PURIFICATION METHOD OF CARBON FLUORIDES

Abstract: A purification method of carbon fluorides by removing non-bonding fluorine from carbon fluorides. The removing treatment is carried out by contacting gases with the non-bonding fluorine. Such gases are HCℓ, SO₂, NO₂, H₂, steam and a mixed gas thereof.

Description: The present invention relates to a method for purifying carbon fluorides, particularly to a method for removing a non-bonded fluorine which is remaining in carbon fluorides or regulating an amount thereof. Hitherto, carbon fluorides are widely used as active materials for batteries by utilizing their electrochemical properties, or as solid lubricants by utilizing their excellent lubricity, or also as water and oil repellents. The carbon fluorides are prepared by reacting carbon materials such as natural or artificial graphites with fluorine gas. It is known that the carbon fluorides can have two chemical structures, i.e. (CF) n and (C₂F) n , depending on starting materials or preparation conditions. Also, it is known that unreacted fluorine which does not bond to a carbon atom is present in the resulting carbon fluorides and, that the unreacted fluorine gives various effects. For example, when carbon fluorides containing a large amount of this non-bonded fluoride are used as active materials for batteries, the non-bonded fluorine causes a Li surface of collector to corrode and increases an internal resistance, which results in lowering of battery characteristics. In addition, an initial discharge voltage sometimes rises to a high voltage, e.g. 7.0 V, to give damage to IC circuits and the like. Accordingly, it is said that the non-bonded fluorine in carbon fluorides should be removed therefrom. As used for active materials for batteries, however, a too small amount of the non-bonding fluorine is not desirable, because a discharge voltage, particularly an initial discharge voltage becomes lowered. Therefore, a purification method by which an amount of the non-bonded fluorine in carbon fluorides can be controlled is desired, but prior purification methods are not necessarily satisfactory. For example, Japanese Tokkyo Kokoku No. 36790/1981 discloses a treating method with mixed solutions of alcohols and strong acids or strong alkalis. The treating method has problems that strong reagents such as strong acids or strong alkalis are used, that post steps such as water linsing, filtration and drying are required after the treatment, and that an amount of the remaining non-bonded fluorine is difficult to control. Japanese Tokkyo Kokoku No. 13930/1988 discloses a treating method with ammonia gas. The method, however, has a high danger due to the use of combustible ammonia gas. Moreover, NH₄F produced by the reaction happens to be contained in the treated carbon fluorides as a contaminant. In order to remove NH₄F, a post treatment in which NH₄F is sublimated is required. As mentioned above, this method has problems to be improved. The present invention relates to a safe and easy purification method by which a delicate control can be achieved. According to the present invention, there can be provided a purification method in which carbon fluorides are subjected to contact treatment with a gaseous material selected from the group consisting of hydrogen chloride gas, sulfur dioxide gas, nitrogen dioxide gas, hydrogen gas, steam or a mixture thereof. Figs. 1 and 2 show graphs of characteristics of discharge voltages of the batteries fabricated in Example 4. The particular gases used in the present invention can react with the non-bonded fluorine to produce gaseous fluorides. Preferred examples are hydrogen chloride gas, sulfur dioxide gas, nitrogen dioxide gas, hydrogen gas, steam, or a mixture thereof. These gases react with the non-bonded fluorine according to the following schemes. F₂ + 2HCℓ → 2HF↑ + Cℓ₂↑ F₂ + SO₂ → SO₂F₂↑ F₂ + 2NO₂ → 2FNO₂↑ F₂ + H₂ → 2HF↑ 2F₂ + 2H₂O → 4HF↑ + O₂↑ The reaction products are all gases which can easily be removed from the carbon fluorides. Particularly, the gases of HCℓ, NO₂, SO₂ and steam are incombustible or hard to burn, and thus can be handled in safety. The particular gases are preferably used in a range from the same molar amount to three times larger than that of the non-bonded fluorine to be removed. The reaction can be conducted below a decomposition temperature of the carbon fluoride (about 350°C), and preferably at a relatively low temperature range from room temperature to 100°C. The treating time is not particularly limited and varies depending on the kind of carbon fluorides, an amount of non-bonded fluorine to