Secondary batteries containing electrode material obtained by pyrolysis

Abstract: An electrode material is made of a carbonaceous mate­ rial obtained by the pyrolysis of an organic compound capable of forming the graphite structure. This carbonaceous material is such that the spacing of (002) planes, d002, is at least 3.37Å and the crystallite size in the directionof c axis, Lc, is not more than 220 Å, as determined by X-ray wide-angle diffractiometry, and the line width pp between peaks in the first differential of the absorption spectrum of electron spin resonance is at least 10 gauss. Classes of organic compound wherein C - C bonds change to a benzene structure on pyrolysis are disclosed. Pyrolysis can be at 300-3,000 for 10 minutes to 20 hours. The electrode material can be in various forms and is capable of providing a stable secondary battery that pro­ duces high electromotive force and which has high energy density.

Description: The present invention relates to a secondary battery containing an electrode material that is made of a carbonaceous material having a specific pseudographite structure and electron state and which is capable of making a lightweight and non-polluting electrochemical cell having high energy and maximum power densities. In order to meet the recent requirement for using less energy in industries and to make the most of the rapid progress of electronic devices, it is strongly desired to develop new batteries which are light in weight and small in size and which produce great electromotive force and exhibit high maximum power and energy densities. The present invention provides such a secondary battery. Positive and negative electrodes made of the material specified hereinafter are submerged in a specified liquid electrolyte, and an electromotive force is then readily generated by applying an external voltage so that the positive electrode is doped with negative ions, and the negative electrode with positive ions. Thereafter, the electrodes are connected to an external load and a current is caused to flow by removing the respective ions from the positive and negative electrodes. This cycle of doping ions and removing them can be used as electrochemical charge and discharge reactions in the battery. A battery may also be constructed by using one electrode which is made of the material specified in the present invention and the other electrode made of a known material. The use of carbonaceous materials as electrode materials is already known. For example, it is reported in J. Electrochem. Soc., 125, 687 (1978) that when metallic lithium is used as the negative electrode and graphite as the positive electrode, BF 4 - , ClO 4 - or I - can be doped between graphite layers during charging and such ions are removed by discharging, thus producing reversible charge-discharge cycles. However, the negative ions doped between graphite layers repel each other and this puts limits on the amount of negative ions that can be doped electrochemically. Furthermore, the cell produces an energy density as low as 100 W.h/kg and no higher energy densities can be obtained. If graphite is used as the negative electrode, positive ions such as Li + ions can be doped between graphite layers but such positive ions are very unstable within the liquid electrolyte and will easily react with it. The use of activated carbon fibers as the material for the two electrodes is disclosed in Japanese Patent Application (OPI) Nos. 58-35881 and 59-149654. But the cells using such electrode materials generate an electromotive force as low as 1.2 to 2.9 volts. The cells have low energy densities while experiencing high self-discharge after charging. Japanese Patent Application (OPI) No. 58-93176 proposes a cell configuration that uses as the material for both electrodes a carbonaceous pyrolyzed polymer. But this cell produces low electromotive forces in the range of 1.2 to 1.4 volts and their short circuit current is as low as 30 µmA ta 4 mA. Additionally, the cell has a fairly low energy density. The polymer material is selected from those which by calcination, under a reaction such as dehydrogenation and dechlorination, to thereby form a compound having a conjugation system. Examples of polymer materials include polyacrylonitrile; polyvinyl chloride; polyvinylidene chloride; polyoxydiphenylene; polyimides, such as pyromellitic imide, polybenzoxazole imide, polyimidazopyrrolon imide, polyamide imide and polyhydrazide imide; polyamide; polysemicarbazide; polybenzoxyazinone and the like. The polymer material calcination product employed can also be obtained by the