CN102600808A - 纳米多孔碳材料，以及利用其的***和方法 - Google Patents

纳米多孔碳材料，以及利用其的***和方法 Download PDF

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Publication number
CN102600808A
CN102600808A CN2012100401953A CN201210040195A CN102600808A CN 102600808 A CN102600808 A CN 102600808A CN 2012100401953 A CN2012100401953 A CN 2012100401953A CN 201210040195 A CN201210040195 A CN 201210040195A CN 102600808 A CN102600808 A CN 102600808A
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porous carbon
carbon compound
aforementioned
carbon
chlorine
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小弗朗克·迪梅奥
J·唐纳德·卡拉瑟斯
迈克尔·J·沃德延斯基
詹姆斯·V·麦克马纳斯
约瑟夫·马尔祖洛
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Entegris Inc
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Advanced Technology Materials Inc
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    • B01D53/02—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography
    • B01D53/04—Separation of gases or vapours; Recovering vapours of volatile solvents from gases; Chemical or biological purification of waste gases, e.g. engine exhaust gases, smoke, fumes, flue gases, aerosols by adsorption, e.g. preparative gas chromatography with stationary adsorbents
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Abstract

本发明提供了一种多孔碳复合物，与单独的纳米多孔碳相比，其具有的孔隙至少部分地填充有赋予所述复合物增强的特性(是关于选自由硬度、耐磨性和韧性组成的组中的特性)的材料。多孔碳材料也描述作为用于氯气的储存介质，或作为氢储存介质，例如用于氢燃料电池。

Description

纳米多孔碳材料,以及利用其的***和方法
本申请是申请日为2007年1月29日、申请号为200780010455.X、名称为“纳米多孔碳材料，以及利用其的***和方法”的专利申请的分案申请。
相关申请的交叉引用
根据35 USC 119的规定，本发明因此要求2006年1月30日以Frank Dimeo，Jr.等的名义提交的名为“用于流体存储/分配、脱硫、及红外辐射发射的含碳材料，及利用其的装置和方法(CARBONACEOUS MATERIALS USEFUL FOR FLUIDSTORAGE/DISPENSING，DESULFURIZATION，AND INFRAREDRADIATION EMISSION，AND APPARATUS AND METHODSUTILIZING SAME)”的美国临时专利申请60/763,258的优先权。因此，该美国临时专利申请的披露内容以其全文结合于此以供各种目的参考。
