JP2013535557A - 多孔質材料を製造する方法 - Google Patents
多孔質材料を製造する方法 Download PDFInfo
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- 239000011148 porous material Substances 0.000 title claims abstract description 37
- 238000004519 manufacturing process Methods 0.000 title description 18
- 239000000203 mixture Substances 0.000 claims abstract description 39
- 239000002736 nonionic surfactant Substances 0.000 claims abstract description 36
- 239000002243 precursor Substances 0.000 claims abstract description 29
- 239000000758 substrate Substances 0.000 claims abstract description 21
- 238000010924 continuous production Methods 0.000 claims abstract description 20
- 229920000642 polymer Polymers 0.000 claims abstract description 20
- 238000000576 coating method Methods 0.000 claims abstract description 15
- 239000011248 coating agent Substances 0.000 claims abstract description 14
- 239000003575 carbonaceous material Substances 0.000 claims abstract description 13
- 238000000151 deposition Methods 0.000 claims abstract description 11
- 238000010438 heat treatment Methods 0.000 claims abstract description 10
- 238000001035 drying Methods 0.000 claims abstract description 7
- 239000007788 liquid Substances 0.000 claims abstract description 6
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 34
- 229910052799 carbon Inorganic materials 0.000 claims description 26
- 239000004973 liquid crystal related substance Substances 0.000 claims description 20
- 229920001577 copolymer Polymers 0.000 claims description 19
- 239000002131 composite material Substances 0.000 claims description 15
- 239000003795 chemical substances by application Substances 0.000 claims description 13
- -1 polyethylene terephthalate Polymers 0.000 claims description 11
- 239000004990 Smectic liquid crystal Substances 0.000 claims description 9
- 239000002184 metal Substances 0.000 claims description 9
- 229910052751 metal Inorganic materials 0.000 claims description 9
- IAYPIBMASNFSPL-UHFFFAOYSA-N Ethylene oxide Chemical group C1CO1 IAYPIBMASNFSPL-UHFFFAOYSA-N 0.000 claims description 8
- 239000004743 Polypropylene Substances 0.000 claims description 8
- 229920001155 polypropylene Polymers 0.000 claims description 8
- GOOHAUXETOMSMM-UHFFFAOYSA-N Propylene oxide Chemical compound CC1CO1 GOOHAUXETOMSMM-UHFFFAOYSA-N 0.000 claims description 7
- 239000007833 carbon precursor Substances 0.000 claims description 7
- 229910044991 metal oxide Inorganic materials 0.000 claims description 7
- 238000002156 mixing Methods 0.000 claims description 7
- 239000005011 phenolic resin Substances 0.000 claims description 7
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 7
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 7
- 230000008961 swelling Effects 0.000 claims description 7
- AUHZEENZYGFFBQ-UHFFFAOYSA-N 1,3,5-trimethylbenzene Chemical compound CC1=CC(C)=CC(C)=C1 AUHZEENZYGFFBQ-UHFFFAOYSA-N 0.000 claims description 6
- 239000004793 Polystyrene Substances 0.000 claims description 6
- HVYWMOMLDIMFJA-DPAQBDIFSA-N cholesterol Chemical compound C1C=C2C[C@@H](O)CC[C@]2(C)[C@@H]2[C@@H]1[C@@H]1CC[C@H]([C@H](C)CCCC(C)C)[C@@]1(C)CC2 HVYWMOMLDIMFJA-DPAQBDIFSA-N 0.000 claims description 6