calcination of other types of material, for example, pitch. The use of an electroconductive polymer (e.g., polyacetylene or polyparaphenylene) as an electrode material is reported in Kotai Butsuri (Solid-State Physics), 17 (12) , 753 (1982). When polyethylene was used as the material for both electrodes, the cell generated an electromotive force of 2.5 volts, an energy density of 150 W.h/hr and a maximum power density of 17 kW/kg. When a negative electrode made of metallic lithium and a positive electrode made of the polymeric material were used, the respective cell parameters were 3.5 volts, 290 W.h/kg and 3.5 kW/kg. In spite of these good values for cell performance, polyacetylene is unstable and is highly sensitive to oxidative deterioration, causing adverse effects on the cell performance such as cycle life. Furthermore, polyacetylene and polyparaphenylene are not easily dissolvable or meltable and cannot be shaped into various forms of electrodes by ordinary methods. The present inventors made various studies to obtain an electrode material that is stable, generates a great electromotive force, has high maximum power and energy densities and which can be easily shaped into a variety of electrode forms. According to this invention we provide a secondary battery wherein at least one electrode is made of an electrode material which is a carbonaceous material obtained by pyrolyzing an organic compound capable of forming the graphite structure, said carbonaceous material having such a pseudo-graphite structure that the spacing of (002) planes, d002, is 3.37 to 3.70 x 10 -10 m (3.37 to 3.70 Å) and the crystallite size in the direction of c axis, Lc, is 7.0 to 220 x 10 -10 m (7 to 220 Å), as determined by X-ray wide-angle diffractiometry, and the line width Hpp between peaks in the first differential of the absorption spectrum of electron spin resonance is at least 10 gauss and the distance a o , which is twice the spacing of the (110) planes, d110, is at least 2.37 x 10 -10 m (2.37 Å) and not more than 2.47 x 10 -10 m (2.47 Å), and the crystallite size in the direction of an axis, La, is from 10 to 80 x 10 -10 m (10 to 80 Å), the electrodes being submerged in an electrolyte selected from alkali metal salts, alkaline earth metal salts and tetraalkylammonium salts, so that the electrode material is doped with negative ions or positive ions, thereby making the material suitable for use an electrode for a secondary battery. In the accompanying drawings: Fig. 1 is a sketch for the first differential of the absorption spectrum of electron spin resonance, together with the definition of an inter-peak line width ΔHpp; Fig. 2 shows the concept of the behaviour of the inter-peak line width ΔHpp that is divided into six regions, A, B, C, D, E and F as a function of the graphitization temperature; and Figs. 3 to 7 are the first differential of the absorption spectra of electron spin resonance that were obtained for the carbonaceous materials prepared in several of the Examples and Comparative Examples that are given later in this specification. The electrode material used in accordance with the present invention has a pseudo-graphite structure obtained by the pyrolysis of an organic compound capable of forming the graphite structure. The organic compound capable of forming the graphite structure as used in the present invention is such an organic compound that its carbon-carbon bonds will change to a benzene ring structure upon reactions such as decomposition and condensation and that a continuous one-and two-dimensional bonding of such benzene rings forms a plurality of stacked polycyclic aromatic planes. The following compounds may be pyrolyzed to produce carbonaceous material having a pseudo-graphite structure in accordance with the present invention: A) naphthalene, perylene, terrylene, pyrene, chrysene, or coronene; B) a tetracarboxylic acid dianhydride of naphthalene, perylene, terrylene, pyrene, chrysene, or coronene; C) a corresponding tetracarboxylic acid substituted compound of naphthalene, perylene, terrylene, pyrene, chrysene, or coronene. The organic compounds capable of forming the graphite structure are pyrolyzed either in vacuum or under an inert gas (e.g., nitrogen or argon) stream or an oxidizing gas (e.g., air) stream or a mixture of such streams. Usually, the organic compounds are pyrolyzed in vacuum or under an inert gas stream. The mechanism of the pyrolysis is hereunder described with reference to naphthalene-1,4,5,8-tetracarboxylic acid dianhydride of group (A): When (A) is heated with a thermal energy greater than the dissociation energy necessary