WO2020235638A1 - 多孔炭素構造体、その製造方法、それを用いた正極材及びそれを用いた電池 - Google Patents

多孔炭素構造体、その製造方法、それを用いた正極材及びそれを用いた電池 Download PDF

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WO2020235638A1
WO2020235638A1 PCT/JP2020/020143 JP2020020143W WO2020235638A1 WO 2020235638 A1 WO2020235638 A1 WO 2020235638A1 JP 2020020143 W JP2020020143 W JP 2020020143W WO 2020235638 A1 WO2020235638 A1 WO 2020235638A1
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porous carbon
carbon structure
less
range
positive electrode
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French (fr)
Japanese (ja)
Inventor
栄起 安川
隆 亀田
翔一 松田
祥司 山口
伸 木村
仁彦 伊藤
久保　佳実
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National Institute for Materials Science
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National Institute for Materials Science
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Priority to EP20809459.9A priority Critical patent/EP3975322B1/en
Priority to JP2021520848A priority patent/JP7177547B2/ja
Priority to US17/611,984 priority patent/US12272826B2/en
Priority to CN202080035651.8A priority patent/CN113841284B/zh
Publication of WO2020235638A1 publication Critical patent/WO2020235638A1/ja
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Definitions

  • the present invention relates to a porous carbon structure, a method for producing the same, a positive electrode material using the same, and a battery using the same.
  • the present invention particularly relates to a positive electrode material of an air battery having both independence, high ion transport efficiency, high air permeability, and wide reaction field (in the present application, this is referred to as a "positive electrode material” or a “positive electrode structure”. It also relates to a porous carbon structure suitable for (sometimes referred to as) and a battery using the same.
  • Batteries are attracting attention as a driving force that supports a smart society, and their demand is rapidly increasing.
  • the air battery is attracting a lot of attention because of its small size, light weight, and structure suitable for large capacity.
  • An air battery is a battery that uses oxygen in the air as a positive electrode active material and a metal as a negative electrode active material. It is also called a metal-air battery and is positioned as a kind of fuel cell.
  • the air battery is disclosed in Patent Documents 1 and 2, for example, and a typical example thereof is a lithium air battery that uses lithium ions as a metal or compound capable of occluding and releasing lithium ions as a negative electrode active material. Since the positive electrode active material is oxygen in the air and the positive electrode active material can be supplied from the outside of the battery, the air battery has a structure suitable for reducing the size and weight of the battery and further increasing the capacity.
  • the positive electrode structure is required to have a structure capable of taking in a large amount of oxygen from the air. That is, the positive electrode structure is required to have high air or oxygen permeability. In addition, the positive electrode structure is required to have high ion transport efficiency and a wide reaction field, which are characteristics generally required for batteries. Further, in order to make the air battery smaller and lighter and reduce the cost, it is desired that the positive electrode structure be self-supporting.
  • the positive electrode structure is preferably carbon as a material from the viewpoints of ease of handling, cost, weight, green environment, and recycling, and is made porous in order to impart high air or oxygen permeability to the carbon. That is, a porous carbon structure is often used.
  • Ketjen Black (registered trademark) has a large total specific surface area (BET method specific surface area) and has pore diameters of 2 nm or more and 50 nm or less, so-called mesopores and macropores with a pore diameter of 50 nm or more. It is known as a material having a large pore volume and specific surface area, and is used as a raw material for a porous carbon structure used for a positive electrode of an air battery.
  • Ketjen Black® is powdery and does not stand on its own.
  • Ketjen Black registered trademark
  • a method of dispersing a composition consisting of a binder or the like in a solvent and applying the composition to a metal foil or the like by a doctor blade method or the like, or a metal It is necessary to support it on a mesh or the like, and there are problems that the structure becomes complicated, the weight increases, the cost becomes high, and the flowability of air or oxygen is hindered.
  • a carbonaceous wall having pores including mesopores and micropores having a pore diameter smaller than the mesopores and constituting the outer shell of the mesopores has a three-dimensional network structure.
  • the micropores are formed in the carbonaceous wall, the mesopores are open pores, and the pore portions form continuous connecting pores, which is half of the pore size distribution of the pores.