- 229920002223 polystyrene Polymers 0.000 claims description 6
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 claims description 4
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Natural products C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 claims description 4
- 239000002905 metal composite material Substances 0.000 claims description 4
- 229920001568 phenolic resin Polymers 0.000 claims description 4
- 229910052684 Cerium Inorganic materials 0.000 claims description 3
- WHNWPMSKXPGLAX-UHFFFAOYSA-N N-Vinyl-2-pyrrolidone Chemical compound C=CN1CCCC1=O WHNWPMSKXPGLAX-UHFFFAOYSA-N 0.000 claims description 3
- 239000004952 Polyamide Substances 0.000 claims description 3
- 239000004642 Polyimide Substances 0.000 claims description 3
- 239000004721 Polyphenylene oxide Substances 0.000 claims description 3
- 239000004372 Polyvinyl alcohol Substances 0.000 claims description 3
- 229920002125 Sokalan® Polymers 0.000 claims description 3
- 229920006243 acrylic copolymer Polymers 0.000 claims description 3
- 229910052782 aluminium Inorganic materials 0.000 claims description 3
- 229920001400 block copolymer Polymers 0.000 claims description 3
- 229920005605 branched copolymer Polymers 0.000 claims description 3
- 239000006229 carbon black Substances 0.000 claims description 3
- 229910021393 carbon nanotube Inorganic materials 0.000 claims description 3
- 239000002041 carbon nanotube Substances 0.000 claims description 3
- 229920002678 cellulose Polymers 0.000 claims description 3
- 239000001913 cellulose Substances 0.000 claims description 3
- 235000012000 cholesterol Nutrition 0.000 claims description 3
- 239000006258 conductive agent Substances 0.000 claims description 3
- 238000007598 dipping method Methods 0.000 claims description 3
- HYBBIBNJHNGZAN-UHFFFAOYSA-N furfural Chemical class O=CC1=CC=CO1 HYBBIBNJHNGZAN-UHFFFAOYSA-N 0.000 claims description 3
- 229910052737 gold Inorganic materials 0.000 claims description 3
- 229920000578 graft copolymer Polymers 0.000 claims description 3
- 229910021389 graphene Inorganic materials 0.000 claims description 3
- 229910002804 graphite Inorganic materials 0.000 claims description 3
- 239000010439 graphite Substances 0.000 claims description 3
- 229910052738 indium Inorganic materials 0.000 claims description 3
- 229910052742 iron Inorganic materials 0.000 claims description 3
- 229910052748 manganese Inorganic materials 0.000 claims description 3
- 229910052759 nickel Inorganic materials 0.000 claims description 3
- 229910052758 niobium Inorganic materials 0.000 claims description 3
- 239000004745 nonwoven fabric Substances 0.000 claims description 3
- 229910052697 platinum Inorganic materials 0.000 claims description 3
- 229920002492 poly(sulfone) Polymers 0.000 claims description 3
- 229920000058 polyacrylate Polymers 0.000 claims description 3
- 239000004584 polyacrylic acid Substances 0.000 claims description 3
- 229920002239 polyacrylonitrile Polymers 0.000 claims description 3
- 229920002647 polyamide Polymers 0.000 claims description 3
- 229920000515 polycarbonate Polymers 0.000 claims description 3
- 239000004417 polycarbonate Substances 0.000 claims description 3