to break the bond between the skeletal carbon and an adjacent hydrogen atom or a substituent, carbon radicals (B) are formed predominantly by homolytic cleavage. A chain of carbon radicals is cyclized to provide a higher molecular weight and the process of graphitization occurs that is characterized by the development of polycyclic aromatic planes. In the initial stage of qraphitization, benzene rings are bound together one-dimensionally to form a one-dimensional graphite structure (C). Subsequently, the benzene rings start to bind with one another two-dimensionally, and gradually expanding polycyclic aromatic planes begin to stack in layers to form a two-dimensional graphite structure (D). The same phenomenon will occur in the pyrolysis of other organic compounds capable of forming the graphite structure; the one-dimensional graphite structure (C) forms as a result cf thermal decomposition or condensation, and subsequently a structure similar to the two-dimensional graphite structure (D) forms. With further progress of carbonization, more benzene rings are bound two-dimensionally and adequately expanded polycyclic aromatic planes stack one on another in an orderly manner to form the ordinary graphite. In accordance with the present invention, all structures that lead to the final graphite are collectively referred to as the pseudo-graphite structure. The organic compounds capable of forming the graphite structure may be carbonized not only by application of thermal energy but also by irradiation by light energy greater than the dissociation energy, as well as by irradiation by accelerated charged particles such as Br + or Ar + or by plasma irradiation. The graphitization reaction of the organic compounds may proceed in any one of the three states, molten, solid and gaseous. The carbonaceous material thus obtained in accordance with the present invention is very stable and will not deteriorate upon standing in air at room temperature. The pseudo-graphite structure in accordance with the present invention can be determined both qualitatively and quantitatively by X-ray wide angle diffractometry. The ordinary graphite shows a sharp diffraction peak corresponding to a (002) plane at about 28 = 26°. In the initial stage of graphitization of the organic compounds capable of forming the graphite structure, a diffraction peak corresponding to the (002) plane does not appear. The one-dimensional graphite obtained by further pyrolysis has a very broad diffraction peak corresponding to the (002) plane and its intensity is low. As two-dimensional polycyclic aromatic planes begin to stack one after another, the diffraction peak corresponding to the (002) plane gradually becomes sharp and its intensity increases. Tne pseudo-graphite structure which characterizes the carbonaceous material used in the present invention is such that the spacing of (002) planes, d002, is 3.37 to 3.67 x 10 -10 m (3.37. to 3.67 Å) and the crystallite size in the direction of axis, Lc, is 7 to 220 x 10 -10 m (12 to 220 Å). Preferably, d002 is 3.40 to 3.67 x 10 -10 m (3.40 to 3.67 Å) whilst Lc is 13 to 150 Å; and more preferably, d002 is 3.41 to 3.67 Å. The pseudo-graphite structure is also determined quantitatively by X-ray wide-angle diffractometry such that the distance a 0 (=2d110) twice the spacing of (110) planes; d110, is preferably at least 2.37 x 10- 10 (2.37 Å) and not more than 2.47 x 10 -10 m (2.47 Å), more preferably at leasr 2.37 x 10 -10 m (2.37 Å) and not more than 2.46 x 10 -10 m (2.46 Å). In the preferred pseudo-graphite structure, the crystallite size in the direction of an axis, La, is not more than 200 x 10 -10 m (200 Å). More preferably, La is at least 7.0 x 10 -10 m (7.0 Å) and not more than 150 x 10 -10 m (150 Å), with the range of 10 to 80 x 10 -10 m (10 to 80 Å) being particularly preferred. The electron state of the carbonaceous material used in the present invention is determined quantitatively by electron spin resonance spectroscopy. More specifically, the line width (ΔHpp in gauss) between peaks in the first differential of the absorption spectrum of electron spin resonance as shown in Fig. 1 is used as the factor for determining the electron state of the carbonaceous material. The line width ΔHpp is at least 10 gauss. Fig. 2 shows the concept of the behaviour of ΔHpp as a function of the carbonization temperature for the condensed polycyclic hydrocarbon compound and polycyclic heterocyclic compound used as the organic compound capable of forming the graphite structure. According to the finding of the present inventors, the behaviour of ΔHpp can be divided into