Porous active carbon prepared from aromatic condensation polymer and use thereof in electrodes for electrochemical cells

Abstract: An insoluble and infusible substrate with a polyacen-type skeletal structure having a hydrogen/carbon atomic ratio of from 0.05 to 0.60 and containing open pores having an average diameter of not more than 10 micrometers, said substrate being a heat-treated, escpacially carbonized, product of an aromatic condensation polymer consisting of carbon, hydrogen and oxygen. The substrate, when doped with a dopant, gives an electrically conductive material. When having a specific surface area of at least 600 m²/g, the substrate is especially useful as an electrode of an organic cell.

Description: This invention relates to an organic electrolyte cell comprising a positive electrode, a negative electrode and an electrolytic solution, one or both of said positive and negative electrodes being composed of porous active carbon having a specified surface area and containing open pores. In recent years, there has been an increased tendency toward the reduction of the size, thickness and weight of electronic devices, and this has led to the need to reduce the size, thickness and weight of a cell constituting a power supply for the electronic devices. Nowadays, silver oxide cells find extensive use as a small-sized electric cell having high performance, and furthermore, lithium cells have been developed and come into commercial acceptance as a dry cell of a small thickness or a small-sized light-weight high-performance cell. Since, however, these cells are primary cells, they cannot be used for long periods of time by repeating charging and discharging. On the other hand, nickel and cadmium cells have been commercially used as a secondary cell of high performance, but have been found to be unsatisfactory in regard to the reduction of size, thickness and weight. Lead batteries have long been used in various industrial fields as secondary cells of a large capacity, but suffer from the defect of having large weight. This cannot be avoided since they use lead peroxide and lead as electrodes. Attempts have recently been made to reduce the size of these batteries and improve their performance in order to use them as cells for electric automobiles, but have not proved to be commercially successful. There is still a strong demand for secondary cells having a large capacity and light weight. As stated above, the cells now in commercial use have their own advantages and disadvantages, and are used selectively according to the intended uses. There has, however, been a strong need for the reduction of the size, thickness or weight of the cells. As a cell meeting such a need, a cell has recently been studied and proposed in which a thin film-like polyacetylene, i.e. an organic semiconductor, doped with an electron donating or accepting substance is used as an electrode active substance. This cell is a secondary cell having high performance and has a possibility of being reduced in thickness and weight. But it has the serious dedfect that polyacetylene is a very unstable substance which is easily oxidized by oxygen in air or thermally degenerated. Accordingly, an electric cell from this material must be produced in an inert gaseous atmosphere. In addition, there is a restriction on the production of polyacetylene in a form suitable as electrodes. Japanese Laid-Open Patent Publication No. 35881/1983 proposes an electrochemical cell comprising carbon fibers having a specific area of 1,000 to 10,000 m 2 /g as at least one of its electrodes. The specification of this Publication shows that the carbon fibers have a diameter of 10 to 20 micrometers, and are formed into a sheet or the like for use as an electrode. An object of this invention is to provide an organic electrolytic cell. A further object of this invention is to provide an organic electrolytic cell having a large capacity per unit weight and a high energy density. A further object of this invention is to provide an economical organic electrolytic secondary cell which can be reduced in size, thickness and weight and is easy to produce. A further object of this invention is to provide a secondary cell which has a high electromotive force and a low internal resistance and can be charged and discharged over a long period of time. According to the present invention, the above objects and advantages are achieved by an organic electrolyte cell comprising a positive electrode, a negative electrode and an electrolytic solution, one or both of said positive and negative electrodes being composed of porous active carbon having a specific surface area, measured by the BET method, of at least 600 m 2 /g and containing open pores having an average pore diameter of 0,2 to 10 micrometers, said porous active carbon being a carbonized product of an aromatic condensation polymer consisting of carbon, hydrogen and oxygen, and said electrolytic solution being a solution in an aprotic organic solvent of a compound capable of forming ions which can dope said electrode by electrolysis. In the accompanying drawing:- Figure 1 is an electron micrograph of the section of a porous active carbon film in accordance with this invention; In this micrographs, the thick line shown at right bottom measures 5 micrometers. The aromatic condensation polymer used in this invention is a condensation product between an aromatic hydrocarbon compound having a phenolic hydroxyl group and an aldehyde. Examples of suitable aromatic hydrocarbon compounds are phenols such as phenol, cresol and xylenol, but are not