Solvent-Free Sol-Gel Carbon Structure Tuning for Higher Yield
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for producing carbon materials for electrical energy storage and distribution devices face limitations due to low carbon yield, high processing costs, and non-optimized pore structures, which affect performance at high temperatures and during repeated charge/discharge cycles.
Innovation Solution
A solvent-free method for preparing polymers and converting them into carbon materials with tunable pore structures, involving physical blending of polymer precursors, crosslinking agents, and subsequent pyrolysis and activation processes to enhance carbon yield and reduce processing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional solvent-based sol-gel polymerization is used, then polymer gel can be formed, but carbon yield is low and processing costs are high due to solvent removal requirements
Solution Approach 1:
The invention extracts and eliminates the solvent component from the traditional sol-gel polymerization process. By using solvent-free conditions with solid polymer precursors and crosslinking agents, the method removes the need for solvent addition and subsequent solvent removal steps, directly improving carbon yield and reducing processing costs associated with solvent handling and energy-intensive drying operations.
Solution Approach 2:
The invention changes the physical state parameters of the reactants from liquid/solution phase to solid phase. By using solid polymer precursors and crosslinking agents instead of dissolved species, the process fundamentally alters the reaction medium parameters, enabling solvent-free polymerization and eliminating the need for solvent removal while maintaining gel formation capability.
2Manufacturing precision
If activated carbon is produced by pyrolyzing existing carbon-containing materials, then carbon material is obtained, but pore structure is non-optimized and ash content is high
Solution Approach 1:
The invention performs preliminary action by forming a controlled polymer gel network structure before pyrolysis. The gel structure, created through solvent-free polymerization of specific precursors, establishes a predetermined pore architecture that is then preserved during carbonization. This pre-formed structure ensures optimized pore distribution in the final activated carbon, avoiding the non-optimized structures that result from direct pyrolysis of conventional carbon materials.
Solution Approach 2:
The invention uses composite polymer precursor systems consisting of multiple components (polymer precursors and crosslinking agents) that work together to form a structured gel network. This composite approach allows for controlled pore formation and structural development during polymerization, which translates to optimized pore structures in the final carbon material while minimizing ash content through careful precursor selection.
3Reliability
If high surface area carbon is used, then ion mobility increases, but device complexity increases for achieving optimized pore size distribution
Solution Approach 1:
The invention applies local quality by creating specific pore size distributions at different locations within the carbon structure. Through controlled polymerization of specific precursor combinations, the method generates a hierarchical pore structure with micropores, mesopores, and macropores in predetermined proportions and distributions, optimizing ion mobility at different scales without requiring complex post-processing or device design modifications.
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 achieves higher carbon yield, reduced processing costs, and optimized pore structures, leading to improved performance in electrical energy storage devices with enhanced ion mobility, power density, and cycle life efficiency.
Implementation Method 1
blending a mixture of solid and/or liquid polymer precursors; and 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
pyrolysis or pyrolysis and activation of the solvent-free polymer network to produce tunable carbon
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.