- 229920000728 polyester Polymers 0.000 claims description 3
- 229920000570 polyether Polymers 0.000 claims description 3
- 229920001721 polyimide Polymers 0.000 claims description 3
- 229920000098 polyolefin Polymers 0.000 claims description 3
- 229920002451 polyvinyl alcohol Polymers 0.000 claims description 3
- 239000004800 polyvinyl chloride Substances 0.000 claims description 3
- 229920000915 polyvinyl chloride Polymers 0.000 claims description 3
- 229910052707 ruthenium Inorganic materials 0.000 claims description 3
- 229910052710 silicon Inorganic materials 0.000 claims description 3
- 229910052709 silver Inorganic materials 0.000 claims description 3
- 229910052718 tin Inorganic materials 0.000 claims description 3
- 229910052719 titanium Inorganic materials 0.000 claims description 3
- 238000012546 transfer Methods 0.000 claims description 3
- 229910052721 tungsten Inorganic materials 0.000 claims description 3
- 229910052720 vanadium Inorganic materials 0.000 claims description 3
- 229920002554 vinyl polymer Polymers 0.000 claims description 3
- 229910052725 zinc Inorganic materials 0.000 claims description 3
- 238000010000 carbonizing Methods 0.000 claims description 2
- 239000000843 powder Substances 0.000 claims description 2
- 238000011437 continuous method Methods 0.000 claims 15
- 238000004581 coalescence Methods 0.000 claims 1
- 238000000034 method Methods 0.000 abstract description 33
- 239000004094 surface-active agent Substances 0.000 description 29
- 239000000463 material Substances 0.000 description 12
- 230000015572 biosynthetic process Effects 0.000 description 10
- 239000013335 mesoporous material Substances 0.000 description 10
- 239000000693 micelle Substances 0.000 description 10
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 7
- 238000003786 synthesis reaction Methods 0.000 description 7
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 7
- 238000006243 chemical reaction Methods 0.000 description 6
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 5
- 238000003763 carbonization Methods 0.000 description 4
- 238000009826 distribution Methods 0.000 description 4
- 238000000802 evaporation-induced self-assembly Methods 0.000 description 4
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 4
- 239000002563 ionic surfactant Substances 0.000 description 3
- 239000002808 molecular sieve Substances 0.000 description 3
- 238000011160 research Methods 0.000 description 3
- 239000000377 silicon dioxide Substances 0.000 description 3
- 235000012239 silicon dioxide Nutrition 0.000 description 3
- URGAHOPLAPQHLN-UHFFFAOYSA-N sodium aluminosilicate Chemical compound [Na+].[Al+3].[O-][Si]([O-])=O.[O-][Si]([O-])=O URGAHOPLAPQHLN-UHFFFAOYSA-N 0.000 description 3
- 239000000243 solution Substances 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- KRHYYFGTRYWZRS-UHFFFAOYSA-N Fluorane Chemical compound F KRHYYFGTRYWZRS-UHFFFAOYSA-N 0.000 description 2
- 238000003917 TEM image Methods 0.000 description 2
- 239000004974 Thermotropic liquid crystal Substances 0.000 description 2
- 229910010413 TiO 2 Inorganic materials 0.000 description 2
- 230000004913 activation Effects 0.000 description 2