limited to these. For example, they may be methylene-bis-phenols represented by the following formula wherein x and y, independently from each other, represent 0, 1 or 2, or hydroxy-biphenyls and hydroxynaphthalenes. For practical purposes, phenols, particularly phenol, are preferred. The aromatic condensation polymer used in this invention may also be a modified aromatic polymer from a aromatic hydrocarbon compound having a phenolic hydroxyl group partly replaced by an aromatic hydrocarbon compound having no phenolic hydroxyl group such as xylene and toluene, and an aldehyde, such as a condensation product of phenol, xylene and formaldehyde. Examples of the aldehyde are formaldehyde, acetaldehyde and furfural. Formaldehyde is preferred. The phenol/formaldehyde condensate may be a novolak, or a resol, or a composition of both. The preparation of the aromatic condensation polymer and the further treatment may be performed, for example, in the following manner. A precondensate between an aromatic hydrocarbon compound having a phenolic hydroxyl group with or without an aromatic hydrocarbon compound having no phenolic hydroxyl group and an aldehyde is prepared, and an aqueous solution of the precondensate and an inorganic salt is formed. The aqueous solution is poured into a suitable mold, and heated while inhibiting evaporation of water, whereby it is cured and converted into such a form as a film or a cylindrical article. The cured article is then washed to remove the inorganic salt contained in it. The resultant porous cured condensate is heated to 400 to 800°C in a non-oxidizing atmosphere. The inorganic salt used together with the precondensate is a pore forming agent to form open pores in the cured article and is removed in a later step. Examples of the inorganic salt are zinc chloride, sodium phosphate, potassium hydroxide and potassium sulfide. Of these, zinc chloride is especially preferred. The inorganic salt is used in an amount 2.5 to 10 times the weight of the precondensate. If its amount is less than the lower limit, it is difficult to obtain a porous cured article having open pores. If, on the other hand, it is larger than the upper limit, the heat-treated product finally obtained undesirably tends to have a reduced mechanical strength. The aqueous solution of the precondensate and the inorganic salt can be prepared by using water in an amount 0.1 to 1 times the weight of the inorganic salt. The aqueous solution having a viscosity of 100,000 to 100 poises is poured into a suitable mold, and heated to a temperature of, for example 50 to 200°C. It is important that during the heat-treatment, evaporation of water in the aqueous solution should be inhibited. It is thought that the precondensate undergoes heating in the aqueous solution and gradually cures and grows to a three-dimensional network structure while separating from the inorganic salt and water. The inorganic salt can be removed from the cured product by washing it fully with water, dilute hydrochloric acid, etc. After the removal of the inorganic salt, the cured product is dried to give a porous cured condensate in which open pores are developed. Since the porous cured condensate is of the three-dimensional network structure in the resin portion or open cells therein, it contains open pores into and out of which a fluid is permitted to flow easily. The pores have an average pore diameter of as small as not more than 10 micrometers, for example 10 to 0.03 micrometer. The porous condensate has a uniform diameter and a sharp pore diameter distribution. By properly selecting the composition of an aqueous solution of an uncured phenolic resin containing an inorganic salt and the heat-curing conditions, it is possible to obtain porous articles of varying pore diameters ranging from a very fine porous article having an average pore diameter of from 0.03 to 0.1 micrometer to a porous article having an average pore diameter of about 10 micrometers. Such articles, therefore, can be used in various fields, for example, as filters for separating relatively large particles, separators for electric cells, and separation of bacteria or colloidal particles. The porous cured condensate obtained has an apparent density of 0.3 to 0.7 g/cm 3 . The preferred rate of temperature elevation during the heat-treatment slightly differs depending upon the type of the aromatic condensation polymer, its shape, the degree of the curing treatment, etc. Generally, the temperature can be elevated from room temperature to about 300°C at a relatively large rate, for example 100°C/hour. At temperatures above 300°C, the thermal decomposition of the aromatic condensation polymer begins to evolve gases such as steam (H 2 O), hydrogen, methane and carbon monoxide, and therefore, the temperature is advantageously elevated at a sufficiently slow rate. The porous active carbon can be produced by the method as mentioned above wherein the cured product is fired (carbonized) in a non-oxidizing atmosphere instead of heat-treating it. Firing can usually be carried out until the temperature exceeds 800°C. The porous active carbon usually has an apparent density (bulk density) of 0.2 to 0.6 g/cm 3 . Namely, it has a relatively high porosity to a relatively low porosity. Usually, the mechanical strength of a porous material varies with its apparent density. The porous active carbon mentioned above has such a strength as can fully withstand use in practical applications even when its apparent density is, for example, 0.2 g/cm 3 . Since the porous active carbon has fine open pores, a fluid can smoothly come into