Solvent-Free Sol-Gel Carbon Structure for Tunable Pore Yield
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Solution Overview
Problem
Existing methods for producing activated carbon materials for electrical energy storage and distribution devices suffer from low carbon yield, high processing costs, and non-optimized pore structures, which affect performance at high temperatures and voltages, and are limited by the use of solvents that do not integrate into the carbon network.
Innovation Solution
A solvent-free method for preparing polymers and carbon materials through blending solid polymer precursors, followed by pyrolysis and activation, allowing for tunable pore structures and improved carbon yield, without the need for energy-intensive solvent removal processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional sol-gel polymerization is conducted in the presence of solvents, then polymer gel can be formed with pore structure, but carbon yield is reduced and processing costs increase due to energy-intensive solvent removal
Solution Approach 1:
The invention extracts and eliminates the solvent component from the traditional sol-gel polymerization process. By conducting polymerization in the absence of solvent using only solid polymer precursors and crosslinking agents, the method removes the need for subsequent solvent removal steps, thereby increasing carbon yield and reducing energy consumption while maintaining the desired pore structure through void spaces between solid particles
Solution Approach 2:
The invention changes the physical state parameters of the reaction system from liquid (solvent-based) to solid (solvent-free). By using solid polymer precursors and crosslinking agents and conducting polymerization in the solid state, the process eliminates solvent removal requirements and directly produces carbon materials with optimized pore structures
2Manufacturing precision
If pyrolysis of existing carbon-containing materials is used to produce activated carbon, then carbon material can be obtained, but pore structure is non-optimized and ash content is high (1% or higher)
Solution Approach 1:
The invention performs preliminary action by synthesizing the polymer gel structure in advance using solid precursors before pyrolysis. The pore structure is established during the solid-state polymerization phase through controlled crosslinking and void formation between particles, so that when pyrolysis occurs, the optimized pore structure is preserved and ash content is minimized since no chemical activation agents are introduced
3Area of stationary object
If chemical activation is used to produce activated carbon, then surface area and porosity can be enhanced, but the material becomes unsuitable for high performance electrical devices due to impurity introduction
Solution Approach 1:
The invention converts the traditionally harmful effect of using chemical activation agents (which introduce impurities) into a benefit by completely eliminating the need for chemical activation. The method achieves enhanced surface area and porosity through physical void spaces created during solid-state polymerization, preserving material purity and electrical device performance while still obtaining the desired activated carbon properties
4Manufacturing precision
If solvent-based sol-gel polymerization is used to create tunable pore structure, then pore structure can be controlled, but carbon yield per mass of precursor is reduced
Solution Approach 1:
The invention changes the physical state parameters from liquid solvent-based system to solid-state system. By using solid polymer precursors and crosslinking agents, the method eliminates solvent mass from the final product, thereby increasing carbon yield per mass of precursor while maintaining pore structure control through void spaces between solid particles and controlled crosslinking density
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 carbon materials with optimized micropore and mesopore distributions, enhancing ion mobility and power density, and reducing production costs, suitable for high-performance electrical energy storage devices.
Implementation Method 1
a) blending a mixture of solid and/or liquid polymer precursors; and b) aging the mixture at a temperature and for a time sufficient for the one or more polymer precursors to react with each other and form a polymer gel
Implementation Method 2
heating polymer gel particles that were formed in absence of solvent to obtain a carbon material
Implementation Method 3
The resulting polymer can then optionally be converted to carbon materials by any number of post-processing procedures, including pyrolysis and/or activation
Data Source
AI summary
The present application is directed to methods for solvent-free preparation of polymers and their subsequent processing into activated carbon materials. These methods unexpectedly demonstrate ability to tune pore structure in the polymer gel and carbon produced there from, while also providing distinct advantages over the current art.