six regions, A to F. Region A corresponds to the initial stage of carbonization and the value of Hpp is smaller than 7 (indicating a very sharp peak in the spectrum) and either remains constant or decreases slightly with the increasing temperature. In region B, Hpp increases gradually and is in the range of 7 ≤ΔHpp≤10. Region B may contain an extension of region A having a sharp peak (ΔHpp≤7), as indicated by the dashed line. In region C, ΔHpp increases rapidly and is in the range of 10<ΔHpp∋1000. Region C may also contain an extension of region A having a sharp peak (ΔHpp<7), as indicated by the dashed line. In region D, a hyperbroad peak exists in the spectrum and ΔHpp>1000. In some cases, it is apparently impossible to detect the absorption spectrum in region D. The exact reason for this is not clear but the existence of a hyperbroad peak would be the primary cause. In region E, ΔHpp decreases and is in the range of 7≤ΔHpp≤1000. In region F, a sharp peak appears again and ΔHpp is smaller than 7. The horizontal axis of the graph in Fig. 2 indicates the graphitization temperature, but it should be understood that given the same graphitization temperature, ΔHpp may vary and belong to different regions depending upon other conditions for graphitization such as the rate of temperature increase and the period for which said graphitization temperature is retained. In an extreme case, there may exist no distinct separation between each region. It is not clear what the electron states ranging from regions A to F mean in physical terms. Most probably, the peaks in regions A and B may be explained by unpaired electrons that exist stably in the long conjugated chain. Conduction electrons would be responsible for the peaks in regions C, D, E and F. Conduction electrons may make some contribution to the peak in region B. For the purpose of the present invention, the electron states in regions C, D and E having ΔHpp not smaller than 10 gauss are necessary. Electron states having ΔHpp of at least 12 gauss are preferred, with ΔHpp of at least 15 gauss being particularly preferred. when organic polymeric compounds are used as the organic compounds capable of forming the graphite structure, the behaviour of their values of ΔHpp as a function of the graphitization temperature is not necessarily the same as shown in Fig. 2. But even in this case, the line width, ΔHpp, between peaks in the first differential of the absorption spectrum of electron spin resonance must be at least 10 gauss. Some carbonaceous materials prepared for use in the present invention may exhibit two or more signals in the first differential of the absorption spectrum of electron spin resonance, and even such materials are included within the scope of the present invention if at least one of the signals has an interpeak line width, ΔHpp, of 10 gauss or more. Carbonaceous materials may also be obtained that have no clearly distinguishable signals in the first differential of the absorption spectrum electron spin resonance; such materials are also included within the scope of the present invention if there exists no signal having an interpeak line width, ΔHpp, of less than 10. The pyrolysis temperature relates to the degree of growth of the intended polymer conjugate. In order to achieve a balance between the ease of doping electrolyte ions, the stability of doped charges and the electrical conductivity of undoped polymer conjugate, the proper pyrolysis temperature is selected preferably from the range of 300 to 3,000°C, more preferably from the range of 400 to 2,500°C. The pyrolysis period is generally at least 5 minutes and the preferred range is from 10 minutes to 20 hours. The range of 20 minutes to 10 hours is particularly preferred. By providing a larger specific surface area for the electrode material formed, a battery capable of producing a higher maximum power density can be obtained. Therefore, in order to ensure a high maximum power density, the shaped article of the electrode material formed or a shaped article containing such electrode material preferably has a specific surface area of at least 10 m 2 /g, more preferably at least 50 m 2 /g, and most preferably at least 100 m 2 /g. This object can be attained by pyrolyzing the organic compound either under an oxidizing gas (water vapor, or CO 2 ) stream or under a stream of a mixture of such oxidizing gas and an inert gas. Another effective way is to perform a preliminary pyrolysis under an inert gas stream, followed by another pyrolyzing step under an oxidizing gas stream or under a stream of a mixture of an oxidizing gas and an inert gas. The