  • the value width is 2 nm or less
  • the half-value width of the connecting hole diameter distribution of the connecting holes is 50 nm or more
  • the pore volume occupied by the pores having a pore diameter of 1 nm or more is 1.0 ml / g or more and 4.0 ml / g or less.
  • the positive electrode layer that follows the pore volume of the raw material porous carbon, and further exceeds the pore volume of the raw material porous carbon.
  • a positive electrode layer having a large pore volume is desired.
  • the oxygen concentration in the oxidizing gas is in the range of more than 0.03% and less than 5% when the carbonization treatment is performed in the atmosphere of the oxidizing gas, according to [14].
  • a method for producing a porous carbon structure [16] The method for producing a porous carbon structure according to any one of [13] to [15], wherein the treatment temperature of the carbonization treatment is in the range of 350 ° C. or higher and 3000 ° C. or lower. [17] In the carbonization treatment, the pore volume occupied by the pores having a diameter of 1 nm or more and 1000 nm or less of the product obtained by the carbonization treatment is 1.02 of the pore volume of the pore volume of the porous carbon.
  • the porous carbon structure (that is, self-supporting film) as defined in the present invention means copper (Cu), tungsten (W), aluminum (Al), nickel (Ni), and titanium (Ti) in the positive electrode layer. ), Gold (Au), Silver (Ag), Platinum (Pt), Palladium (Pd), Stainless (SUS) and other metal units, or metal mesh made of alloys containing metal-containing components, carbon fibers and polyester fibers. It means that it does not include a support such as a non-woven fabric or a woven cloth composed of the above components, or does not form a positive electrode layer on a substrate using a metal foil such as aluminum foil, nickel foil, or SUS foil as a substrate.
  • the lower limit of the pore volume preferably, 2.2 cm 3 / g or more, more preferably 2.4 cm 3 / g or more
  • the upper limit of the pore volume is preferably 7.0 cm 3 / g or less, more preferably 6.
  • the range is 0 cm 3 / g or less. This can have a large discharge capacity. This can have an even larger discharge capacity.
  • the lower limit of the pore volume is preferably 4.0 cm 3 / g or more, more preferably 4.1 cm 3 / g or more, and the upper limit of the pore volume is preferably 10.0 cm 3 / g or less, more preferably 9.
  • the range is 0 cm 3 / g or less.
  • the lower limit of the pore volume preferably, 2.5 cm 3 / g or more, more preferably 2.6 cm 3 / g or more
  • the upper limit of the pore volume is 7.0 cm 3 / g or less, more preferably The range is 6.5 cm 3 / g or less. This can have high load characteristics. As a result, it is possible to have high load characteristics while maintaining the strength of the porous carbon structure. If the pore volume occupied by the pores having a diameter of 1 nm or more and 200 nm or less in the condition (b) and the pore volume occupied by the pores having a diameter of 200 nm or more and 10,000 nm or less in the condition (e) are within the above ranges, respectively.
  • the lower limit of the apparent density is preferably 0.07 g / cm 3 or more, more preferably 0.09 g / cm 3 or more, and the upper limit of the apparent density is preferably 0.18 g / cm 3 or less, more preferably 0.17 g. / cm 3 or less of the range. As a result, it has pores and can have high strength. The apparent density can thereby have more vacancies and higher strength.
  • the skeleton is mainly composed of carbon. It is more preferable to contain 90% by weight or more, more preferably 93% by weight or more of carbon. When the amount of carbon is 90% by weight or more, the efficiency of ion transport is likely to be increased, and the reaction field when used as the positive electrode structure of the battery is likely to expand. Further, the skeleton preferably contains conductive carbon, and more preferably made of conductive carbon. By containing or being composed of conductive carbon, the conductivity of the porous carbon structure is increased, and the conductivity when this porous carbon structure is used as the positive electrode structure of the battery is increased. As a result, the internal resistance of the battery is lowered and the output of the battery is improved.
  • the fluorine (F) content contained in the porous carbon structure of the present invention can be 0.002 mg or less (0.0002 mass% or less) in 1 g of the porous carbon structure.
  • the content can be set to the above-mentioned content or less.