be removed, a treating temperature, or a gas concentration when using a diluent gas. The treating time may be generally five minutes to ten hours, preferably 30 minutes to five hours, whereby a desired non-bonded fluorine content can be achieved. The particular gases in the invention may be used at pure state, or may be diluted with inert gases. The inert gases used as carrier gases are gases which do not react with fluorine, and may be, for instance, helium gas, argon gas, nitrogen gas, or air. The concentration of the particular gas may be 1 to 50 % by volume, preferably 3 to 30 % by volume. The reaction treatment can be carried out by contacting the particular gases with the carbon fluorides, preferably by passing the gass therethrough. As a reactor, a solid-gas catalytic reactor can be employed. The reactor may be a stationary type or a fluidized type, and is preferably made of monel which is resistant to fluorine and hydrogen fluoride. After contacting the particular gas to react with the non-bonded fluorine, the resulting reaction products (gas) remained in the carbon fluoride can be easily removed by passing an inert gas and drying, if necessary. The inert gases are the gases used as the carrier gases, and the drying may be carried out at a temperature of not more than 150°C for five hours, generally for about one hour. According to the purification method of the present invention, the control of non-bonded fluorine content can be achieved very easily. Namely, an amount of non-bonded fluoride to be removed is previously calculated by subtracting the desired amount from the initial amount in the carbon fluoride, and then the particular gas is passed in the same molar amount as the calculated amount of non-bonded fluoride to be removed. When a concentration of the particular reacting gas is regulated in response to the amount to be removed, more delicate control can be achieved. Generally when a treating time becomes shorter, a treating temperature should be raised or a concentration of the particular reacting gas should be increased. In view of efficiency, it had better to raise a treating temperature. Also, since sampling of the carbon fluoride to be treated is easy, the removed amount of non-bonded fluorine can be easily monitored. Accordingly, by referring the sampling date to a concentration of the reacting gas or a treating time, more precise control of a non-bonded fluorine content can be effected. The control of concentration of the reacting gas can be easily carried out by supplying the reacting gas from separate sources while the inert gas and regulating the flow rates of both gases with flow meters. The purification method of the present invention is explained by Examples. Example 1 A tube of monel with disturbing plates was charged with 100 g of a carbon fluoride, and the gas shown in Table 1 was passed therethrough for two hours (flow rate: 500 cc/min). The carbon fluoride used was a carbon fluoride (C₂F) n made from an artificial graphite, and had a fluorine content of 48.6 % by weight and a non-bonded fluorine content of 1.17 % by weight. After the contact treatment, the carbon fluoride was dried by passing nitrogen gas through the carbon fluoride at a rate of 1ℓ/min for one hour with heating at 100°C. A non-bonded fluorine content of the treated carbon fluoride and the amount of decrease of the non-bonded fluorine are shown in Table 1. An amount of non-bonded fluorine was measured by the following iodometry. A measuring flask of 50 mℓ is charged with about 500 mg of a carbon fluoride, and thereto 15 mℓ of ethanol is added. After shaking for five minutes, 20 mℓ of 0.5N KI solution is added and shaked well again for five minutes, and then allowed to stand for 20 minutes. A demineralized water is added to make a total volume of 50 mℓ. After shaking well, the solution is filtrated with a 5C filter paper, and the filtrate is shaked well, and then 10 mℓ of the filtrate is pored to a 50 mℓ beaker. This filtrate is titrated with a N/100 hypo (when a non-bonded fluorine content is very little, a N/1000 hypo is used). The non-bonded fluorine content is calculated according to the following equation. Example 2 A carbon fluoride (C₂F) n (F₂ content: 48.6 %, non-bonded F₂ content: 1.17 %) was treated in the same procedures as in Experimental No. 1-5 of Example 1 except that a steam concentration of the N₂-steam mixed gas system of Experimental No. 1-5 of Example 1 was changed as in Table 2. The mixed gas was passed at 500 cc/min for two hours at 100°C. The results are shown in Table 2. Example 3 In the treating system of Experimental No. 1-6 of