organic compound to be pyrolyzed is shaped to a variety of forms such as fibres, powders, granules, films, sheets and felt. Electrode materials in a fibrous, powder or granular form may be used as cell electrodes after they are shaped into the form of paper sheet or film by any of the known techniques. The carbonaceous material obtained by pyrolyzing the organic compound may be independently used as the electrode material of the present invention. If desired, such carbonaceous material may be supplemented with or supported on, a conductive material (e.g., carbon fibres), an insulating material or a reinforcing material. In this latter case, the amount of the electrode material in the shaped article is not limited to any particular value, but preferably, the electrode material is present in an amount of at least 50 wt%, with the range of 70 wt% and upward being particularly preferred. A variety of carbonaceous materials, metallic materials and conductive ceramics may be used as the conductive additives. Suitable insulating materials include ceramics such as Al 2 O 3 and SiO 2 , and glassy materials such as borosilicate glass and silicate glass. The organic compound used in the present invention may be supported on the conductive additive, insulating material or reinforcing materials by various methods. First, the organic compound is supported on the carrier by a suitable technique and the compound on the carrier is carbonized by heating. Suitable presupporting techniques include gasification at temperatures not higher than the thermal decomposition point of the compound, solubilization in a solvent and dispersion in the same. Secondly, the compound is first gasified by either evaporation or sublimation and then deposited on the carrier as graphitization proceeds. Thirdly, a molten compound is brought into contact with, or impregnated in, the carrier and then, is graphitized to make the compound on the carrier. The proportion of the carbonaceous material carried is not limited to any particular value, but the preferred range is from 0.1 to 99 wt%. The range of 1 to 97 wt% is particularly preferred. The electrode material used in the present invention may be used as either positive or negative electrode or both. The electrode material is submerged in an electrolyte to make a primary or secondary battery. Any of the known electrolytes may be used and they include tetraalkylammonium salts (counter anions are perchlorate ion, phosphorus hexafluoride ion, thallium hexafluoride ion, arsenic hexafluoride ion, antimony hexafluoride ion, halide ions, nitrate ion, sulfate ion and rhenium tetraoxide ion), alkali metal salts, alkaline earth metal salts (counter ions are the same as listed above), as well as halides, perchlorates and nitrates of transition metals, rare earth elements and noble metals. Any of the solvents that are commonly used in conventional batteries may be used, and they include water, dimethyl sulfoxide, acetonitrile, propylene carbonate, 4-butyrolactone, formamide, tetrahydrofuran and 1,2-dimethoxyethane. The batteries fabricated by using the electrode material of the present invention as shown above are stable, produce high electromotive force, have high maximum power and energy densities, and can be used with a variety of electrode shapes. The carbonaceous material in accordance with the present invention finds many other uses as electrical and electronic materials in solar cells, sensors, capacitors and conductors. The various parameters that characterize the carbonaceous material of the present invention are determined by the following respective methods (in the equation one Å unit = 10 -6 m). (1) d002, the spacing of (002) planes, and d110, the spacing of (110) planes: A powder of carbonaceous material (flaky carbonaceous material is reduced to a powder in an agate mortar) is packed into a sample cell together with ca. 15 wt% of the powder of an internal standard substance, a high-purity silicon powder of the standard grade for x-ray analysis. A wide-angle X-ray reflection diffractometer scan is obtained with monochromatic CuKα radiation from a graphite monochrometer. Instead of making corrections associated with the Lorentz factor, polarization factor, absorption factor and atomic scattering factor, the following simple and convenient method is used. Draw a baseline for the scan curves corresponding to diffractions at (002) and (110) planes. Plot the substantial intensities as calculated from the baseline, obtaining corrected curves for (002) and (110) planes. Draw an angular axis at a height which is two-thirds of the height of the peak