Porous Carbon Material Phase Separation Pore Structure
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Solution Overview
Problem
Existing porous carbon materials struggle to create a structure with both continuous and non-continuous pores, which limits their application in composite materials and hinders the efficient filling and use of fluids due to unidirectional pore formation during activation processes.
Innovation Solution
A process involving a carbonizable resin and an eliminable resin, mixed in specific proportions, undergoes phase separation and fixation without chemical reactions, resulting in a porous carbon material with a continuous porous structure and a portion without continuous pores, enhancing electrical and thermal conductivity, and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If activation process is used to form pores from surface toward inner part, then porous carbon material can be produced at low cost, but continuous communicating pores cannot be formed
Solution Approach 1:
The patent applies preliminary action by forming the continuous porous structure through phase separation of carbonizable resin and eliminable resin before carbonization. The eliminable resin creates a pre-formed continuous pore network that persists through carbonization, unlike conventional activation that forms pores unidirectionally from the surface. This preliminary pore formation enables communicating pores to exist before any activation treatment.
Solution Approach 2:
The patent utilizes phase transitions by employing phase separation between carbonizable resin and eliminable resin to create distinct continuous and discontinuous phases. The eliminable resin phase forms continuous pores after removal, while the carbonizable resin forms the solid matrix. This phase separation mechanism fundamentally differs from conventional activation and enables continuous pore connectivity.
2Productivity
If continuous porous structure is formed throughout the material, then fluid filling efficiency is improved, but electrical conductivity and mechanical strength decrease
Solution Approach 1:
The patent applies local quality by creating spatially differentiated pore structures: continuous pores are localized in specific regions to enable fluid filling, while discontinuous pores are localized in other regions to maintain mechanical strength and electrical conductivity. The phase separation process naturally creates this non-uniform distribution, with the eliminable resin forming continuous phases in certain areas and discontinuous phases in others.
Solution Approach 2:
The patent segments the pore structure into continuous and discontinuous portions through phase separation. The eliminable resin forms a segmented continuous phase that provides fluid pathways, while the carbonizable resin forms a segmented matrix that maintains structural integrity. This segmentation allows different regions to fulfill different functions simultaneously.
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 material allows for efficient fluid filling and passage through continuous pores, while the non-continuous structure enhances electrical and thermal conductivity, and mechanical strength, particularly in resisting compressive rupture and maintaining structural integrity.
Implementation Method 1
a process involving a carbonizable resin and an eliminable resin, mixed in specific proportions, undergoes phase separation and fixation without chemical reactions
Implementation Method 2
enhancing electrical and thermal conductivity
Implementation Method 3
enhancing electrical and thermal conductivity
Data Source
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AI summary
The present invention provides: a porous carbon material which includes a portion having a continuous porous structure and a portion having no continuous porous structure and has even pore size and matrix size in the material center part thereof, thereby being easy to composite with other materials and being able to be used in various applications; a porous-carbon-material precursor; a process for producing the porous-carbon-material precursor; and a process for producing the porous carbon material. A porous carbon material of the invention is a porous carbon material which includes a portion having a continuous porous structure and a portion having substantially no continuous porous structure, in which the portion having the continuous porous structure has a structural period of 0.002 to 1 µm.