技术领域
本发明涉及纳米多孔碳材料(纳米多孔性材料，nanoporouscarbon materials)，其可用于流体储存/分配的应用，还涉及利用该材料的***和方法，以及用于摩擦学应用和作为超韧性结构材料的浸渍纳米多孔碳材料。
背景技术
在许多应用中含碳材料都用作流体吸收介质，包括流体纯化、流体储存与分配，以及流体过滤。
具有商业意义的一种特殊应用是流体储存与分配***，其中将含碳吸附剂材料设计(deployed)为吸附性地保留吸附状态的流体，并在合适的分配条件下释放该流体进行分配，诸如施加热以实现流体的热解吸，施加减压条件以实现流体的解吸，和/或施加浓度梯度，诸如通过使载气流动(该载气与其上保留流体的吸附剂接触)，而导致该流体的解吸以及其在载流体中被带走。
流体储存与分配***披露于2004年6月1日授权的以J.DonaldCarruthers的名义的名为“具有整体式碳吸附剂的气体储存和分配***(Gas storage and dispensing system with monolithic carbonadsorbent)”的美国专利6,743,278中，其公开内容以其全文结合于此，以供各种目的的参考。该专利描述了一种整体式碳物理吸附剂，其特征是以下特征的至少之一：(a)在25℃和650托的压力下用砷化氢气体测定的填充密度，该密度大于吸附剂的每升400g砷化氢；(b)吸附剂的总孔隙的至少30％包括尺寸在约0.3至约0.72纳米范围的狭缝形状小孔(slit-shaped pore)，以及总孔隙的至少20％包括直径小于2(＜2)纳米的微孔；以及(c)在温度低于1000℃下通过热裂解和可选的活化而形成，且散密度(堆比重，bulkdensity)为每立方厘米约0.80至约2.0克。
除了流体储存和分配***之外，传统上将碳用作高强度复合物的成分，如增强介质。另外，在复合材料应用中，碳用作玻璃碳复合物中的连续介质，其可用于各种摩擦学的应用中，但是其具有高度易脆性的固有缺点，因而易于破裂而失去物理整体性。
发明内容
本发明涉及纳米多孔碳材料，其可用于流体储存/分配的应用，还涉及利用该材料的***和方法，以及用于摩擦学应用和作为超韧性结构材料的浸渍纳米多孔碳材料。
在一方面，本发明涉及一种纳米多孔碳复合物，包括具有孔隙的纳米多孔碳，与单独的纳米多孔碳相比，该孔隙至少部分地填充有赋予复合物增强的特性(是关于选自由硬度、耐磨性和韧性组成的组的特性或特征)的材料复合物。
另一方面，本发明涉及包含这种纳米多孔碳复合物的氢储存***。
在另一方面，本发明涉及包含纳米多孔碳复合物的氢燃料产生能量***。
本发明另一方面涉及包含多孔碳的氯气储存***。
本发明的另一方面涉及制造复合材料的方法，包括用材料来至少部分地填充纳米多孔碳的空隙，与单独的纳米多孔碳相比，该材料可赋予复合物增强的特性(是关于选自由硬度、耐磨性和韧性组成的组的特性)。
在另一方面，本发明涉及用于进行氢分配的氢储存方法，包括使用包括含有硼的纳米多孔碳的氢储存介质。
本发明另一方面涉及一种产生能量的方法，包括使用包括含有硼的纳米多孔碳的氢储存介质。
本发明另一方面涉及一种储存氯气的方法，包括以吸附状态将氯气保持(hold)在多孔碳(多孔性碳，porous carbon)上。
本发明的其他方面、特征和实施方式通过以下的披露内容和所附的权利要求将更加显而易见。
附图说明
图1是根据本发明的一种实施方式的浸渍碳结构构件的透视图。
图2是根据本发明的一种实施方式的流体储存与分配装置的示意性正视图，构造成用于向流体利用设施供给流体。
具体实施方式
本发明涉及适用于摩擦学的和超韧性结构材料应用的，以及在流体储存/分配应用中具有效用的纳米多孔碳材料。本发明也涉及利用这种纳米多孔碳材料的***和方法。
本发明在一方面涉及纳米浸渍碳复合材料，其用补强材料(complimentary material)进行浸渍而得到用于各种目的的复合物，例如作为具有高度耐磨特性的摩擦学材料，作为抗冲击的韧性材料和作为装甲材料和防刺穿装甲材料。