in each curve and obtain the midpoint of the line defined by the two points where a line parallel to that angular axis intersects the scan curve. Correct the angle of the midpoint by the internal standard to obtain a value twice the angle of diffraction. Substitute this value and the wavelength of CuKα radiation, λ. into the following two equations of Bragg's law: d002 = λ 2sin Å d110 = λ 2sine Å wherein λ: 1.5418 A : the angle of diffraction corresponding to d002 or d110. (2) Crystallite size in c and a axes, Lc and La: Obtain the half-width β at a point half the height of the peak in each of the corrected scan curves prepared in (1), and substitute this value into the following equations: Lc = K·λ βcos Å La = K·λ βcos Å Various values may be taken for the shape factor K, but in the present inventicn, 0.90 is used. For the meanings of λ and , see (1), (3) Line width between peaks in the first differential of the absorption spectrum of electron spin resonance, ΔHpp: The first differential of the absorption spectrum of electron spin resonance was measured with JEOL HES-FE 1X ESR spectrometer in the X-band. A powder of carbonaceous material (flaky carbonaceous material is reduced tc a powder in an agate mortar) is put into a capillary tube (ID:1 mm) which is placed in an ESR tube (OD: 5 mm). The radio-frequency magnetic field is modulated by an amount of 6.3 gauss. All the procedures above are followed within air at 23°C. The value of ΔHpp is determined by comparison to a standard sample, Mn 2+ /MgO, (4) Elemental analysis: A sample is dried in vacuum at 120°C for ca. 15 hours. Then, the sample is transferred onto a hot plate in a dry hox and dried in vacuum at 100°C for 1 hour. A portion of the dried sample is put into an aluminum cup in an argon atmosphere, and the carbon content is determined from the weight of CO 2 gas evolved as a result of combustion whereas the hydrogen content is determined from the weight of H 2 O also evolved by combustion. In the Examples that follow, an elemental analyzer of Perkin-Elmer Model 240 C was used. The following Examples and Comparative Examples are provided to illustrate the invention. Units of crystal plane spacing are given in Ångstrom units as is customary; one Å = 10 -10 m. EXAMPLE 1-1 A powder of naphthalene-1,4,5,8-tetracarboxylic acid dianhydride was put in a magnetic crucible and preliminarily graphitized by heating at one atmosphere in a N 2 gas stream under the following conditions: the temperature was elevated to T R = 375°C at a rate of Vt = 10°C/mm, and that temperature was retained for Ht = 30 minutes. The powder was cooled to room temperature and again heated in N 2 stream to T R = 460°C at a rate Vt = 10°C/min., followed by holding for Ht = 30 minutes. The first differential of the absorption spectrum of electron spin resonance for the resulting flaky carbonaceous material is shown in Fig. 3, from which one can see that ΔHpp = 11.2 gauss. The intensity of a diffraction curve for the same material was weak; d002 = 3.67 Å and Lc = 13.0 Å. A portion (1.8 mg) of the carbonaceous material was wrapped with a platinum screen to make a positive electrode. This positive electrode and a metallic lithium negative electrode were submerged in an electrolyte (l.O M solution of lithium perchlorate in propylene carbonate) to make a battery. The battery was charged at 59 µA (5 µA/mg) for 333 minutes until 1.180 coulombs of electric charge (0.1 C/mg) was stored. The charged battery had an open circuit voltage Voc of 4.54 volts and was capable of producing high electromotive force. After charging, the battery was left to stand in the open circuit state; the self-discharge at 10th hour was 3.5%, indicating high stability of the battery. EXAMPLE 1-2 A powder of the same material as used in Example 1-1 was preliminarily graphitized by heating in a N 2 stream under the following conditions: Vt = 10°C/min., T R = 375°C and Ht = 30 min. The powder was cooled to room temperature and graphitized under the following conditions: Vt = 10°C/min., T R = 570°C and Ht = 30 min. A flaky carbonaceous material was obtained; ΔHpp = 110.4 gauss. The intensity of a diffraction curve for this material was weak: d002 = 3.67 Å and Lc = 13.1 Å. A battery was fabricated as in Example 1-1 using 16.9 mg of this carbonaceous material as a positive electrode. The battery was charged for 333 minutes at 84 µA (5 µA/mg) until the charge stored was 1.690 C (0.1 C/mg). The charged battery hada Voc of 4.50 volts and was capable of producing high electromotive force. After charging, the battery was left to stand in the open circuit state; the self-discharge