Title: System and method for forming activated carbon aerogels and performing 3D printing

Abstract

Making a carbon aerogel involves 3-D printing an ink to make a printed part, removing the solvent from the printed part, and carbonizing the printed part (with the solvent removed) to make the aerogel. The ink is based on a solution of a resorcinol-formaldehyde resin (RF resin), water, and an organic thickener. Advantageously, the RF resin contains an acid catalyst, which tends to produce carbon aerogels with higher surface areas upon activation than those produced from methods involving an ink composition containing a base catalyzed resin.

Inventors:

Chandrasekaran, Swetha; Baumann, Theodore F.; Worsley, Marcus A.

Issue Date:

Tue Sep 08 00:00:00 EDT 2020

Research Org.:

Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)

Sponsoring Org.:

USDOE

OSTI Identifier:

1735227

Patent Number(s):

10767062

Application Number:

15/613,630

Assignee:

Lawrence Livermore National Security, LLC (Livermore, CA)

Patent Classifications (CPCs):

B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29C - SHAPING OR JOINING OF PLASTICS

B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29K - INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS

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B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29C - SHAPING OR JOINING OF PLASTICS

B29C64/106 - using only liquids or viscous materials, e.g. depositing a continuous bead of viscous material

B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29K - INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS

B29K2061/04 - Phenoplasts
B29K2401/00 - Use of cellulose, modified cellulose or cellulose derivatives, e.g. viscose, as filler
B29K2509/02 - Ceramics

B - PERFORMING OPERATIONS B29 - WORKING OF PLASTICS B29L - INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

B29L2031/3406 - {Components, e.g. resistors}

B - PERFORMING OPERATIONS B33 - ADDITIVE MANUFACTURING TECHNOLOGY B33Y - ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING

B33Y10/00 - Processes of additive manufacturing
B33Y70/00 - Materials specially adapted for additive manufacturing
B33Y70/10 - Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
B33Y80/00 - Products made by additive manufacturing

C - CHEMISTRY C01 - INORGANIC CHEMISTRY C01B - NON-METALLIC ELEMENTS

C01B32/00 - Carbon
C01B32/05 - Preparation or purification of carbon not covered by groups C01B32/15, C01B32/20, C01B32/25, C01B32/30

C - CHEMISTRY C08 - ORGANIC MACROMOLECULAR COMPOUNDS C08G - MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS

C08G8/22 - Resorcinol

C - CHEMISTRY C09 - DYES C09D - COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS

C09D11/03 - characterised by features other than the chemical nature of the binder
C09D11/103 - of aldehydes, e.g. phenol-formaldehyde resins

H - ELECTRICITY H01 - BASIC ELECTRIC ELEMENTS H01G - CAPACITORS

H01G11/32 - Carbon-based, e.g. activated carbon materials
H01G11/52 - Separators
H01G11/86 - specially adapted for electrodes

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DOE Contract Number:  

AC52-07NA27344

Resource Type:

Patent

Resource Relation:

Patent File Date: 06/05/2017

Country of Publication:

United States

Language:

English

Subject:

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CHEMISTRY; 36 MATERIALS SCIENCE