Three-dimensional carbon structures
View Patent ↗The method of the present disclosure is directed towards the formation of a three-dimensional carbon structure and includes the steps of adding a radical initiator to an amount of carbon starting material, forming a mixture, placing the mixture in a mold, maintaining the mixture and the mold at an elevated temperature for a period of time to form a thermally cross-linked molded mixture and removing the thermally cross-linked molded mixture from the mold. The disclosure also includes a three-dimensional carbon structure, with that structure including a thermally cross-linked carbon base material in a predetermined formation.
1. A method of forming a carbon structure, the method comprising the steps of:
providing a carbon material, wherein the carbon material is a nano material selected from the group consisting of multiwalled carbon nanotubes, single walled carbon nanotubes and combinations thereof;
contacting the carbon material with a radical initiator to form a mixture;
heating the mixture for a period of time to form the carbon structure, wherein the hardness of the carbon structure is from about 0.7 MPa to about 4.9 MPa.
2. The method of claim 1 , wherein the ratio of carbon material to radical initiator in the mixture is between 1:0.5 to 1:4.
3. The method of claim 1 , wherein a solvent is added to the mixture.
4. The method of claim 3 , wherein the solvent is chloroform.
5. The method of claim 1 , wherein the mixture is heated to about 60° C. for about 24 hours.
6. The method of claim 1 , wherein the radical initiator is selected from the group consisting of a peroxide, benzoyl peroxide, a compound with a peroxide functional group (ROOR'), methyl ethyl ketone peroxide, Di-tert-butyl peroxide, benzoyl peroxide, acetone peroxide, bisacylphosphine oxide (BAPO), aluminophosphate (MAPO), tert-Amylperoxy-2-ethyl (TAPO) or azobisisobutyronitrile (AIBN) and combinations thereof.
7. The method of claim 1 , wherein the elastic modulus of the carbon structure is from about 16 MPa to about 84 MPa.
8. The method of claim 1 , wherein the carbon structure has a pore diameter of between about 125 nm and about 325 μm.
9. The method of claim 1 , wherein the carbon structure has a porosity of about 20% to about 95%.
10. The method of claim 1 , wherein the carbon structure has a dimension greater than about 1 mm.
11. The method of claim 1 , further comprising annealing the carbon structure at about 150° C. for about 20 minutes.
12. A method of forming a carbon structure, the method comprising the steps of:
providing a carbon material;
contacting the carbon material with a radical initiator to form a mixture;
heating the mixture for a period of time to form the carbon structure, wherein the carbon structure has a pore diameter of between about 125 nm and about 325 μm.
13. The method of claim 12 , wherein the elastic modulus of the carbon structure is from about 16 MPa to about 84 MPa.
14. The method of claim 12 , wherein the hardness of the carbon structure is from about 0.7 MPa to about 4.9 MPa.
15. The method of claim 12 , wherein the carbon structure has a porosity of about 20% to about 95%.
16. The method of claim 12 , further comprising annealing the carbon structure at about 150° C. for about 20 minutes.
17. A method of forming a carbon structure, the method comprising the steps of:
providing a carbon material;
contacting the carbon material with a radical initiator to form a mixture;
heating the mixture for a period of time to form the carbon structure, wherein the carbon structure has a porosity of about 20% to about 95%.
18. The method of claim 17 , wherein the elastic modulus of the carbon structure is from about 16 MPa to about 84 MPa.
19. The method of claim 17 , wherein the hardness of the carbon structure is from about 0.7 MPa to about 4.9 MPa.
20. The method of claim 17 , wherein the carbon structure has a pore diameter of between about 125 nm and about 325 μm.
21. The method of claim 17 , further comprising annealing the carbon structure at about 150° C. for about 20 minutes.