  • FIG. 4 is a flowchart showing a manufacturing process of the porous carbon structure of the present invention.
  • a mixture slurry is prepared (step S1).
  • the mixture is 50% by weight or more, 85% by weight or less of porous carbon particles, 1% by weight or more, 15% by weight or less of carbon fibers, 5% by weight or more, 49% by weight or less of a binder polymer material, and those. It preferably consists of a uniformly dispersed solvent.
  • carbon fibers are not always necessary, it is more preferable to include carbon fibers because the inclusion of carbon fibers exhibits a reinforcing effect on the porous carbon structure.
  • porous carbon particles carbon black containing Ketjen black (registered trademark), carbon particles formed by the template method, and the like can be used.
  • the porous carbon particles preferably have a BET method specific surface area of 1000 m 2 / g or more and 1500 m 2 / g or less, and a pore volume of 3.0 cm 3 / g or more occupied by pores having a diameter of 1 nm or more and 1000 nm or less. , 4.0 cm 3 / g or less in the range, and diameter 1nm or more, 200 nm or less of pore volume occupied by pores 2.0 cm 3 / g or more, 3.0 cm 3 / g or less in the range satisfying the.
  • a porous carbon structure satisfying the above conditions (a) to (d) can be more easily obtained.
  • a carbon fiber having a fiber diameter of 0.1 ⁇ m or more and 20 ⁇ m or less and a length of 1 mm or more and 20 mm or less can be used.
  • a polymer material such as polyacrylonitrile (PAN), polysulfone, or solvent-soluble polyimide can be used as the binder polymer material, but in view of environmental problems and the like, it does not contain a fluorine (F) element. It is preferable to use a molecular material.
  • PAN polyacrylonitrile
  • F fluorine
  • solvent examples include dimethyl sulfoxide (DMSO), N-methylpyrrolidone (NMP), dimethylformamide (DMF), dimethylacetamide (DMA) and the like.
  • molding is performed (step S2).
  • the molding method is not particularly limited, and examples thereof include a wet film forming method using a well-known doctor blade or the like.
  • the roll coater method, the die coater method, the spin coating method, the spray coating method and the like can also be mentioned.
  • the shape after molding can be various shapes depending on the purpose. For example, a sheet having a uniform thickness.
  • step S3 solvent immersion is performed.
  • the sample molded in step S2 is immersed in a solvent having low solubility in the binder polymer material by a non-solvent-induced phase separation method.
  • a porous membrane is formed.
  • the solvent examples include water, alcohols such as ethyl alcohol, methyl alcohol, and isopropyl alcohol, and mixed solvents thereof.
  • water is preferable in that it is excellent in handleability
  • alcohol is preferable in that it has a characteristic that the discharge capacity when a battery is manufactured using the finally prepared multilayer carbon structure is high.
  • drying is performed (step S4).
  • various solvents are volatilized from the molded product (porous film) obtained in step S3.
  • the drying method include a method of placing in a dry air environment, a vacuum drying method, and a vacuum drying method.
  • heating may be performed at a temperature exceeding the boiling point of the solvent.
  • an infusibilization treatment is performed (step S5).
  • This treatment is performed for the purpose of preventing the knotted polymer material from being melt-separated in the carbonization treatment step of the next step and the shape of the molded body from being deformed. Specifically, it can be achieved by solidifying the knotted polymer material by oxidatively cross-linking it.
  • the infusibilization treatment is performed by heating in an oven or infrared irradiation under air circulation.
  • the temperature is preferably 250 ° C. or higher and 350 ° C. or lower. By setting the temperature to 250 ° C. or higher, the problem that the oxidative cross-linking of the knotted polymer material may be insufficient and may be melted in the carbonization step of the next step is avoided.
  • This step may be omitted depending on the type of the knotting polymer material used or the type of oxidizing gas in the carbonization treatment step of the next step.
  • the atmosphere of the oxidizing gas can preferably be a gas containing oxygen, air, water and carbon dioxide (CO 2 ). With these, most of the polymer material to be attached can be burnt and removed, and a part of the porous carbon particles can be burnt and removed.