浸渍剂可以是任何合适的类型，如引入到碳材料的孔隙中而得到具有既定使用用途的所需性能的复合物。为了这种目的，碳材料适合具有这样的孔隙：含有的小孔足够深且遍及材料的大范围，而能够以简单有效的方式实现浸渍进行。例如，碳可以具有的纳米孔隙，包括平均孔径小于10nm的小孔，这可以理解为，具体的孔径、孔径分布、孔曲折度等可以在本发明的普通实践中进行很大程度的改变。
可以用于浸渍碳材料的孔隙的示例性技术包括但不限于溶液沉积、气相沉积、离子注入等。
在一种实施方式中，浸渍剂材料包括聚合物。作为这种聚合物浸渍应用的实例，纳米多孔碳材料可以采用聚合物如高分子量硅树脂(硅酮)或聚乙二醇进行浸渍，而生产超韧性耐冲击装甲。在这种被浸渍材料的使用中，提高材料的耐冲击性将会导致在聚合物中的石墨板(graphitic plate)之间形成长程连接，以至于获得高度的断裂韧性。
可替换地，聚合物纤维诸如长链芳香聚酰胺纤维或以商标名Kevlar、PBO、Zorlon和Spectra商购获得的纤维也可以用于浸渍剂。在这种浸渍的目的是实现纳米孔的聚合物渗透，以提供多锚点和高强度纤维的三维阵列，由此获得高的断裂韧性材料。这种被浸渍的材料所赋予的优点包括降低重量，提高强度，以及能够以生料状态(green state)形成模塑结构，而容许获得独特形状的耐冲击韧性(ballistic toughness)材料。
在另一种实施方式中，浸渍剂材料选自坚硬材料之中，术语“坚硬”是指材料的固有的硬度和韧性特征，使其区分于“软”材料诸如以上描述的聚合物和纤维。
在这种应用中的浸渍剂能够是与碳原位反应而形成提供所需性能的碳化物和/或其他反应产物的前体材料。作为实例，钨能够通过合适的气相沉积技术浸渍到碳材料的纳米小孔中，诸如通过有机钨前体的挥发而使钨蒸气渗透碳材料的小孔，而在沉积期间和/或通过随后对材料进行热处理而转化成碳化钨。
碳化钨是高度致密材料，是人们所知的最硬材料之一。此前由于其难于进行机加工的特性而使其用途受限。这种困难能够通过提供一种具有最终所需构型的成形的多孔碳制品，在其孔隙中生成碳化钨之后，提供具有所需尺寸和构型的成品而得到克服。碳的孔隙例如能够使用化学气相沉积技术进行渗透，采用羰基钨或六氟化钨以使钨沉积在小孔中，随后在高温条件下反应而原位生成碳化钨。
这种碳/碳化钨复合物能够进行制造而提供贫铀的替代材料，例如在用作装甲穿刺武器的抛射体。目前，贫铀用于这种装甲耐穿刺应用，但是贫铀是有毒材料，而国际上正集中努力消除在武器使用中产生的相同问题。
更一般而言，这种碳孔隙浸渍能够用于形成结构上的分级材料，其中孔隙浸渍到多孔碳的一定深度或尺寸，或其中采用扩散特性而在多孔碳材料的一定深度或尺寸之内提供浸渍剂的浓度梯度。
其他能够用于本发明具体实施方式的坚硬浸渍剂包括而不限于，铅、钛、铝、氧化铝、硅、氧化硅等。
使用浸渍剂至少部分填充多孔碳材料的孔隙能够产生新的复合材料，且有能力以生料状态产生宽变化范围的构型和结构形式，该生料状态随后转化成具有所需形状和/或功能特性的材料，例如用于装甲穿刺子弹和相应密集的装甲的超硬和/或超密材料。
在本发明的其他实施方式中，多孔碳引入硼以提供高氢负载容量的氢储存介质。然后，硼化的多孔碳就能负载氢，以便通过该多孔碳储存氢，并且在分配条件下由此释放出氢以提供氢，例如用于氢燃料电池或其他用氢设备或过程。以这种方式，含硼多孔碳提供的氢储存介质具有很高的负载容量，这能够用于诸如氢能源交通工具的应用中。
硼能够以任何合适的方式及通过任何合适的技术引入到多孔碳材料中。在一种优选的实施方式中，硼通过离子注入可至少部分地引入到多孔碳材料中，复合采用硼的离子注入和气相沉积或溶液沉积技术的复合，能够用于产生具有所需性能的含硼碳材料。
本发明的另一方面涉及使用多孔碳作为负压储存条件下的氯储存介质。尽管多孔碳此前已经用作宽变化范围的能够吸附于这种材料上的流体和气体的储存介质，但是由于液体通常比气体所占体积要小许多数量级，并且因为氯通常以加压液体的形式进行储存和运输，所以并未考虑氯气用于这种储存应用。