- 238000005266 casting Methods 0.000 description 2
- 238000004132 cross linking Methods 0.000 description 2
- 230000008021 deposition Effects 0.000 description 2
- 230000002209 hydrophobic effect Effects 0.000 description 2
- 125000001165 hydrophobic group Chemical group 0.000 description 2
- 238000005470 impregnation Methods 0.000 description 2
- 239000012229 microporous material Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000006116 polymerization reaction Methods 0.000 description 2
- 229920002635 polyurethane Polymers 0.000 description 2
- 239000004814 polyurethane Substances 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 238000001338 self-assembly Methods 0.000 description 2
- 238000001988 small-angle X-ray diffraction Methods 0.000 description 2
- 238000000935 solvent evaporation Methods 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- 238000004627 transmission electron microscopy Methods 0.000 description 2
- 239000004976 Lyotropic liquid crystal Substances 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 150000004703 alkoxides Chemical class 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 229920000359 diblock copolymer Polymers 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 230000008020 evaporation Effects 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-M hydroxide Chemical compound [OH-] XLYOFNOQVPJJNP-UHFFFAOYSA-M 0.000 description 1
- 230000002535 lyotropic effect Effects 0.000 description 1
- 229910000000 metal hydroxide Inorganic materials 0.000 description 1
- 150000004706 metal oxides Chemical class 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- 229920001197 polyacetylene Polymers 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 238000013341 scale-up Methods 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 230000002522 swelling effect Effects 0.000 description 1
- 238000001308 synthesis method Methods 0.000 description 1
- 229920000428 triblock copolymer Polymers 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B32/00—Carbon; Compounds thereof
- C01B32/90—Carbides
Landscapes
- Chemical & Material Sciences (AREA)
- Organic Chemistry (AREA)
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Inorganic Chemistry (AREA)
- Carbon And Carbon Compounds (AREA)
- Battery Electrode And Active Subsutance (AREA)
- Chemically Coating (AREA)
- Inorganic Compounds Of Heavy Metals (AREA)
- Inert Electrodes (AREA)
- Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
Abstract
Description
本願は、2010年8月6日に提出された米国特許仮出願第61/371,293号に基づくものであり、該仮出願の全体が、参照することによりここに盛り込まれる。
本発明は、多孔質材料を製造するための連続法、特にロール・トゥー・ロール方式で鋳型技術を使用して多孔質材料を製造する連続法に関する。
起自己集合用の骨格にコーティングされる。その後、ポリウレタンスポンジは熱的に処理され、バッチ法によってメソポーラスカーボンの大量生産を実現する。依然として、自動大量生産の要件を満たすことができない。今に至るまで、連続的または自動化手段を介してEISA法による大量生産を実施することは、未解決の課題のままである。
鋳型法によって多孔質材料を合成する、大量生産可能な合成方法が提供される。一般的に、本発明によれば、多孔質材料を製造するための連続法は、混合物を形成するために非イオン性界面活性剤を炭素質材料の前駆体と混合する工程、及びその混合物を不織布基材上にコーティング又は堆積する工程、それに続いて乾燥又は加熱を行う工程を含む。加えて、形成される多孔質材料に応じて、乾燥又は加熱工程の後に熱処理を随意に行ってもよい。
。加えて、非イオン性界面活性剤が、酸化エチレン(EO)共重合体、酸化プロピレン(PO)共重合体、ブチレンオキシド共重合体、ビニルピリジン共重合体、ビニルピロリドン、エピクロルヒドリン共重合体、スチレン共重合体、アクリル共重合体、又はそれらの組み合わせであることができる。