and out of it, and because of its high specific surface area, has excellent activity. Moreover, since the porous active carbon can permit various types of physical adsorption on it smoothly and in great quantities by utilizing its fine open pores and high specific surface area, it can be suitably used not only as an electrode of an organic cell as stated above, but also as an adsorbent material or a separating material. For example, a cell of the second type built by using undoped porous active carbon and lithium as electrodes and a 1 mole/liter propylene carbonate solution of LiClO 4 as an electrolytic solution has an electromotive force of about 3 V after building. When ClO 4 - ions are doped into the porous active carbon by applying voltage from an external power supply, its electromotive force is 3.5 to 4.5 V. According to the second mechanism, doping of an electron donating dopant into porous active carbon corresponds to discharging, and undoping corresponds to charging. For example, the cell of the above structure has an electromotive force of about 3 V immediately after building. When lithium ions are doped into porous active carbon by releasing an electric current outside, its electromotive force is 1.0 to 2.5. When lithium ions are undoped by applying voltage from an external powder supply, the electromotive force again becomes about 3 V. The doping or undoping may be carried out at a fixed current or voltage or under conditions where the current and voltage vary. But the amount of the dopant doped into the porous active carbon is preferably 0.5 to 10 % in terms of the number of ions doped per carbon atom of the active carbon. The cell of this invention comprising the porous active carbon as an electrode is a secondary cell which can be repeatedly charged and discharged. Its electromotive force differs according to the construction of the cell. The first type has an electromotive force of 1 to 3 V. The second type has an electromotive force of 3.5 to 4.5 V when operated in accordance with the first mechanism, and about 3 V when operated in accordance with the second mechanism. The cell of this invention particularly has a high energy density per unit weight thereof, and when doped in proper amounts, has an energy density of about 300 WH/kg of the porous active carbon. The cell of this invention has a power density much higher than that of a lead battery although it differs depending upon the structure of the cell. Furthermore, the use of the porous active carbon in this invention as an electrode can lead to the production of a secondary cell which has a low internal resistance, and can be repeatedly charged and discharged, and of which performance does not decrease over an extended period of time. The secondary cell of this invention comprising porous active carbon as one electrode permits easier incoming of an electrolytic solution than a conventional secondary cell comprising active carbon fibers as an electrode because the former uses porous active carbon. Furthermore, since doping on the interface is carried out smoothly, it is a secondary cell of high performance with a high capacity and a high output. It can be reduced in size, thickness and weight and its performance is not reduced over an extended period of time. In the present application, the average pore diameter of open pores are measured and defined as follows:- A sample is photographed through an electron microscope at a magnification of 1,000 to 10,000 X. A given straight line is drawn across the micrograph, and the number of pores, n , which cross the straight line is counted. The average pore diameter ( d ) is then calculated in accordance with the following equation. wherein ℓi is the length of a line segment cut by a pore that crosses the straight line, is the is the sum of the length of the n pores, and n is the number of pores which cross the straight line and is at least 10. The following examples illustrate the present invention more specifically. EXAMPLE 1 (1) An aqueous solution prepared by mixing a watersoluble resol (about 60 % in concentration), zinc chloride and water in a weight ratio of 10:25:4 was poured onto a glass plate by a film applicator to form a film. A glass plate was put over the aqueous solution formed into a film, and the film as heated at about 100°C for 1 hour while inhibiting evaporation of water. The porous cured phenolic resin film was fired (carbonized) in a siliconit electric furnace in a nitrogen stream to 900°C at a temperature elevating rate of 40°C/hour, washed with dilute hydrochloric acid and then water, and then dried. The resulting porous film having a thickness of about 200 microns and an apparent density of about 0.3 g/cm 3 . It had so good mechanical strength as not to be able to be imagined from active carbon, and also had some flexibility. The film had a BET specific surface area of as high as 1800 m 2 /g.To observe the pores of the resulting active carbon film, an electron micrograph of the section of the film was taken. The micrograph is shown in Figure 1. It is seen from Figure 1 that the resulting film had a three-dimensional network structure and contained fine open pores having a diameter of not more than 10 micrometers. (2) A cell was built using the resulting active carbon film as a positive electrode, metallic lithium as a negative electrode, and a solution of LiBF 4 in fully dehydrated propylene carbonate in a concentration of 1.0 mole/liter as an electrolytic solution. A stainless steel mesh was used as a current collector, and a felt of glass fibers, as a separator. This cell is of the second