然而，这种氯的加压液态形式产生了安全和毒性问题，尤其是所涉及的氯的用量很大时。例如，2005年1月6日Norfolk SouthernCorp运载化学品的货运火车撞上了Avondale Mills Plant inGraniteville，South Carolina，USA附近停靠的火车。货车所载化学品就包括加压液氯。作为碰撞事故的结果，有毒氯气释放到碰撞地点周围的空气中，导致10多人死亡，附近住所的5000居民需要疏散。
气态形式的氯作为多孔碳上的被吸附物进行储存，从初始考虑，作为包装氯的模式并未显现出经济上的可行性或可实践性，但令人惊讶的是，人们发现，当保持(hold)加压液氯的封闭体积的负载容量相比于负压下其上具有吸附的氯气的等体积多孔碳的容量时，多孔碳的实际容量超过了高压液体容纳体积(containmentvolumn)约30％。
由于在Graniteville，South Carolina，USA碰撞地点的氯灾难性释放，在低于大气压下，在盛装多孔碳吸附剂的管式拖车型轨道车中相同数量的氯气的运输(如Norfolk Southern Corp.货运火车所载的)，与导致所发生的死亡和损毁的高压释放相比，将会使氯气释放速率降低约1/100,000。
与相应的加压液氯的封闭体积的容量相比，通过在多孔碳上的气态氯储存能够实现氯储存中容量的惊人改进，这是由于以下事实：封闭体积以能够储存的加压液氯的数量而受限制，因为在封闭体积的环境温度变化能够导致蒸发、气体膨胀以及密封结构的破裂。因此，支持加压液氯的封闭体积必须进行设计，并用于适应封闭体积所在的环境温度的升高，以及来自液氯的蒸发和气体膨胀。
然而，在负压下在多孔碳上的气态氯的储存中，气态氯通过物理吸附力而固定在多孔碳吸附剂上，使得相比于通过支持加压液氯的相应的体积所能达到的，在负压下能够更加有效地使用容纳多孔碳肌肤及的体积。因此，由于在多孔碳上吸附氯气的负压气体储存条件，伴随高度安全改进，实现了氯储存容量惊人的及不可预期的改进。
因此，氯气能够有效地以吸附状态在负压下储存，而避免了与现有技术中加压液氯的储存和运输相关的危险，并显著地改进单位储存体积的氯的容量。在使用上，氯气通过任何合适的热介导解吸、压力梯度介导解吸和/或浓度梯度介导解吸技术易于从多孔碳吸附剂进行分配。例如，真空泵可以用于分配操作中以实现氯从多孔碳的解吸。
除了氯之外，这种基于吸附剂的储存与分配方法可以适用于氨，或适用于光气，或适用于其他工业气体。
现在参照附图，图1是根据本发明一种实施方式的浸渍碳结构构件10的透视图。浸渍的碳结构构件10由具有图中所示的前表面14的主体部分12构成。
浸渍的碳结构构件10可以是宽变化范围类型的制品的组成部分。这种组件例如可以由用长链芳香聚酰胺纤维，或以商标名Kevlar，PBO，Zorlon和Spectra商购的纤维，或用长链的硅树脂或聚乙二醇聚合物，或用碳化钨或其他金属碳化物浸渍的多孔碳制造而成。对于这种应用的多孔碳可形成或提供有任何合适孔径和孔径分布的孔隙，而适合该结构构件的最终用途。
结构构件自身能够适用于各种应用中的任何应用，如超韧性复合物体装甲、车载装甲、缓冲器构件或耐冲击元件，或作为用于军工制品结构或涂层的致密材料，作为皱折笔记本电脑、个人数字助手、极地运动手表和深海传感组件等的外罩材料。
浸渍剂组分可以以任何合适的方式沉积于多孔碳材料的孔隙中，诸如小孔的气相沉积(化学气相沉积、等离子体接触等)、溶液沉积、真空排空和高压浸渍、或任何有效地向多孔碳的孔隙中引入增强组分或其前体的其他技术或方法。
图2是根据本发明的一种实施方式的流体储存与分配装置42的示意性正视图，在工艺过程***40中设计用于向流体利用设施56供给流体。
如所示的流体储存与分配设备42包含一个容纳吸收介质48的流体储存和分配的容器44，该吸收介质能够按以下形式由多孔碳材料形成：以不连续的(例如珠状或颗粒)形式、或可替换地以单片整体形式，诸如一个或多个多孔碳吸附剂制品，其中每一个可以按砖状、块状、盘状、薄板状或其他形状用于使用流体的应用中的流体如气体的储存和分配。
容器44在其上部颈区域连接到包括在阀体中的流量控制阀元件(未显示)的阀头组件46，该阀体能够在操纵盘50的控制作用下在全开位置和全关闭位置之间进行转换，而实现流体从容器44进行排放。打开该阀门，把容器44的内部体积暴露于耦合于阀头组件的排放端口的线52中的低压，使容器中的多孔碳吸附剂介质上吸附的流体解吸而流过阀头中的阀且流过排放端口进入流体排放线52进行分配。
