# US 9,520,594 B2 · Porous carbon product with layer composite structure

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- Number: US 9,520,594 B2
- Document ID: US9520594B2
- Status: Granted
- Kind: B2
- Application number: 14/110,665
- Filed: 2012-03-27
- Published: 2014-02-13
- Granted: 2016-12-13
- Earliest claimed: 2011-04-08
- Assignees: Heraeus Quarzglas GmbH & Co. KG
- Applicants: Christian Neumann; Jörg Becker
- Inventors: Christian Neumann; Jörg Becker
- Web page: https://patentgrep.com/patent/US9520594B2

## CPC

- H01M 4/366: {as layered products}
- C01B 32/00: Carbon; Compounds thereof (C01B21/00, C01B23/00 take precedence; percarbonates C01B15/10; carbon black C09C1/48)
- C03B 19/1492: {Deposition substrates, e.g. targets}
- C03B 37/005: Manufacture of flakes
- C04B 35/524: obtained from polymer precursors, e.g. glass-like carbon material
- C04B 35/636: Polysaccharides or derivatives thereof
- C04B 38/0032: {one of the precursor materials being a monolithic element having approximately the same dimensions as the final article, e.g. a paper sheet which after carbonisation will react with silicon to form a porous silicon carbide porous body}
- H01M 4/0416: {involving impregnation with a solution, dispersion, paste or dry powder (H01M4/0438 takes precedence)}
- H01M 4/0471: {involving thermal treatment, e.g. firing, sintering, backing particulate active material, thermal decomposition, pyrolysis}
- H01M 4/049: {Manufacturing of an active layer by chemical means}
- H01M 4/136: Electrodes based on inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy
- H01M 4/1397: of electrodes based on inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy
- H01M 4/362: {Composites}
- H01M 4/5815: {Sulfides}
- H01M 4/587: for inserting or intercalating light metals
- H01M 4/625: {Carbon or graphite}
- H01M 10/0525: Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries
- C01P 2006/12: Surface area
- C04B 2235/3418: Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
- C04B 2235/48: Organic compounds becoming part of a ceramic after heat treatment, e.g. carbonising phenol resins
- C04B 2235/6028: Shaping around a core which is removed later
- H01M 4/382: {Lithium (H01M4/405 takes precedence)}
- H01M 2004/021: {Physical characteristics, e.g. porosity, surface area}
- Y02E 60/10: Energy storage using batteries
- H01M: PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
- C01B: NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; {METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C}
- C03B: MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C04B: LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE {(roofing granules E04D7/005)}; CERAMICS (devitrified glass-ceramics C03C10/00); REFRACTORIES; TREATMENT OF NATURAL STONE
- C01P: INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- Y02E: REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

## Abstract

Inexpensive product consisting of porous carbon, with a pore structure which is suitable for retaining electrode parts which can be used in particular for a use as an electrode material for a lithium-sulphur secondary battery, and a method comprising the following method steps: (a) providing a template consisting of inorganic material which contains spherical nanoparticles and pores, (b) infiltrating the pores of the template with a precursor for carbon of a first variety, (c) carbonizing so as to form an inner layer on the nanoparticles with a first microporosity, (d) infiltrating the remaining pores of the template with a precursor substance for carbon of a second variety, (e) carbonizing the precursor substance, wherein an outer layer with a second microporosity which is lower than the first microporosity is produced on the inner layer, and (f) removing the template so as to form the carbon product with layer composite structure, comprising an inner layer consisting carbon with a first, relatively high microporosity, which has a free surface facing a cavity, and an outer layer consisting of carbon with a second, relatively low microporosity, which has a free surface facing away from the cavity.

## Claims

### Claim 1

A porous carbon product comprising
a layer composite structure having an inner layer of a first carbon variety, said inner layer being in contact with an outer layer of a second carbon variety,
wherein the inner layer has a first microporosity and a surface facing a cavity, and the outer layer has a second microporosity lower than the first microporosity of the inner layer and a surface facing away from the cavity.

### Claim 2 (depends on 1)

The carbon product according to claim 1, wherein the inner layer consists of turbostratic carbon and has a mean layer thickness in the range of 1-50 nm.

### Claim 3 (depends on 1)

The carbon product according to claim 1, wherein the outer layer consists of graphite-like carbon and has a mean layer thickness of at least 2 nm.

### Claim 4 (depends on 1)

The carbon product according to claim 1, wherein the carbon product has a hierarchical pore structure.

### Claim 5 (depends on 1)

The carbon product according to claim 1, wherein the carbon product is in a form of porous carbon flakes of carbon layers having a mean layer thickness in the range of 10 μm to 500 μm.

### Claim 6 (depends on 1)

The carbon product according to claim 1, wherein the inner layer consists of turbostratic carbon and has a mean layer thickness in the range of 2 to 10 nm.

### Claim 7 (depends on 5)

The carbon product according to claim 5, wherein the mean layer thickness of the carbon layers is in a range of 20 μm to 100 μm.

### Claim 8 (depends on 5)

The carbon product according to claim 5, wherein the mean layer thickness of the carbon layers is at least 10 μm and less than 50 μm.