at 10th hour was 4.6%, indicating high stability of the battery. EXAMPLE 1-3 A fiberglass filter (GA 200 of Toyo Roshi Kaisha Ltd.) was used as a carrier. A powder (ca. 100 mg) of the same material as used in Example 1-1 was put in a magnetic crucible and a rectangle of the fiberglass filter (26.6 mg) was buried in the powder. The powder was preliminarily graphitized by heating in N 2 stream under the following conditions: Vt = 10°C/min., T R = 375°C and Ht = 30 minutes. The powder was deposited onto the fiberglass filter by sublimation. The powder was cooled to room temperature and graphitized by another heating in N 2 stream under the following conditions: Vt = 10°C/min., T R = 520°C and Ht = 30 min. As a result of carrying the carbonaceous material, the fiberglass filter increased in weight to 31.8 mg. The carbonaceous material was uniformly carried on the filter in a proportion of 16.4%. The carried carbonaceous material had ΔHpp = 11.7 gauss. The intensity of a diffraction curve for this material was weak; d002 = 3.62 Å and Lc = 13.2 Å. The respective values of ΔHpp, d002 and Lc were determined using a pure carbonaceous material obtained by graphitization in magnetic crucible under the same conditions as used above. A battery was fabricated as in Example 1-1 using 31.8 mg of the fiberglass filter (corresponding to 5.2 mg of the pure carbonaceous material) as a positive electrode. The battery was charged for 250 minutes at 104 µA (20 µA/mg) until the charge stored was 1.645 C (0.32 C/mg). The charged battery had a Voc of 4.88 volts and was capable of producing high electromotive force, The charged battery had a high theoretical energy density, 370 w.h/kg. COMPARATIVE EXAMPLE 1-1 A powder of the same material as used in Example 1-1 was graphitized by heating ina N 2 stream under the following conditions: Vt = 10°C/min., T R = 375°C and Ht = 30 rain. A first differential of the absorption spectrum of electron spin resonance for the resulting powder of carbonaceous material is shown in Fig. 4, from which one can see that ΔHpp = 6.7 gauss. A battery was fabricated as in Example 1-1 using 23.7 mg of the carbonaceous material as a positive electrode. This battery was charged for 333 minutes at 118 µA (5 uA/mg) until the charge stored was 2.370 C (0.1 C/mg). With the progress of charging, the potential increased rapidly to give Voc which was as high as 5.38 volts, but when the charging was completed, a momentary voltage drop occurred. Additionally, the electrolyte turned yellow as the charging proceeded. Because of these problems, i.e., high overvoltage and decomposition of the electrolyte, the carbonaceous material prepared in Comparative Example 1-1 was not suitable for as an active material for battery electrodes. EXAMPLE 2-1 A powder of perylene-3,4,9,10-tetracarboxylic acid dianhydride was graphitized by heating in a N 2 stream under the following conditions: Vt = 10°C/min., T R = 570°C and Ht = 60 min. The first differential of the absorption spectrum of electron spin resonance for the resulting powder of carbonaceous material is shown in Fig. 5, from which one can see that ΔHpp = 105.1 gauss. The intensity of a diffraction curve for the same material was weak; d002 = 3.61 Å and Lc = 13.3 Å. Two portions (7.4 mg each) of the carbonaceous material was individually wrapped with a platinum screen to make positive and negative electrodes, which were separated by a fiberglass filter. The outer surfaces of the electrodes were also covered with a fibreglass filter, which was fixed by wrapping a polytetrafluoroethylene tape partly around the electrodes. A battery was fabricated by submerging both electrodes in an electrolyte which was composed of a 1.0 M solution of lithium perchlorate in propylene carbonate. This battery was charged for 667 minutes at 37 µA (5 µA/mg) until the charged stored was 1.480 C (0.2 C/mg). The charged battery had Voc = 3.25 volts and was capable of producing high electromotive force. Immediately after completion of the charging, the battery was shorted to produce a short circuit current Isc of 294 mA. The maximum power density Pmax was 14.5 kW per kg of the sum of the weight of the active material for both electrodes and that of doped ions. COMPARATIVE EXAMPLE 2-1 A powder of the same material as used in Example 2-1 was graphitized by heating in a N 2 stream under the following conditions: Vt = 10°C/min., T R = 530°C and Ht = 60 min. The resulting carbonaceous material had ΔHpp of 5.7 gauss. A battery was fabricated as in Example 2-1 by using two portions (10.0 mg each) of the carbonaceous material as positive and negative