type in accordance with the first operating mechanism. Specifically, doping of BF 4 - , an electron accepting dopant, into the porous active carbon corresponds to charging, and undoping, to discharging. The amount of doping is expressed as the number of ions doped per carbon atom of the active carbon. In the present invention, the number of ions doped is determined from the current that flowed through the circuit. Immediately after building, the cell had a voltage of 3.0 V. By applying voltage to the cell from an external power supply, BF 4 - ions were doped in the porous active carbon for 3.5 hours at a fixed current so that the amount of doping per hour was 1 %. After doping, the cell had an open circuit voltage of 4.4 V. Then, a fixed current was passed through the circuit so that the amount of undoping per hour became 1 %. Thus, the BF 4 - ions were undoped until the open circuit voltage reached 3.0 V. In the above test, the ratio of the amount of undoping to the amount of doping was 80 %. EXAMPLE 2 This example illustrates a secondary cell of the first type in this invention in which both the positive and negative electrodes were composed of a shaped article of porous active carbon. A cell was built by using the porous active carbon film obtained in Example 1 was positive and negative electrodes and a 1 mole/liter propylene carbonate solution of (C 2 H 5 ) 4 NClO 4 as an electrolyte solution, and subjected to a charging-discharging test. Immediately after building, the cell had a voltage of 0 V. Then, by applying voltage to the cell from an external power supply, ClO 4 - ions were doped into the positive electrode, and (C 2 H 5 ) 4 N + ions, into the negative electrode. This charging was carried out for 3 hours at such a speed that the amount of doping per hour was 1 %. The open circuit voltage at this time was 3.0 V. Then, the ClO 4 - and (C 2 H 5 ) 4 N + ions were undoped at the same speed as in charging to discharge the cell. The discharging was continued until the cell voltage reached 0 V. The relation of the charging and discharge voltages to the amount of doping was nearly linear, and the cell had characteristics resembling those of a capacitor. Assuming that this cell is a capacitor, the capacity of the capacitor was calculated and found to be 25 F/g (F: farad). COMPARATIVE EXAMPLE 1 A plain-weave fabric of Kaynol fibers (a fabric of phenolic resin fibers made by Japan Kaynol Co., Ltd.) was fired (carbonized) to 900°C in a siliconit electric furnace in a non-oxidizing atmosphere. Then, steam was blown into the electric furnace at the same temperature to perform activating treatment for about 1 hour. The resulting active carbon fabric had a BET specific surface area of 1600 m 2 /g, and a fiber diameter of about 15 micrometers. The fabric had hardly any mechanical strength. A cell was built in the same structure as in Example 2 using the active carbon fabric as positive and negative electrodes, and subjected to a charging-discharging test under the same conditions. Assuming that the cell was a capatcitor, its capacity was calculated as 16 F/g.

Claims: An organic electrolyte cell comprising a positive electrode, a negative electrode and an electrolytic solution, one or both of said positive and negative electrodes being composed of porous active carbon having a specific surface area, measured by the BET method, of at least 600 m 2 /g and containing open pores having an average pore diameter of 0.2 to 10 micrometers, said porous active carbon being a carbonized product of an aromatic condensation polymer consisting of carbon, hydrogen and oxygen, and said electrolytic solution being a solution in an aprotic organic solvent of a compound capable of forming ions which can dope said electrode by electrolysis. The organic cell of claim 1 wherein the pores spread in a three-dimensional network structure in the porous active carbon. The organic cell of claim 1 wherein the porous active carbon has a bulk density of 0.2 to 0.6 g/cm 2 . The organic cell of claim 1 wherein the porous active carbon is in the form of a film, a plate or a composite thereof. The organic cell cf claim 1 wherein the positive electrode is composed of the porous active carbon and the negative elecrode is composed of an alkali metal or an alkaline earth metal. The organic cell of claim 1 wherein the negative electrode is composed of the alkali metal and the alkali metal is lithium. The organic cell of claim 1 wherein both the positive and negative electrodes are composed of the porous active carbon. The organic cell of claim 1 wherein the compound capable of forming dopable ions is LiI, NaI, NH 4 I, LiClO 4 , LiAsF 6 , LiBF 4 , KPF 6 , NaP 6 , (C 2 H 5 ) 4 NClO 4 , (n-C 4 H 9 )S 4 NClO 4 , (C 2 H 5 ) 4 NBF 4 , (n-C 4 H 9 ) 4 PF 6 or LiHF 2 . The organic cell of claim 1 wherein the aprotic organic solvent is ethylene carbonate, propylene carbonate, gamma-butyrolactone, dimethylformamide, dimethylacetamide, dimethyl sulfoxide, acetonitrile, dimethoxyethane, tetrahydrofuran, methylene chloride or sulfolane. Porous active carbon having a specific surface area, measured by the BET method, of at least 600 m 2 /g and containing open pores having an average pore diameter of 0.2 to 10 micrometers and being a carbonized product of an aromatic condensation polymer consisting of carbon, hydrogen and oxygen.

Inventors: HATO YUKINORI, OSAKI TAKUJI, SAKURAI KAZUO, YATA SHIZUKUNI, HATO, YUKINORI, OSAKI, TAKUJI, SAKURAI, KAZUO, YATA, SHIZUKUNI
Applicants: KANEBO LTD, KANEBO LTD.
Application year: 1986
Main classification: H01M4
IPC codes: C04B38, H01B1, H01M4, H01M10