electrode, where the resistance
increases at low frequencies as charge storage occurs in deeper
pores through longer paths of electrolyte.
[0331] The frequency at which a -45 degree phase angle is reached
at 2.0 V bias is f.sub.o.about.0.17 Hz. The reactance Z''
(imaginary part of the impedance) at this frequency is
.about.-4.7.OMEGA..quadrature. so the calculated capacitance at
this frequency, assuming a series-RC circuit, is C=-1/(2.pi.f.sub.o
Z'')=.about.0.2 F. Thus at 2.0 V the calculated figure of merit
(FOM) values described by Miller ("Pulse Power Performance of
Electrochemical Capacitors: Technical Status of Present Commercial
Devices," Proc. 8th International Seminar on Double Layer
Capacitors and Similar Energy Storage Devices, Deerfield Beach,
Fla. (Dec. 7-9, 1998)) are .about.7.8 W/g and .about.2.2 W/ml.
Table 12 lists FOMs for the tested sample material. The larger the
FOM values, the more suitable the material for pulse
applications.
TABLE-US-00013 TABLE 12 Calculated gravimetric and volumetric
Figure of Merit (FOM) of the disclosed carbon material in a test
sample with organic electrolyte at a voltage of 2.0 V. Mass and
volume include that of the two dry electrodes only. Packaged
devices are expected to have values reduced by two to four times,
depending on product size. f.sub.0 = -45 deg. Reactance C = 1/(2pi
Gravimetric Volumetric freq. @ -450.degree. ImZ Hz) E/M E/V FOM FOM
Sample (Hz) (.OMEGA.) (F) (J/g) (J/cc) ((W/g) (W/mL) 9AC16 #3 0.17
-4.70 0.203 46.6 13.4 7.8 2.2
[0332] With electrolyte included, mass FOM will drop to about 4 W/g
and the volume value will remain unchanged. Packaging mass and
volume impact to the FOMs will be greatest for small devices. For
instance, a further four-fold reduction in the FOMs is expected for
"button" size devices, while a two-fold reduction might result for
hybrid vehicle size capacitor modules. FOM values of some
commercial products are tabulated in Table 13. The disclosed carbon
material compares very favorably to the commercial devices on a
weight basis, primarily because of the relatively high "turn-on"
frequency (0.17 Hz). It is expected that the volumetric performance
can be improved by reducing particle size by grinding or other
processing.
TABLE-US-00014 TABLE 13 FIGURE of Merit (FOM) of commercial
electrochemical capacitor products at their rated voltages. (This
data was obtained from small- and large- size commercial
electrochemical capacitors in 1998, see Miller.) E/M E/v Mass FOM
Volume FOM EC PRODUCT (J/g) (J/cm.sup.3) (W/g) (W/cm.sup.3)
Powerstor 1.3 1.9 2.1 3.0 Maxwell PC0323 6.2 6.9 1.0 1.1 Maxwell
PC7223 9.7 12.8 0.5 0.64 Maxwell PC0223 4.5 9.9 0.5 1.1 cap-XX card
0.047 0.062 1.3 1.7 cap-XX 120 F 7.4 7.0 0.74 0.7 cap-XX 30 F 1.3
1.3 2.7 2.7 cap-XX 10 F 0.54 0.61 3.6 4.1 cap-XX 250 F 2.2 1.6 2.2
1.6 ELNA 4.4 5.0 0.36 0.4 Panasonic 6.7 7.2 0.34 0.37 ELIT 9.4 F
0.093 0.31 0.95 3.2 ESMA 2.2 4.3 0.22 0.43 Powercell 7.3 10 0.07
0.09 ELIT 20 kJ 1.2 2.7 0.2 0.46 ECOND 8/16/0.8 0.68 2.1 0.09 0.27
ECOND 8/16/10 0.51 1.7 0.43 1.4
[0333] Another way of showing the performance of a capacitor is by
showing the energy-power relationship in the Ragone representation
as shown in FIG. 14. The energy that can be delivered decreases as
the power increases. The energy and power values shown in the
figure were determined experimentally with constant power
discharges from 2.0 V to 0.5 V. Comparison to commercial devices is
difficult because of the unknowns associated with packaging mass
and volume and because commercial organic electrolyte capacitors
often use acetonitrile and operate at higher voltages.