F127(EO106PO70EO106)とフェノール樹脂をエタノール中で混合して混合物を形成することによって、アルコール堆積液を形成する。混合物を、ポリエチレンテレフタレート(PET)の不織布基材上に堆積する。次に、乾燥工程を行い、エタノールを25℃で蒸発させる。次に、転化工程(i)を100℃で行い、フェノール樹脂を重合させる。重合体が堆積した不織布基材の複合材を得る。
ポリマーを堆積したPP不織布複合材を得るために、実施例1と同じ手順でF127及びフェノール樹脂の混合物をポリプロピレン(PP)不織布基材上に堆積する
Claims (25)
- 多孔質材料を製造するための連続法あって、
連続相、及び非イオン性界面活性剤を含有する液晶中間相を含む混合物(炭素質材料の前駆体が本質的に前記連続相に位置する)を形成するために、非イオン性界面活性剤と炭素質材料の前駆体とを混合する工程、
前記混合物を不織布基材上にコーティング又は堆積する工程;
前記混合物を乾燥又は加熱する工程;並びに
重合体を形成するために前記前駆体を転化する工程、
を含む連続法。 - 多孔質炭素を形成するために、前記重合体を炭化する工程をさらに含む、請求項1の連続法。
- 炭素−金属複合材又は炭素−金属酸化物複合材が得られるように、金属前駆体又は金属粉を前記混合物に加える工程をさらに含む、請求項2の連続法。
- 前記炭素−金属複合材及び前記炭素−金属酸化物複合材の少なくとも1種が、Ti、Pt、Ag、Au、Al、Ru、Fe、V、Ce、Zn、Sn、Si、W、Ni、Co、Mn、In、Os、Cu、Nb、又はそれらの酸化物を含む、請求項3の連続法。
- 前記液晶中間相が、スメクティック相又はスメクティックヘキサゴナル相である、請求項1の連続法。
- 前記液晶中間相が、約2nm〜約20nmの直径を有する柱状である、請求項5の連続法。
- 前記非イオン性界面活性剤が、5〜24の親水性親油性バランス(HLB)値を有する、請求項1の連続法。
- 前記非イオン性界面活性剤が、17〜24の親水性親油性バランス(HLB)値を有する、請求項1の連続法。
- 前記非イオン性界面活性剤が、6〜10の親水性親油性バランス(HLB)値を有する、請求項1の連続法。
- 前記混合物が、2つの連続相、又は連続液晶中間相及び連続非液晶相を含む、請求項1の連続法。
- ロール・トゥー・ロール方式で前記混合物を前記不織布基材上にコーティング又は堆積する工程をさらに含む、請求項1の連続法。
- 前記重合体から前記非イオン性界面活性剤を除去する工程をさらに含む、請求項1の連続法。
- 前記非イオン性界面活性剤を除去する工程が、前記重合体を加熱することを含む、請求項12の連続法。
- 前記混合物が、キャスティング、含浸、噴霧、ディッピング、グラビア、ドクターブレード、スロット、スリット、カーテン(curtain)、リバース(reverse)
若しくはトランスファーコーティング、又は印刷によって前記不織布基材上にコーティング又は堆積される、請求項1の連続法。 - 前記炭素質材料の前記前駆体が、炭素前駆体を含む、請求項1の連続法。
- 前記炭素前駆体が、フェノール樹脂、フルフラール誘導体重合体、ピッチ、酸化ポリスチレン、ポリアクリロニトリル、ポリビニルアルコール、ポリ塩化ビニル、又はそれらの組み合わせを含む、請求項15の連続法。
- 複合材を形成するために、炭素ナノチューブ、カーボンブラック、グラファイト又はグラフェンを前記混合物に加える工程をさらに含む、請求項1の連続法。
- 前記非イオン性界面活性剤が、ブロック、グラフト、又は分岐共重合体を含む、請求項1の連続法。
- 前記非イオン性界面活性剤が、酸化エチレン(EO)共重合体、酸化プロピレン(PO)共重合体、ブチレンオキシド共重合体、ビニルピリジン共重合体、ビニルピロリドン、エピクロルヒドリン共重合体、スチレン共重合体、アクリル共重合体、又はそれらの組み合わせを含む、請求項1の連続法。
- 前記非イオン性界面活性剤の分子量が、500〜20000である、請求項1の連続法。
- 前記非イオン性界面活性剤の分子量が、5000〜15000である、請求項1の連続法。
- 前記不織布基材が、ポリビニル誘導体、ポリエステル、ポリカーボネート、ポリアミド、ポリイミド、セルロース、ポリオレフィン、ポリスルホン、ポリエチレンテレフタレート(PET)、ポリプロピレン(PP)、そのハロゲン化誘導体、又はその複合材を含む、請求項1の連続法。
- 前記混合物に膨潤剤を加える工程をさらに含む、請求項1の連続法。
- 前記膨潤剤が、1,3,5‐トリメチルベンゼン(TMB)、コレステロール、ポリスチレンポリエーテル、ポリエーテルアミン、ポリアクリレート、ポリアクリル酸、又はそれらの誘導体を含む、請求項23の連続法。
- 前記混合物に導電剤を加える工程をさらに含む、請求項1の連続法。
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US37129310P | 2010-08-06 | 2010-08-06 | |
US61/371,293 | 2010-08-06 | ||
PCT/CN2011/075776 WO2012016480A1 (en) | 2010-08-06 | 2011-06-15 | Process for manufacturing porous material |
Publications (2)
Publication Number | Publication Date |
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JP2013535557A true JP2013535557A (ja) | 2013-09-12 |
JP5674937B2 JP5674937B2 (ja) | 2015-02-25 |
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JP2013523475A Active JP5674937B2 (ja) | 2010-08-06 | 2011-06-15 | 多孔質材料を製造する方法 |
JP2013523480A Active JP5747080B2 (ja) | 2010-08-06 | 2011-08-04 | 多孔質材料の製造方法 |
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JP2013523480A Active JP5747080B2 (ja) | 2010-08-06 | 2011-08-04 | 多孔質材料の製造方法 |
Country Status (5)
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---|---|
US (2) | US8993052B2 (ja) |
JP (2) | JP5674937B2 (ja) |
CN (2) | CN103189131A (ja) |
TW (2) | TWI504560B (ja) |
WO (2) | WO2012016480A1 (ja) |
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CN103189131A (zh) | 2013-07-03 |
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