  • the atmosphere of the oxidizing gas more preferably further contains an inert gas such as argon (Ar) gas, nitrogen (N 2 ) gas, helium (He) gas.
  • the oxygen concentration may be in the range of more than 0.03% and less than 5% as described above.
  • the oxygen concentration in the range of more than 0.03% and less than 5% avoids the problem that the oxidation treatment tends not to proceed, which may occur when the oxygen concentration is lower than the range, and also oxygen. Since the problem that the porous carbon structure may be excessively burned by the oxidizing gas and split or the strength becomes insufficient, which may occur when the concentration is higher than the above range, is avoided. This is because it is preferable from the viewpoint of achieving the above-mentioned object of the chemical treatment.
  • the oxygen concentration is more preferably in the range of 0.04% or more and 4% or less. Within this range, the oxidation treatment proceeds more efficiently.
  • the oxygen concentration is more preferably in the range of 0.05% or more and 4% or less. Within this range, the oxidation treatment proceeds even more efficiently, and the porous carbon structure of the present invention can be obtained with high efficiency. Even more preferably, it is in the range of 0.2% or more and 2% or less. Within this range, the oxidation treatment proceeds further, and the porous carbon structure of the present invention can be obtained with higher efficiency and higher yield.
  • the atmosphere of the inert gas is a rare gas such as argon (Ar), nitrogen (N 2 ) or the like.
  • Ar argon
  • N 2 nitrogen
  • the carbonization treatment in the atmosphere of the oxidizing gas is carried out at a temperature of 800 ° C. or lower, it is preferable to carry out the carbonization treatment step in the atmosphere of the inert gas.
  • the carbonized polymer material that remains in the contact portion between the porous carbon particles and is deposited in the bond of the porous carbon particles increases the electron conductivity of the porous carbon structure and the porous carbon structure. Allows for stronger strength.
  • the temperature of the carbonization treatment in the atmosphere of the inert gas is preferably 800 ° C. or higher, more preferably 900 ° C. or higher.
  • the upper limit is not particularly limited, but 3000 ° C. or lower is preferable in terms of cost.
  • the original pore volume and specific surface area of the pores appear. Furthermore, by oxidizing a part of the porous carbon particles themselves, the pore volume and the specific surface area of the pores of the obtained porous carbon structure are increased compared to those originally possessed by the raw material porous carbon particles. To do. When a part of the binder polymer material and the porous carbon particles are burnt down, the voids between the particles are increased accordingly. Moreover, the produced porous carbon structure has sufficient and practical mechanical strength to have self-supporting property. This means that the attachment polymer existing between the porous carbon particles that contributes to the binding between the porous carbon particles contributes to the binding between the porous carbon particles by the above carbonization treatment. It shows that it is carbonized as it is.
  • the coin cell 600 in the third embodiment is composed of a laminated structure in which a negative electrode structure 610 and a positive electrode structure 620 are laminated via a separator 660. Then, this laminated structure is restrained by the coin cell type restraint 630. An insulating oar ring is arranged between the coin cell type restraint 630 and the metal mesh 680 (not shown), and the insulating property between the restraint 630 and the positive electrode structure 620 is ensured.
  • the air battery was named in the sense that oxygen in the air becomes the positive electrode active material, it suffices to supply at least 21% or more of the oxygen concentration in the air, but it is diffusion-controlled. Higher concentrations are preferred to reduce the effect, and the best properties can be achieved if pure oxygen can be supplied.
  • the negative electrode structure 610 may be a normally used negative electrode structure.
  • a structure composed of a current collector 635 and a metal layer 640 containing an alkali metal and / or an alkaline earth metal applied thereto can be mentioned.
  • the metal layer 640 a layer made of lithium metal can be typically mentioned.
  • the separator used in existing metal batteries can be used.
  • the separator 660 is selected from the group consisting of porous membranes made of synthetic resins such as polyethylene, polypropylene and polyolefin, glass fibers and non-woven fabrics.
  • the separator 660 is filled with an electrolytic solution. At this time, it is preferable that the space 670 is also filled with the electrolytic solution.
  • the air battery using the positive electrode structure 510 of the present invention has been described in detail with reference to FIG. 7, but the positive electrode structure 510 of the present invention is not limited to the air battery and is any metal. Applicable to batteries.