electrodes. The battery was charge for 667 minutes at 50 µA (5 µA/mg) until the charge stored was 2.000 C (0.2 C/mg). The potential between the elec trodes increased rapidly when a charge of about 1.26 C had been stored. Because of this excessively high overvoltage, the carbonaceous material prepared in comparative Example 2-1 was unsuitable for use as an active material for battery electrodes. EXAMPLE 2-2 A powder of the same material as used in Example 2-1 was graphitized by heating in N 2 stream under the following conditions: Vt = 10°C/min., T R = 920°C and Ht = 60 min. The first differential of the absorption spectrum of electron spin resonance for the resulting powder of carbonaceous material is shown in Fig. 6, from which one can see that ΔHpp = 1294 gauss. The intensity of a diffraction curve for the carbonaceous material was weak; d002 = 3.62 Å and Lc = 13.8 Å. A battery was fabricated as in Example 2-1 by using two portions (10.2 mg each) of the carbonaceous material as positive and negative electrodes. The battery was charged for 667 minutes at 51 µA (5 µA/mg) until the charge stored was 2.040 C (0.2 C/mg). The charged battery had Voc = 3.60 volts and was capable of producing high electromotive force. The short circuit current Isc of the battery was 298 mA and the maximum powder density Pmax was as high as 11.7 kw/kg. EXAMPLE 2-3 A powder of the same material as used in Example 2-1 was preliminarily graphitized by heating in N 2 stream under the following conditions: Vt = 10°C/min., T R = 920°C and Ht = 60 min. The powder was cooled to room temperature and graphitized by rapid heating in Ar stream to T R = 1,600°C at which temperature the powder was held for Ht = 60 min. The first differential of the absorption spectrum of electron spin resonance for the resulting powder of carbonaceous material is shown in Fig. 7, from which one can see that Hpp = 81.9 gauss. An X-ray diffractiometry gave d002 = 3.47 Å and Lc = 50.0 Å. A battery was fabricated as in Example 2-1 by using two portions (13.4 mg each) of the carbonaceous material as positive and negative electrodes. The battery was charged for 667 minutes at 67 µA (5 µA/mg) until the charge stored was 2.680 C (0.2 C/mg). The charged battery had Voc = 3.80 volts and was capable of producing high electromotive force. The battery had Isc = 380 mA and Pmax = 12.1 kW/kg.

Claims: A secondary battery wherein at least one electrode is made of an electrode material which is a carbonaceous material having a pseudo-graphite structure and being obtained by pyrolyzing any of the following compounds: A) naphthalene, perylene, terylene, pyrene, chrysene, or coronene; B) a tetracarboxylic acid dianhydride of naphthalene, perylene, terrylene, pyrene, chrysene, or coronene; C) a corresponding tetracarboxylic acid substituted compound of naphthalene, perylene, tecrylene, pyrene, chryseae, or coronene said carbonaceous material having such a pseudo-graphite structure that the spacing of (002) planes, d002, is 3.37 to 3.70 x 10 -10 m and the crystallite size in the direction of c axis, Lc, is 7.0 to 220 x 10- 10 m, as determined by x-ray wide-angle diffractiometry, and the line width ΔHpp between peaks in the first differential of the absorption spectrum of electron spin resonance is at least 10 gauss and the distance a o , which is twice the spacing of the (110) planes, d110, is at least 2.37 x 10 -10 m (2.37 Å) and not more than 2.47 x 10 -10 m (2.47 Å), and the crystallite size in the direction of a axis, La, is from 10 to 80 x 10 -10 m (10 to 80 Å), the electrode being submerged in an electrolyte selected from alkali metal salts, alkaline earth metal salts and tetraalkylammonium salts, so that the electrode material is doped with negative ions or positive ions, thereby making the same an electrode for a secondary battery. A secondary battery according to claim 1, wherein in the electrode material the spacing of (002) planes, d002, is at least 3.40 x 10 -10 m and the crystallite size in the direction of c axis, Lc, is at least 7 x 10 -10 m and not more than 150 x 10 -10 m, as determined by X-ray wide-angle diffractiometry. A secondary battery according to claim 1 or 2, wherein the line width (ΔHpp) between peaks in the first differential of the absorption spectrum is at least 12 gauss.

Inventors: ITSUBO AKIRA, MIYABAYASHI MITSUTAKA, NAKANO YOSHITOMO, TAKAHASHI MASAMI, UEDA MITSURU, ITSUBO, AKIRA, MIYABAYASHI, MITSUTAKA, NAKANO, YOSHITOMO, TAKAHASHI, MASAMI, UEDA, MITSURU
Applicants: MITSUBISHI CHEM CORP, MITSUBISHI CHEMICAL CORPORATION
Application year: 1985
Main classification: H01M4
IPC codes: H01M4, C04B35, H01M10