Porous Carbon Support Structure for Silicon Anode Cycle Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for producing carbon materials struggle with controlling molecular weight and composition, particularly in manufacturing porous carbon supports for negative electrode materials, which affect charge/discharge capacity, cycle characteristics, and mechanical properties.
Innovation Solution
A method involving pyrolysis and condensation polymerization of petroleum-based raw materials to synthesize pitch, followed by solidification and stabilization, carbonization, and activation, with specific conditions to control pore characteristics and deposit silicon, resulting in a porous carbon support with controlled mesopores and micropores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pitch is synthesized from solid raw materials such as palm kernel shells, then carbon materials can be produced, but molecular weight and composition are difficult to control
Solution Approach 1:
The patent changes the raw material parameter from solid biomass (palm kernel shells) to liquid petroleum-based feedstocks (pyrolysis fuel oil, naphtha cracking bottom oil, vacuum residue). This parameter change enables precise control over molecular weight and composition through established refining processes while maintaining carbon material production capability. The liquid feedstocks have well-defined molecular structures that can be controlled through pyrolysis temperature and residence time parameters.
2Productivity
If pitch is used as raw material, then high yield and low cost are achieved, but pore characteristics are difficult to control for deep pore deposition
Solution Approach 1:
The patent controls pore characteristics by adjusting pyrolysis parameters (temperature, heating rate, residence time) and pitch composition parameters (aromatic content, molecular weight distribution). By optimizing these parameters, the patent achieves both high yield from pitch and controlled pore size distribution that enables deep pore deposition during chemical vapor deposition, resolving the contradiction between productivity and manufacturing precision.
3Device complexity
If conventional pitch production methods are used, then simple processing is achieved, but charge/discharge capacity and cycle characteristics are insufficient
Solution Approach 1:
The patent improves charge/discharge capacity and cycle characteristics by optimizing pitch synthesis parameters (temperature, pressure, catalyst selection) and carbonization parameters (heating rate, final temperature, atmosphere control). These parameter optimizations enhance the electrochemical performance of the resulting carbon materials while maintaining relatively simple processing steps, balancing device complexity and reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method produces a porous carbon support that enables high charge/discharge capacity, improved cycle characteristics, and excellent mechanical properties, facilitating effective silicon deposition and enhancing the performance of negative electrode materials.
Implementation Method 1
synthesizing pitch by pyrolysis and condensation polymerization of a petroleum-based raw material
Implementation Method 2
synthesizing pitch by pyrolysis and condensation polymerization of a petroleum-based raw material
Implementation Method 3
mesopores are formed in the outer portion and micropores are formed in the inner portion such that silicon can be sufficiently deposited into the inner pores
Data Source
Figure 1~3
Figure 4
AI summary
The present invention relates to a method for producing a porous carbon support, comprising the steps of (1) synthesizing pitch by pyrolysis and condensation polymerization of a petroleum-based raw material, (2) solidifying the pitch to obtain a solid-phase pitch, and (3) producing a carbon support from the solid-phase pitch, wherein the pitch in step (1) satisfies the following relational formula 1. [Relational formula 1] S/SP × 100 + MP ≤ 0.5 In relational formula 1, S is the mass ratio of saturated hydrocarbons derived from a saturates-aromatics-resins-asphaltenes (SARA) analysis of the synthesized pitch, SP is a softening point of the pitch, and MP is the volume ratio of anisotropic (mesophase) content in the synthesized pitch.