Mesoporous carbon materials
A conductive mesoporous carbon composite comprising conductive carbon nanoparticles contained within a mesoporous carbon matrix, wherein the conductive mesoporous carbon composite possesses at least a portion of mesopores having a pore size of at least 10 nm and up to 50 nm, and wherein the mesopores are either within the mesoporous carbon matrix, or are spacings delineated by surfaces of said conductive carbon nanoparticles when said conductive carbon nanoparticles are fused with each other, or both. Methods for producing the above-described composite, devices incorporating them (e.g., lithium batteries), and methods of using them, are also described.
1. A conductive mesoporous carbon composite comprising conductive carbon nanoparticles embedded within a continuous mesoporous carbon matrix which is a continuous phase of a carbon material derived from a resin polymer by carbonization, wherein said conductive mesoporous carbon composite possesses at least a bimodal pore size distribution comprised of at least a first mode of mesopores and a second mode of mesopores, wherein said first mode of mesopores have pore walls constructed of the mesoporous carbon matrix and have a pore size ranging from 2 to 8 nm, and wherein said second mode of mesopores have pore walls delineated by surfaces of said conductive carbon nanoparticles being fused with each other and have a pore size of at least 10 nm and up to 50 nm, and wherein the conductive mesoporous carbon composite is in the form of a film having a thickness of up to 50 microns.
2. The mesoporous carbon composite of claim 1 , wherein said second mode of mesopores contributes at least 80% of a total pore volume of the conductive mesoporous carbon composite.
3. The mesoporous carbon composite of claim 1 , wherein said second mode of mesopores has a pore size of at least 12 nm and up to 50 nm.
4. The mesoporous carbon composite of claim 1 , wherein said second mode of mesopores has a pore size of at least 15 nm and up to 50 nm.
5. The mesoporous carbon composite of claim 1 , wherein said second mode of mesopores has a pore size of at least 10 nm and up to 20 nm.
6. The mesoporous carbon composite of claim 1 , wherein said conductive carbon nanoparticles are comprised of carbon onion nanoparticles.
7. The mesoporous carbon composite of claim 1 , wherein said conductive carbon nanoparticles are comprised of carbon black nanoparticles.
8. The mesoporous carbon composite of claim 1 , wherein said conductive carbon nanoparticles are comprised of carbon nanotubes.
9. The mesoporous carbon composite of claim 1 , wherein said conductive carbon nanoparticles are comprised of buckminsterfullerene nanoparticles.
10. The mesoporous carbon composite of claim 1 , wherein said film has a thickness of up to 1 micron.
11. The mesoporous carbon composite of claim 1 , wherein said film has a thickness of up to 100 nm.
12. The mesoporous carbon composite of claim 1 , wherein said conductive mesoporous carbon composite further includes micropores that contribute up to 35% of a total pore volume, wherein said micropores have a pore size less than 2 nm.
13. The mesoporous carbon composite of claim 1 , wherein said conductive mesoporous carbon composite is substantially absent of micropores.
14. A method for fabricating a conductive mesoporous carbon composite having conductive carbon nanoparticles contained within a continuous mesoporous carbon matrix which is a continuous phase of a carbon material derived from a resin polymer by carbonization, the method comprising subjecting a film of a precursor composition to a curing step followed by a carbonization step, the precursor composition comprising: (i) a templating component comprised of a block copolymer, (ii) a phenolic component, (iii) a crosslinkable aldehyde component, (iv) an acid catalyst, and (v) conductive carbon nanoparticles, wherein said carbonization step comprises heating the precursor composition at a carbonizing temperature of at least 300° C. and up to 2000° C. for sufficient time to convert the precursor composition to a conductive mesoporous carbon composite comprising said conductive carbon nanoparticles embedded within said continuous mesoporous carbon matrix, wherein said conductive mesoporous carbon composite possesses at least a bimodal pore size distribution comprised of at least a first mode of mesopores and a second mode of mesopores, wherein said first mode of mesopores have pore walls constructed of the mesoporous carbon matrix and have a pore size ranging from 2 to 8 nm, and wherein said second mode of mesopores have pore walls delineated by surfaces of said conductive carbon nanoparticles being fused with each other and have a pore size of at least 10 nm and up to 50 nm, and wherein the conductive mesoporous carbon composite is in the form of a film having a thickness of up to 50 microns.
15. The method of claim 14 , wherein said carbonizing temperature is at least 300° C. and up to 1500° C.
16. The method of claim 14 , wherein said carbonizing temperature is at least 300° C. and up to 1000° C.
17. The method of claim 14 , wherein said carbonizing temperature is at least 300° C. and up to 900° C.
18. The method of claim 14 , wherein said carbonizing temperature is at least 300° C. and up to 850° C.
19. The method of claim 14 , wherein said carbonizing temperature is at least 300° C. and up to 800° C.
20. The method of claim 14 , wherein said curing step comprises heating the precursor composition at a temperature up to 200° C. for an amount of time that permits curing of the precursor composition.
21. The method of claim 14 , wherein said block copolymer comprises a poloxamer triblock copolymer.
22. The method of claim 14 , wherein said phenolic component is comprised of at least one phenolic compound.
23. The method of claim 22 , wherein said phenolic compound is selected from the group consisting of phenol, catechol, resorcinol, dihydroquinone, phloroglucinol, cresols, halophenols, aminophenols, hydroxybenzoic acids, and dihydroxybiphenyls.
24. The method of claim 14 , wherein said crosslinkable aldehyde component is selected from organoaldehydes and organodialdehydes.
25. The method of claim 14 , wherein said crosslinkable aldehyde component is selected from formaldehyde and glyoxal.
26. The method of claim 14 , wherein said conductive carbon nanoparticles are included in an amount of 5 to 95 percent by weight of the conductive carbon nanoparticles and phenolic component.
27. The method of claim 14 , wherein said conductive carbon nanoparticles are included in an amount of 10 to 90 percent by weight of the conductive carbon nanoparticles and phenolic component.
28. The method of claim 14 , wherein said conductive carbon nanoparticles are included in an amount of 15 to 85 percent by weight of the conductive carbon nanoparticles and phenolic component.
29. The method of claim 14 , wherein said conductive carbon nanoparticles are included in an amount of 20 to 80 percent by weight of the conductive carbon nanoparticles and phenolic component.
30. The method of claim 14 , wherein said conductive carbon nanoparticles are included in an amount of 25 to 75 percent by weight of the conductive carbon nanoparticles and phenolic component.
31. The method of claim 14 , wherein said second mode of mesopores contributes at least 80% of a total pore volume of the conductive mesoporous carbon composite.
32. The method of claim 14 , wherein said second mode of mesopores has a pore size of at least 12 nm and up to 50 nm.
33. The method of claim 14 , wherein said second mode of mesopores has a pore size of at least 15 nm and up to 50 nm.
34. The method of claim 14 , wherein said second mode of mesopores has a pore size of at least 10 nm and up to 20 nm.
35. The method of claim 14 , wherein said conductive carbon nanoparticles are comprised of carbon onion nanoparticles.
36. The method of claim 14 , wherein said conductive carbon nanoparticles are comprised of carbon black nanoparticles.
37. The method of claim 14 , wherein said conductive carbon nanoparticles are comprised of carbon nanotubes.
38. The method of claim 14 , wherein said conductive carbon nanoparticles are comprised of buckminsterfullerene nanoparticles.