Hard Carbon Electrode Material via Controlled Carbonization and Steam Activation

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Solution Overview

Problem

Current methods for producing active carbon lack control over crystallization during the carbonization process, affecting the activation process and resulting in suboptimal pore and electrochemical characteristics, particularly when using polyurethane as a precursor.

Innovation Solution

A method involving the carbonization of polyurethane in a high-temperature furnace under nitrogen, followed by steam activation to control crystallinity and remove oxygen functional groups, thereby enhancing the specific surface area and electrochemical properties of the active carbon.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If polyurethane is carbonized without oxidation/stabilization treatment, then the process is simpler, but the carbonization yield is lower and crystal grain distribution is wider

Engineering Contradiction:

Improvecarbonization yieldVSAvoidprocess complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent applies preliminary oxidation/stabilization treatment to the polyurethane precursor before carbonization. This preliminary action modifies the precursor structure to improve carbonization yield and narrow crystal grain distribution, resolving the contradiction between yield and process simplicity by adding a controlled preparatory step that enhances overall process efficiency.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If carbonization temperature is not controlled, then the process is easier, but the crystallinity of hard carbon is uncontrolled affecting activation

Engineering Contradiction:

Improvecrystallinity controlVSAvoidtemperature control complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent implements precise control of carbonization temperature as a key parameter to regulate the crystallinity of hard carbon. By systematically adjusting temperature parameters during carbonization, the method achieves controlled crystallinity that directly influences activation performance, resolving the contradiction between manufacturing precision and process complexity through parameter optimization.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If oxygen functional groups are not removed after activation, then the process is shorter, but electrochemical characteristics show resistance to organic electrolyte

Engineering Contradiction:

Improveelectrochemical performanceVSAvoidprocess steps

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies a post-activation treatment step to remove oxygen functional groups from the activated carbon. This preliminary action (performed after activation) eliminates electrochemical resistance to organic electrolytes, resolving the contradiction between electrochemical performance and process length by adding a targeted removal step that enhances device reliability.

Inventive Principle:

Principle #10Preliminary action

4Ease of manufacture

If conventional activation methods are used, then the process is standard, but chemical activators are required which are costly and environmentally harmful

Engineering Contradiction:

Improvecost and environmental impactVSAvoidpore characteristics

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent employs steam activation in an inert or controlled atmosphere environment, replacing conventional chemical activators. This approach eliminates the need for costly and environmentally harmful chemical substances while maintaining precise control over pore characteristics, resolving the contradiction between ease of manufacture (cost/environment) and manufacturing precision (pore quality).

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

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

This method achieves higher yields and improved pore and electrochemical characteristics without the need for chemical activators, making it environmentally friendly and cost-effective for producing high-specific-surface-area hard carbon-based electrode materials.

Implementation Method 1

heating the polyurethane under a nitrogen atmosphere by supplying nitrogen gas into the high temperature furnace to carbonize the polyurethane

Methodology Applied

Scientific EffectCarbonization: Pyrolysis

Implementation Method 2

supplying steam to activate the hard carbon under a steam atmosphere, thereby producing an active carbon

Methodology Applied

Scientific EffectSteam activation: Oxidation

Data Source

PatentUS10547050B2High specific surface area hard carbon-based electrode active material through carbonization process control and electrode active material by thereof

Publication Date: 2020.01.28 JEONJU MACHINERY RES CENT

AI summary

A method of preparing a hard carbon-based electrode active material having high specific surface area by carbonization process control, comprises charging polyurethane into a high temperature furnace, supplying oxygen gas to the high temperature furnace and oxidizing the polyurethane under an oxygen atmosphere, supplying a nitrogen gas to the high temperature furnace and heating to carbonize a stabilized polyurethane under a nitrogen atmosphere, thereby producing a hard carbon, heating the hard carbon under a nitrogen atmosphere and supplying steam to activate the hard carbon under a steam atmosphere, thereby producing an active carbon, supplying hydrogen and reducing the active carbon under a hydrogen atmosphere, and cooling the active carbon under a nitrogen atmosphere.