Porous Carbon Material with Continuous Structure

Solution Overview

Problem

Existing porous carbon materials lack sufficient electrical conductivity, thermal conductivity, and mechanical strength, limiting their applications in electric and electronic materials, heat exchange, and other functional uses.

Innovation Solution

A porous carbon material with a continuous porous structure composed of interconnected carbon branches and pores, combined with carbon crystal grains, enhancing electrical and thermal conductivity and mechanical properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of stationary object

If porous carbon materials are produced using conventional methods (particulate activated carbons, activated-carbon fibers, carbon nanotubes, or meso-porous carbons from templates), then porosity is achieved, but electrical conductivity, thermal conductivity, and mechanical strength are insufficient

Engineering Contradiction:

ImproveporosityVSAvoidmechanical strength

Core Design Contradiction:

Weight of stationary objectVSStrength

Solution Approach 1:

The patent employs a porous spherical carbon material with controlled porosity (30-70%) as the core structure. This porous structure is achieved through template methods or foaming techniques, creating voids within the spherical carbon matrix that provide necessary porosity while maintaining structural integrity through the continuous carbon phase.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent creates a composite structure by combining porous spherical carbon material with carbon fibers. The carbon fibers are oriented in the flow direction and embedded within the porous spherical carbon matrix, forming a hybrid composite that leverages the porosity of spherical carbons and the mechanical strength and conductivity of carbon fibers.

Inventive Principle:

Principle #40Composite materials

2Weight of stationary object

If porous carbon materials are produced using conventional methods, then porosity is achieved, but electrical conductivity and thermal conductivity are insufficient

Engineering Contradiction:

ImproveporosityVSAvoidelectrical conductivity

Core Design Contradiction:

Weight of stationary objectVSUse of energy by moving object

Solution Approach 1:

The patent creates a composite structure by combining porous spherical carbon material with carbon fibers. The carbon fibers are oriented in the flow direction and embedded within the porous spherical carbon matrix, forming a hybrid composite that leverages the porosity of spherical carbons and the mechanical strength and conductivity of carbon fibers.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent ensures continuous conductive pathways by orienting carbon fibers in the flow direction and embedding them within the porous spherical carbon matrix. This continuous arrangement of conductive carbon fibers throughout the porous structure enables efficient electrical and thermal conductivity while maintaining porosity for fluid flow.

Inventive Principle:

Principle #20Continuity of useful action

3Weight of stationary object

If porous carbon materials are produced using conventional methods, then porosity is achieved, but resistance to deformation under pressure is insufficient

Engineering Contradiction:

ImproveporosityVSAvoidpressure resistance

Core Design Contradiction:

Weight of stationary objectVSStress or pressure

Solution Approach 1:

The patent creates a composite structure by combining porous spherical carbon material with carbon fibers. The carbon fibers are oriented in the flow direction and embedded within the porous spherical carbon matrix, forming a hybrid composite that leverages the porosity of spherical carbons and the mechanical strength and conductivity of carbon fibers.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies different structural characteristics to different regions and functions: the porous spherical carbon material provides overall porosity and flow channels, while the embedded carbon fibers provide localized reinforcement for pressure resistance and conductivity in the flow direction. This spatial differentiation of structural qualities optimizes both porosity and mechanical performance.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS10087076B2Porous carbon material

Publication Date: 2018.10.02 TORAY INDUSTRIES INC

AI summary

Provided is a porous carbon material which has excellent electrical conductivity, thermal conductivity, pressure resistance, and strength against tension and compression. This porous carbon material at least partially includes a continuous porous structure, and exhibits excellent electrical conductivity, thermal conductivity, pressure resistance, and strength against tension and compression by containing carbon crystal grains therein.