Example 11
Comparison of Different Methods for Preparing the Carbon
Materials
[0334] A comparison of different methods for preparation of carbon
materials was performed by preparing polymer gels as described
above and either flash freezing in liquid nitrogen as described
above or freezing more slowly on a freezer shelf. The studies
indicate that flash freezing results in a carbon material having
higher mesoporosity and superior electrochemical properties. The
freeze drying, pyrolysis and activation conditions were as
follows:
[0335] The polymer gel was ground with a mechanical grater using a
2 mm grinder fitting. The polymer gel was then flash frozen with
liquid N.sub.2 and shelf frozen at -50.degree. C. After flash
freezing, the polymer gel was freeze dried according to the
following protocol: [0336] 1. Hold at -50.degree. C. and 50 mTorr;
[0337] 2. Ramp from -50.degree. C. to -30.degree. C. in 30 mins at
50 mTorr; [0338] 3. Ramp from -30.degree. C. to +25.degree. C. in
220 mins at 50 mTorr; and [0339] 4. Continual `hold` at +25.degree.
C. and 50 mTorr.
[0340] After freeze drying, the polymer gel was pyrolyzed in a tube
furnace by ramping the temperature up by 5.degree. C. per minute
under N.sub.2 gas to 900.degree. C., dwelling at 900.degree. C. for
60 minutes under N.sub.2 gas and then ramping down to ambient
temperature under N.sub.2 gas. The pyrolyzed material was then
activated in a tube furnace to a target weight loss. The activation
parameters can be adjusted to obtain the desired activation
result.
[0341] Table 14 summarizes dried gel and pyrolyzed carbon
characterization from these two methods.
TABLE-US-00015 TABLE 14 Dried Gel and Pyrolyzed Carbon
Characteristics Based on Preparation Method Total Weight Pore Tap
Process Loss SSA Volume Density Sample # Conditions (%) (m.sup.2/g)
(cc/g) (g/cc) RD-111-1-DG Freezing Method 73.4 753 1.40 0.22 Liq
N.sub.2 RD-111-2-DG Freezing Method 73.1 578 0.43 0.45 Shelf Freeze
RD-111-1-PC Pyrolysis 50.5 786 0.94 0.32 60 mins @ 900.degree. C.
RD-111-2-PC Pyrolysis 49.7 664 0.33 0.56 60 mins @ 900.degree. C.
Dried Gel Freezing Method 66.2 609 0.58 0.43 Control Liq N.sub.2
(control chart values)
[0342] FIG. 15 shows that flash frozen polymer gels comprise higher
mesoporosity than gels frozen more slowly. The pore size
distribution (PSD) trend in the dried gel directly translated to
PSD in the activated carbon as depicted in Table 14 and FIG. 16.
For example, the flash frozen dried gel also produced activated
carbon with high total pore volume (+2.0 cc/g) and lower tap
density than the shelf frozen dried gel.
[0343] Liquid nitrogen and shelf frozen dried gels had very similar
activation weight loss per time at temperature, but produced very
different surface area activated carbons. From Table 2, for the
same lower and higher activation parameters, similar weight losses
were achieved but different SSA was measured. For example,
RD-111-1-AC4 and RD-111-2-AC2 were activated for 74 mins at
950.degree. C. and achieved 55.5% and 52.2% weight loss
respectively. The same was found at the lower activation settings
of 55 mins at 950.degree. C. (39.8% and 38.5%). However, for the
given weight losses, different specific surface areas were
attained, FIG. 17.
[0344] The carbon materials prepared by slow freezing had lower
power performance. While not wishing to be bound by theory,
Applicants believe this low power performance can be attributed to
the lack of mesopores in these carbon materials. It is also
believed that this lack of mesoporosity contributes to the higher
tap densities and lower total poor volume of these carbon materials
as shown in Table 15
TABLE-US-00016 TABLE 15 Properties of Activated Carbons Total
Activation Pore Tap Freezing Activation Wt loss Volume Density
Sample # Method Conditions (%) SSA (m.sup.2/g) (cc/g) (g/cc)
RD-111-1-AC1 Liq. N.sub.2 10 mins @ 1 -- -- -- 800.degree. C.
RD-111-1-AC2 Liq. N.sub.2 18 mins @ 1.2 -- -- -- 800.degree. C.
RD-111-1-AC3 Liq. N.sub.2 55 mins @ 39.8 2114 2.06 0.24 950.degree.