Example 1, an amount of decrease (removed) of non-bonded F₂ was measured by raising a treating temperature as in Table 3. The conditions other than the treating temperature were the same as those in Experimental No. 1-6. The results are shown in Table 3. Example 4 A battery was fabricated by using, as an active material, the carbon fluoride prepared in Experimental No. 1-1, No. 1-2, No. 1-3, No. 1-4 or No. 3-4 (each (C₂F) n ), or in Experimental No. 1-7 or No. 1-8 (each (CF) n ). A discharge voltage and discharge time were measured with respect to the just fabricated battery and the battery after storing for one year at 45°C. The fabrication and the measurement were done by the following manner. The positive electrode was prepared by mixing well the carbon fluoride ((C₂F) n or (CF) n ), acetylene black as an electric conductor and Polyflon® fine powder (PTFE powder avairable from Daikin Industries, Ltd.) as a binder (10 : 1 : 3) by a homogenizer, compressing about 40 mg of the admixture under a pressure of 200 kg/cm² to give a disc having a diameter of 10 mm. A nickel net (12 mm x 112 mm) was interposed between two discs, and then compressed under a pressure of about 10 kg/cm². After that, the product was dried under a reduced pressure, and then weighed and kept in a dry box. A negative electrode was prepared by cutting a lithium plate (10 mm x 10 mm x 1 mm) out of a lithium block, and held on a nickel net. The negative electrodes were positioned on both sides of the positive electrode. An electrolyte was prepared by distilling a commercially available γ-butyrolactone under a reduced pressure of about 20 mm Hg, and drying with a molecular sieve 4A. Lithium borofluoride was used by drying a commercially available lithium borofluoride under vacuum at about 120°C in a rotary evaporator. A 1N battery electrolyte was prepared in a dry box and kept therein as it was. A battery was fabricated by setting each electrode in a test cell and pouring the battery electrolyte thereto. After allowing to stand for day and night, discharge test was begun at 25°C with a discharge resistor of 10 kΩ. All the data were calculated per 50 mg of the active material (only (C₂F) n ). The discharge time shown in Table 4 represents a discharge time until a discharge voltage goes down to 2.5 V. The results are shown in Table 4. Also, with respect to the batteries just after the fabrication using the carbon fluorides of Experimental No. 1-1, No. 1-2 and No. 3-4 (each (C₂F) n ) and with respect to the batteries stored for one year at 45°C using the carbon fluorides of Experimental No. 1-7 and No. 1-8 (each (CF) n ), discharge voltage change was measured with lapse of time. The results are shown in Fig. 1 ((C₂F) n ) and Fig. 2 ((CF) n ). As is clear from Fig. 1 and Table 4, according to the method of the present invention, an initial discharge voltage of the battery using the (C₂F) n as an active material can be lowered to near an average discharge voltage. Therefore, there is no danger that an excess electric current flushes at a time of switching on. With respect to the (CF) n as shown in Fig. 2 and Table 4, the discharge time of the battery according to the present invention does scarcely shorten even after storing for one year at 45°C, and is longer by two hours than that of the battery using the untreated carbon fluoride. Such two hours difference of discharge time is in case of continuous discharge, and the difference becomes larger in case of practical use where a battery repeatedly switches on and off. Such stability of shelf life can be observed with respect to the (C₂F) n . According to the purification method of the present invention, a non-bonded fluorine content in carbon fluorides can be delicately controlled by contacting with a cheap and safe gas at a relatively low temperature.

Claims: A method for removing non-bonded fluorine from carbon fluorides by subjecting the carbon fluorides to contact treatment with a gaseous material selected from the group consisting of hydrogen chloride gas, sulfur dioxide gas, nitrogen dioxide gas, hydrogen gas, steam or a mixture thereof. The method of Claim 1, wherein the gaseous material contains an inert gas as a carrier gas. The method of Claim 2, wherein the inert gas is selected from the group consisting of helium gas, argon gas, nitrogen gas and air. The method of Claim 1, wherein the treatment is carried out at a temperature of room temperature to 100°C.

Inventors: KOYAMA, SATOSHI, MAEDA, TADAYUKI, OKAMURA, KAZUO
Applicants: DAIKIN INDUSTRIES, LIMITED
Application year: 1989
Main classification: C01B31
IPC codes: C01B31, H01M6, H01M4