  • the battery characteristics of each coin cell (lithium-air battery) thus obtained were evaluated in a pure oxygen atmosphere.
  • the conditions for battery evaluation are the current densities of 0.4 mA / cm 2 and the higher current densities of 0.6 mA / cm 2 and 0.8 mA / cm 2 , and the end point of discharge is when the voltage drops to 2.3 V.
  • the discharge capacity per positive electrode weight was calculated by dividing the obtained discharge capacity by the weight of the porous carbon structure used as the positive electrode.
  • a charge / discharge tester HJ1001SD8, manufactured by Hokuto Denko Co., Ltd.
  • Example 1B Porous carbon structure
  • the porous carbon structure sample (porous carbon structure Nos. 11 to 16) of the present invention and the comparative sample (porous carbon structure Nos. 17 to 25) were prepared, and the prepared porous carbon structure sample was used. The properties of the comparative sample will be described.
  • Porous carbon structure No. 17 for comparison sample
  • Porous carbon structure No. 17 samples were a gas diffusion layer sheet made of carbon fiber (TGP-H-060 manufactured by Toray Industries, Inc.) as a sheet obtained by molding a synthetic slurry into a uniform thickness by a wet film forming method using a doctor blade.
  • TGP-H-060 manufactured by Toray Industries, Inc.
  • the porous carbon structure No. A porous carbon structure was produced in the same manner as in 11. Specific production (manufacturing) conditions are as shown in Table 2.
  • the prepared mixture slurry composition was 90% by weight of Ketjen Black (registered trademark) and 10% by weight of PTFE (manufactured by Daikin Industries, Ltd.) as a binder. , This was dispersed in ethanol to prepare a mixture slurry. This mixture slurry was molded into a uniform thickness by a wet film forming method of a doctor blade to prepare a sheet. Next, as a result of removing the volatile solvent from the prepared sheet and drying it, the film-like material cracked and did not become a self-supporting film. Specific production (manufacturing) conditions are as shown in Table 2.

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JP7648126B2 (ja) 2020-12-08 2025-03-18 国立研究開発法人物質・材料研究機構 空気電池用正極シート、および、それを用いた空気電池
JP2024526572A (ja) * 2021-07-01 2024-07-19 ニッポン・コルンマイヤー・カーボン・グループ・ゲゼルシャフト・ミト・ベシュレンクテル・ハフツング 炭化または黒鉛化された成形部品の製造方法
JP7776540B2 (ja) 2021-07-01 2025-11-26 ニッポン・コルンマイヤー・カーボン・グループ・ゲゼルシャフト・ミト・ベシュレンクテル・ハフツング 炭化または黒鉛化された成形部品の製造方法
JP2023079085A (ja) * 2021-11-26 2023-06-07 国立研究開発法人物質・材料研究機構 多孔炭素膜製造用組成物、多孔炭素膜製造用シート、空気電池正極用の多孔炭素膜の製造方法、及びその方法で得られる多孔炭素膜を正極に用いた空気電池の製造方法
JP2023079084A (ja) * 2021-11-26 2023-06-07 国立研究開発法人物質・材料研究機構 空気電池正極用の多孔炭素膜の製造方法、及びその方法で得られる多孔炭素膜を正極に用いた空気電池の製造方法
JP7486129B2 (ja) 2021-11-26 2024-05-17 国立研究開発法人物質・材料研究機構 空気電池正極用の多孔炭素膜の製造方法、及びその方法で得られる多孔炭素膜を正極に用いた空気電池の製造方法
JP7525116B2 (ja) 2021-11-26 2024-07-30 国立研究開発法人物質・材料研究機構 多孔炭素膜製造用組成物、及び多孔炭素膜製造用シート
WO2024142776A1 (ja) * 2022-12-26 2024-07-04 国立研究開発法人物質・材料研究機構 炭素構造体、空気電池、及び炭素構造体の製造方法
JP2024092093A (ja) * 2022-12-26 2024-07-08 国立研究開発法人物質・材料研究機構 炭素構造体、空気電池、及び炭素構造体の製造方法

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