C. RD-111-1-AC4 Liq. N.sub.2 74 mins @ 55.5 2684 2.50 0.17
950.degree. C. RD-111-2-AC1 Shelf 55 mins @ 38.5 1310 0.63 0.41
Freeze 950.degree. C. RD-111-2-AC2 Shelf 74 mins @ 52.2 1583 0.77
0.36 Freeze 950.degree. C.
Example 12
Alternative Preparation of a Carbon Material
[0345] A carbon material ("Carbon 9") useful in lead acid battery
applications (among others) was prepared according to the following
description. A polymer gel was prepared by polymerization of
resorcinol and formaldehyde (0.5:1) in a water/acetic acid solvent
(80:20) in the presence of ammonium acetate catalyst. The resultant
polymer to solvent ratio was 0.3, and the resorcinol to catalyst
ratio (R/C) was 25. The reaction mixture was placed at elevated
temperature (incubation at 45.degree. C. for about 6 h followed by
incubation at 85.degree. C. for about 24 h) to allow for gellation
to create a polymer gel. Polymer gel particles were created from
the polymer gel with a rock crusher through a screen with 3/4 inch
sized holes. The particles were flash frozen by immersion in liquid
nitrogen, loaded into a lyophilization tray at a loading of 3 to 7
g/in.sup.2, and lyophilized at approximately 50 to 150 mTorr. The
time to dry (as inferred from time for product to reach within
2.degree. C. of shelf temperature) varied with product loading on
the lyophilizer shelf.
[0346] The mass loss on drying the polymer gel was approximately
72%. The surface area of the dried polymer gel was determined to be
691 m.sup.2/g, the total pore volume was 1.05 cc/g and the tap
density was 0.32 g/cc. Dried polymer gel materials comprising
different properties (e.g., surface area, pore structure, etc.) can
be prepared by altering the drying conditions (e.g., pressure,
temperature, time, etc.) described above.
[0347] Dried polymer gel prepared according was pyrolyzed by
passage into a rotary kiln at 900.degree. C. with a nitrogen gas
flow of 200 L/h. The surface area of the pyrolyzed dried polymer
gel was examined by nitrogen surface analysis using a surface area
and porosity analyzer. The measured specific surface area using the
standard BET approach was 737 m.sup.2/g, the total pore volume was
0.64 cc/g. Carbon materials comprising different properties (e.g.,
surface area, pore structure, etc.) can be prepared by altering the
pyrolysis conditions (e.g., temperature, time, etc.) described
above.
[0348] FIG. 18 shows an overlay of the pore size distributions of
various carbon materials. Note that the pore size distribution for
the activated carbon was measured on a micromeritics ASAP2020, a
micropore-capable analyzer with a higher resolution (lower pore
size volume detection) than the Tristar 3020 that was used to
measure the pore size distribution for the dried polymer gel.
[0349] From the DFT cumulative volume plot for the activated carbon
material, it was determined that about 40% of the pore volume
resides in micropores and about 60% of the pore volume resides in
mesopores. Carbon materials comprising different properties (e.g.,
surface area, pore structure, etc.) can be prepared by altering the
activation conditions (e.g., temperature, time, etc.) described
above.
[0350] Pyrolyzed carbon prepared was jet milled using a
manufacturing scale 15 inch diameter jet mill. The average particle
size after jet milling was about 4 to 7 microns. Properties of
Carbon 1 are summarized in Table 16. Table 17 summarizes the range
of properties of various carbon embodiments prepared according the
above procedures.
TABLE-US-00017 TABLE 16 Physiochemical Properties of Carbon 1 Test
Parameter Result Tap Density Tap Density (g/cc) 0.43 N2 Sorption
Isotherm Specific Surface Area (m.sup.2/g) 737 Total pore volume
(cc/g) 0.64 DFT Pore volume >20 .ANG. (cc/g) 0.38 N.sub.2
(p/p0).sub.95/(p/po).sub.5: 2.0-2.7 2.2 (i.e., "P95/P5") Thermal
Gravimetric % weight loss observed between 1.0 Analysis (TGA) 250
to 850 C. Ash Content Calculated from PIXE elemental 0.0008 data
(%) PIXE Purity Sulfur (ppm): ND Silicon (ppm): ND Calcium (ppm):
ND Iron (ppm): 6.2 Nickel ppm): 1.1 Zinc (ppm): ND Copper (ppm): ND
Chromium (ppm): ND All other elements: ND ND = not detected
Example 13
Alternative Preparation of a Carbon Material
[0351] A carbon material ("Carbon 12") having increased energy
density with balanced power performance was prepared according to
the following description. A polymer gel was prepared by
polymerization of resorcinol and formaldehyde (0.5:1) in a
water/acetic acid solvent (80:20) in the presence of ammonium
acetate catalyst. The resultant polymer to solvent ratio was 0.3,
and the resorcinol to catalyst ratio (R/C) was 25. The reaction
mixture was placed at elevated temperature (incubation at
45.degree. C. for about 6 h followed by incubation at 85.degree. C.
for about 24 h) to allow for gellation to create a polymer gel.
