Title: High surface area silicon carbide-coated carbon aerogel

Abstract

A metal oxide-carbon composite includes a carbon aerogel with an oxide overcoat. The metal oxide-carbon composite is made by providing a carbon aerogel, immersing the carbon aerogel in a metal oxide sol under a vacuum, raising the carbon aerogel with the metal oxide sol to atmospheric pressure, curing the carbon aerogel with the metal oxide sol at room temperature, and drying the carbon aerogel with the metal oxide sol to produce the metal oxide-carbon composite. The step of providing a carbon aerogel can provide an activated carbon aerogel or provide a carbon aerogel with carbon nanotubes that make the carbon aerogel mechanically robust. Carbon aerogels can be coated with sol-gel silica and the silica can be converted to silicone carbide, improved the thermal stability of the carbon aerogel.

Inventors:

Worsley, Marcus A; Kuntz, Joshua D; Baumann, Theodore F; Satcher, Jr, Joe H

Issue Date:

2014-01-14

Research Org.:

Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)

Sponsoring Org.:

USDOE

OSTI Identifier:

1117677

Patent Number(s):

8629076

Application Number:

13/051,915

Assignee:

Lawrence Livermore National Security, LLC (Livermore, CA)

Patent Classifications (CPCs):

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02E - REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

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C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA

C04B41/5035 - {Silica}

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02E - REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

Y02E60/13 - Ultracapacitors, supercapacitors, double-layer capacitors

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

B01J21/06 - Silicon, titanium, zirconium or hafnium
B01J35/004 - {Photocatalysts}

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y10 - TECHNICAL SUBJECTS COVERED BY FORMER USPC Y10T - TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

Y10T428/2982 - Particulate matter [e.g., sphere, flake, etc.]

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA

C04B2235/80 - Phases present in the sintered or melt-cast ceramic products other than the main phase

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

B01J23/70 - of the iron group metals or copper

B - PERFORMING OPERATIONS B82 - NANOTECHNOLOGY B82Y - SPECIFIC USES OR APPLICATIONS OF NANOSTRUCTURES

B82Y30/00 - Nanotechnology for materials or surface science, e.g. nanocomposites

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y10 - TECHNICAL SUBJECTS COVERED BY FORMER USPC Y10T - TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

Y10T428/249967 - Inorganic matrix in void-containing component
Y10T428/2993 - Silicic or refractory material containing [e.g., tungsten oxide, glass, cement, etc.]

H - ELECTRICITY H01 - BASIC ELECTRIC ELEMENTS H01G - CAPACITORS

H01G11/36 - Nanostructures, e.g. nanofibres, nanotubes or fullerenes

H - ELECTRICITY H01 - BASIC ELECTRIC ELEMENTS H01M - PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY

H01M4/58 - of inorganic compounds other than oxides or hydroxides, e.g. sulfides, selenides, tellurides, halogenides or LiCoFy

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA

C04B2235/3418 - Silicon oxide, silicic acids, or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
C04B41/5068 - {Titanium nitride}

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

B01J35/04 - Foraminous structures, sieves, grids, honeycombs

H - ELECTRICITY H01 - BASIC ELECTRIC ELEMENTS H01M - PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY

H01M4/48 - of inorganic oxides or hydroxides

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA

C04B35/532 - containing a carbonisable binder

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

B01J21/185 - {Carbon nanotubes

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA

C04B35/83 - Carbon fibres in a carbon matrix
C04B2235/606 - Drying

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

B01J27/22 - Carbides

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA

C04B2235/3895 - Non-oxides with a defined oxygen content, e.g. SiOC, TiON
C04B41/4556 - {coating or impregnating with a product reacting with the substrate, e.g. generating a metal coating by surface reduction of a ceramic substrate}
C04B38/00 - Porous mortars, concrete, artificial stone or ceramic ware
C04B2235/77 - Density

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

B01J27/224 - Silicon carbide
B01J21/063 - {Titanium

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA

C04B41/87 - Ceramics
C04B2235/441 - Alkoxides, e.g. methoxide, tert-butoxide

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

B01J23/06 - of zinc, cadmium or mercury

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA

C04B2235/616 - Liquid infiltration of green bodies or pre-forms
C04B2235/46 - Gases other than oxygen used as reactant, e.g. nitrogen used to make a nitride phase
C04B2235/3856 - Carbonitrides, e.g. titanium carbonitride, zirconium carbonitride
C04B41/455 - {the coating or impregnating process including a chemical conversion or reaction}

H - ELECTRICITY H01 - BASIC ELECTRIC ELEMENTS H01G - CAPACITORS

H01G11/46 - Metal oxides, e.g. ruthenium oxide

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

B01J21/18 - Carbon

H - ELECTRICITY H01 - BASIC ELECTRIC ELEMENTS H01G - CAPACITORS

H01G11/32 - Carbon-based, e.g. activated carbon materials

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

B01J37/084 - {Decomposition of carbon-containing compounds into carbon}

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA

C04B2235/3886 - Refractory metal nitrides, e.g. vanadium nitride, tungsten nitride
C04B41/457 - {Non-superficial impregnation or infiltration of the substrate}
C04B41/5059 - {Silicon carbide}
C04B2235/3826 - Silicon carbides

C - CHEMISTRY C02 - TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE C02F - TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE

C02F1/4691 - {Capacitive deionisation}

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y10 - TECHNICAL SUBJECTS COVERED BY FORMER USPC Y10T - TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

Y10T428/2918 - including free carbon or carbide or therewith [not as steel]

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA

C04B41/5041 - {Titanium oxide or titanates}
C04B35/624 - Sol-gel processing

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

B01J33/00 - Protection of catalysts, e.g. by coating

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y10 - TECHNICAL SUBJECTS COVERED BY FORMER USPC Y10T - TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

Y10T428/249957 - Inorganic impregnant

H - ELECTRICITY H01 - BASIC ELECTRIC ELEMENTS H01M - PROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY

H01M4/366 - {as layered products}

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA

C04B35/52 - based on carbon, e.g. graphite
C04B41/5061 - {Titanium carbide}

B - PERFORMING OPERATIONS B01 - PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL B01J - CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY

B01J23/34 - Manganese

Y - NEW / CROSS SECTIONAL TECHNOLOGIES Y02 - TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE Y02E - REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION

Y02E60/10 - Energy storage

C - CHEMISTRY C04 - CEMENTS C04B - LIME, MAGNESIA

C04B2235/652 - Reduction treatment
C04B2235/5288 - Carbon nanotubes
C04B41/4537 - {by the sol-gel process}
C04B41/009 - {characterised by the material treated}
C04B2235/3232 - Titanium oxides or titanates, e.g. rutile or anatase
C04B35/62655 - {Drying, e.g. freeze-drying, spray-drying, microwave or supercritical drying}

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DOE Contract Number:  

AC52-07NA27344

Resource Type:

Patent

Resource Relation:

Patent File Date: 2011 Mar 18

Country of Publication:

United States

Language:

English

Subject:

36 MATERIALS SCIENCE