Rigid porous carbon structures, methods of making, methods of using and products containing same
AssigneeHyperion Catalysis International, Inc.
InventorsHoward Tennent, David Moy, Chun-Ming Niu
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Abstract
This invention relates to rigid porous carbon structures and to methods of making same. The rigid porous structures have a high surface area which are substantially free of micropores. Methods for improving the rigidity of the carbon structures include causing the nanofibers to form bonds or become glued with other nanofibers at the fiber intersections. The bonding can be induced by chemical modification of the surface of the nanofibers to promote bonding, by adding "gluing" agents and/or by pyrolyzing the nanofibers to cause fusion or bonding at the interconnect points.
Claims35
A rigid porous carbon structure which comprises intertwined, interconnected carbon nanofibers, said rigid porous carbon structure having a surface area greater than about 100 m.sup.2 /gm, being substantially free of micropores and having a crush strength greater than about 5 lb/in.sup.2.
A rigid porous carbon structure which comprises intertwined, interconnected carbon nanofibers, said rigid porous structure having a surface area greater than about 100 m.sup.2 /gm, having a crush strength greater than about 2 lb/in.sup.2, and a density greater than 0.8 g/cm.sup.3.
A method of preparing a rigid porous carbon structure having a surface area greater than at least 100 m.sup.2 /gm, comprising the steps of:
- (a) dispersing a plurality of nanofibers in a medium to form a suspension;
- (b) separating said medium from said suspension to form said structure,
- wherein said nanofibers are interconnected to form said rigid structure of intertwined nanofibers bonded at the nanofibers intersections within the structure.
A method of preparing a rigid porous carbon structure having a surface area greater than at least 100 m.sup.2 /gm, comprising the steps of:
- a) dispersing a plurality of nanofibers in a medium to form a suspension;
- b) using a kneader to obtain a uniform, thick paste of the nanofiber suspension;
- c) extruding or pelletizing the paste;
- d) separately said medium from said suspension to form said structure,
- wherein said nanofibers are intertwined to form said rigid structure of intertwined nanotubes bonded at the nanotube intersections within the structure.
Dependencies are inferred from the claim text.