Polymer gel particles were created from the polymer gel with a rock
crusher through a screen with 3/4 inch sized holes. The particles
were loaded into a lyophilization tray at a loading of 3 to 7
g/in.sup.2, frozen on the shelf of a freeze-dryer until particles
were frozen below -30.degree. C. The frozen particles were
lyophilized at approximately 50 mTorr. The time to dry (as inferred
from time for product to reach within 2.degree. C. of shelf
temperature) varied with product loading on the lyophilizer shelf.
At manufacturing scale, polymer gel particles were loaded on
lyophilization trays in a -30.degree. C. cold room and frozen over
the course of 24 hours. These frozen particles were lyophilized at
approximately 120 mTorr. The time to dry (as inferred from time for
product to reach within 2.degree. C. of shelf temperature) varied
with product loading on the lyophilizer shelf.
[0352] The mass loss on drying the polymer gel was 74.1%. The
surface area of the dried polymer gel was determined to be 515
m.sup.2/g, the total pore volume was 0.39 cc/g and the tap density
was 0.22 g/cc. The pore size distribution of two different batches
of dried polymer gel is shown in FIG. 19 that exhibit a range of
physical properties from altering the lyophilization
parameters.
[0353] Dried polymer gel prepared according to the above procedure
was pyrolyzed by passage into a furnace at 625.degree. C. with a
nitrogen gas flow of 400 L/h. At manufacturing scale, dried polymer
gel prepared according to the above procedure was pyrolyzed by
passage into a rotating kiln furnace set with three hot zones of
685.degree. C., 750.degree. C., and 850.degree. C.
[0354] The surface area of the pyrolyzed dried polymer gel
pyrolyzed by passage into a furnace at 625.degree. C. was examined
by nitrogen surface analysis using a surface area and porosity
analyzer. The measured specific surface area using the standard BET
approach was 622 m.sup.2/g, the total pore volume was 0.33 cc/g.
The surface area of the pyrolyzed dried polymer gel pyrolyzed by
passage into a rotary kiln furnace set with three hot zones of
685.degree. C., 750.degree. C., and 850.degree. C. was examined by
nitrogen surface analysis using a surface area and porosity
analyzer. The measured specific surface area using the standard BET
approach was 588 m.sup.2/g, the total pore volume was 0.25 cc/g.
Carbon materials comprising different properties (e.g., surface
area, pore structure, etc.) can be prepared by altering the
pyrolysis conditions (e.g., temperature, time, etc.) described
above.
[0355] Pyrolyzed carbon material prepared according to above was
activated in a batch rotary kiln at 900.degree. C. under CO.sub.2
for approximately 840 min, resulting in a total weight loss of 50%.
In another case, Pyrolyzed carbon material prepared according to
above was activated in a fluidized bed reactor at 925.degree. C.
under CO.sub.2.
[0356] The surface area of the activated carbon produced by a batch
rotary kiln as described above was examined by nitrogen surface
analysis using a surface area and porosity analyzer. The measured
specific surface area using the BET approach was 1857 m.sup.2/g,
the total pore volume was 0.87 cc/g and the tap density was 0.41
g/cc. In the second case using a fluidized bed reactor, the
resultant material was also measured by nitrogen adsorption
analysis and the measured specific surface area using the BET
approach was 2046 m.sup.2/g, and the total pore volume was 1.03
cc/g.
[0357] FIG. 20 shows an example of the pore size distributions of
the activated carbon material from both the activation conditions
described above. Note that the pore size distribution for the
activated carbon was measured on a micromeritics ASAP2020, a
micropore-capable analyzer with a higher resolution (lower pore
size volume detection) than the Tristar 3020 that was used to
measure the pore size distribution for the dried polymer gel.
[0358] From the DFT cumulative volume plot for the activated carbon
material, it was determined that the 80% of the pore volume resides
in micropores and 20% of the pore volume resides in mesopores. In
the second case of activated carbon materials depicted in FIG. 20,
it was determined that 70% of the pore volume resides in the
micropores and 30% of the pore volume resides in the mesopores.
Carbon materials comprising different properties (e.g., surface
area, pore structure, etc.) can be prepared by altering the
activation conditions (e.g., temperature, time, etc.) described
above.
[0359] Activated carbon prepared was jet milled using a Jet
Pulverizer Micron Master 2 inch diameter jet mill and at the
manufacturing scale, a 15 inch diameter jet mill was used. The
average particle size after jet milling was about 4 to 7
microns.
[0360] Chemical species on the surface of the activated carbon was
removed with a heat treatment process by heating the carbon in an
elevator furnace under nitrogen gas for 1 hour at 900.degree. C.