流体能够以任何合适的方式从容器44进行分配，例如其中的分配包括至少一种选自热介导解吸、压力梯度介导解吸和浓度梯度介导解吸的组成的组的分配形态。
在线52中的分配的流体流过流量控制单元54而达到流体利用设施56。流量控制单元可以包括任何合适的流量控制设备或流量调节元件，例如，稳定器(调节器，regulator)、质量流量控制器、限流孔、流量控制阀、泵、压缩机、文丘里管、喷射器、流量修匀容器(flow-smoothing surge vessel)等。流量控制单元可以包括例如从容器提取流体的真空泵。
流体利用设施56可以是任何合适的类型，适用于待传送的具体流体。该设施可以是例如制造性工艺设施、化学反应器、分配或混合设施等。
在本发明的一种实施方式中，容器44中的多孔碳48含有浸渍到碳介质的孔隙中的硼，例如由前体如乙硼烷、硼氢化物或其他硼源材料通过硼的离子注入进入到孔隙，并且作为氢气的储存介质。在分配条件下，氢气从吸附剂介质解吸，流进分配线52而到达氢利用设施56，其可以是由氢燃料电池单元构成，其中氢燃料用于产生功率输出，例如，车辆推动力。
在本发明的另一种实施方式中，容器44中的多孔碳48含有吸附于其上的氯气，用于储存氯和用于其从容器选择性地进行分配。代替所示气体供给圆筒的容器，可以设计成管式拖车容器(tubetrailer container)，或轨道车容器(railcar vessel)，用于氯的机动运输。通过这种在多孔碳吸附剂介质上以吸附状态的氯的吸附性固定，与现有技术的高压气体容器相比，氯可保持本质上更安全的状态。
正如此处先前所指出的，这种基于吸附剂的储存和分散装置，可以应用于光气、氨或其他工业气体，与现有技术的高压密封结构相比，以本质上更安全的形式储存和运输这些气体。
尽管本发明已经在此处参照了本发明的具体方面、特征和示例性实施方式进行了描述，但是应该理解到，本发明的效用并不仅限于此，而应当扩展涵盖许多其他变体、修改和可替换的实施方式，基于此处所披露的内容，将会把本发明暗示于本发明领域的普通技术人员。相应地，按照以下的权利要求本发明预想在其精神和范围内广泛地进行阐释和解释，这包括所有的这些变体、修改和可替换的实施方式。

Claims (15)

1.一种具有孔隙的多孔碳复合物，包括含有小孔的材料，所述材料选自硅树脂、聚乙二醇、聚合物纤维、芳族聚酰胺纤维、碳化钨、铅、铝、氧化铝、氧化硅和硼。
2.根据权利要求1所述的多孔碳复合物，其中所述孔隙的平均孔径小于10纳米。
3.根据前述权利要求中任一项所述的多孔碳复合物，其中所述材料包括硅树脂。
4.根据前述权利要求中任一项所述的多孔碳复合物，其中所述材料包括聚乙二醇。
5.根据前述权利要求中任一项所述的多孔碳复合物，其中所述纳米多孔碳包含PVDC烧制材料，所述PVDC烧制材料的总孔隙的至少30％由尺寸在约0.3至约0.72纳米范围内的狭缝形状小孔构成，并且所述总孔隙的至少20％包含直径小于2纳米的小孔，且散密度为每立方厘米约0.80至约2.0克。
6.根据前述权利要求中任一项所述的多孔碳复合物，其中所述材料包括芳族聚酰胺纤维。
7.根据前述权利要求中任一项所述的多孔碳复合物，其中所述材料是在所述孔隙中原位生成的反应产物。
8.根据前述权利要求中任一项所述的多孔碳复合物，其中所述材料包括碳化钨。
9.根据前述权利要求中任一项所述的多孔碳复合物，其中所述材料包括选自由铅、铝、氧化铝和氧化硅组成的组中的至少一种材料。
10.根据权利要求1所述的多孔碳复合物，其中所述材料包括离子注入硼。
11.一种包含根据权利要求10所述的多孔碳复合物的氢储存***。
12.一种包含根据权利要求10所述的多孔碳复合物的氢燃料产生能量***。
13.根据权利要求1所述的多孔碳复合物，其中所述材料包括硼。
14.一种制造复合物的方法，包括向多孔碳的小孔中引入选自硅树脂、聚乙二醇、聚合物纤维、芳族聚酰胺纤维、碳化钨、铅、铝、氧化铝、氧化硅和硼的材料。
15.一种产生能量的方法，包括使用包含含硼的多孔碳的氢储存介质。
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