The pH was measured on the treated carbon and was 7.9 indicating a
lack of oxygen containing surface functional groups. Properties of
various carbons prepared by the above method are summarized in
Table 18.
Example 14
Alternative Preparation of a Carbon Material
[0361] A carbon material ("Carbon 13") having increased energy
density with balanced power performance was prepared according to
the following description. A polymer gel was prepared by
polymerization of resorcinol and formaldehyde (0.5:1) in a
water/acetic acid solvent (80:20) in the presence of ammonium
acetate catalyst. The resultant polymer to solvent ratio was 0.3,
and the resorcinol to catalyst ratio (R/C) was 25. The reaction
mixture was placed at elevated temperature (incubation at
45.degree. C. for about 6 h followed by incubation at 85.degree. C.
for about 24 h) to allow for gellation to create a polymer gel.
Polymer gel particles were created from the polymer gel with a rock
crusher through a screen with 3/4 inch sized holes.
[0362] Polymer gel particles were prepared was pyrolyzed by passage
into a furnace at 625.degree. C. with a nitrogen gas flow of 400
L/h.
[0363] The surface area of the pyrolyzed dried polymer gel was
examined by nitrogen surface analysis using a surface area and
porosity analyzer. The measured specific surface area using the
standard BET approach was 585 m.sup.2/g, the total pore volume was
0.28 cc/g. Carbon materials comprising different properties (e.g.,
surface area, pore structure, etc.) can be prepared by altering the
pyrolysis conditions (e.g., temperature, time, etc.) described
above.
[0364] Pyrolyzed carbon material prepared according to above was
activated in a 4'' Fluidized Bed Reactor at 900.degree. C. under a
CO.sub.2 for approximately 15 hours.
[0365] The surface area of the activated carbon was examined by
nitrogen surface analysis using a surface area and porosity
analyzer. The measured specific surface area using the BET approach
was 2529 m.sup.2/g, the total pore volume was 1.15 cc/g and the tap
density was 0.36 g/cc.
[0366] From the DFT cumulative volume plot for the activated carbon
material, it was determined that the 68% of the pore volume resides
in micropores and 32% of the pore volume resides in mesopores.
Carbon materials comprising different properties (e.g., surface
area, pore structure, etc.) can be prepared by altering the
activation conditions (e.g., temperature, time, etc.) described
above.
[0367] Activated carbon prepared was jet milled using a Jet
Pulverizer Micron Master 2 inch diameter jet mill. The average
particle size after jet milling was about 4 to 7 microns.
Example 15
Properties of Various Carbon Materials
[0368] Carbon materials having various properties can be prepared
according to the general procedures described above. Table 17
summarizes the properties of carbon materials prepared according to
the noted examples.
TABLE-US-00018 TABLE 17 Physiochemical Characteristics of Carbons
Prepared According to Examples 2-14 Ratio N.sub.2 PV meso/ Total
Pore Tap adsorbed PV SSA Volume Density (P/Po)95/(P/ total Example
(m.sup.2/g) (cc/g) (g/cc) Po)5 (%) Purity Ex. 12 600-800 0.5-0.9
0.35-0.45 2.0-3.0 40-60% <200 ppm impurities Ash: 0.001-0.03%
Ex. 1-3 1550-2100 1.2-1.6 0.25-0.35 1.8-2.5 52-60% <200 ppm
impurities Ash: 0.001-0.03% Ex. 1-3 2100-2800 1.5-2.7 0.19-0.28
2.0-2.5 52-60% <200 ppm impurities Ash: 0.001-0.03% Ex. 13
1800-2200 0.8-1.2 0.30-0.45 1.2-1.6 20-50% <200 ppm impurities
Ash: 0.001-0.03% Ex. 14 1800-2600 0.7-1.3 0.25-0.45 1.2-1.8 20-50%
<200 ppm impurities Ash: 0.001-0.03%
[0369] The various embodiments described above can be combined to
provide further embodiments. All of the U.S. patents, U.S. patent
application publications, U.S. patent applications, foreign
patents, foreign patent applications and non-patent publications
referred to in this specification and/or listed in the Application
Data Sheet, are incorporated herein by reference, in their
entirety. Aspects of the embodiments can be modified, if necessary
to employ concepts of the various patents, applications and
publications to provide yet further embodiments. These and other
changes can be made to the embodiments in light of the
above-detailed description. In general, in the following claims,
the terms used should not be construed to limit the claims to the
specific embodiments disclosed in the specification and the claims,
but should be construed to include all possible embodiments along
with the full scope of equivalents to which such claims are
entitled. Accordingly, the claims are not limited by the
disclosure.
* * * * *