Patent Description:
There exists a demand for porous carbon materials, especially for use in applications where both electrical conductivity and material permeability are required in the same substance. Such applications are for instance ion transfer cells, in which an electrode material interacts with charge carriers at a solid-liquid boundary.

A porous carbon material which is known in the prior art is carbon black. Carbon black is produced by incomplete combustion of heavy petroleum products such as FCC tar, coal tar, ethylene cracking tar, and a small amount from vegetable oil. Such a process for the production of carbon black is for example disclosed in <CIT>. The applications of porous carbon are generally based on the properties of the pore structure. Known applications are electrodes, such as in lithium ion cells in which simultaneous transport of ions and electrons through the electrode material is required; catalysts, in which a high active surface area and pore accessibility are required; and fuel cells, in which transport of fuel and electrical conductivity are required.

Processes for producing a porous carbon material using a template acting as negative to shape the carbon are known in the prior art. Therein, the carbon material is characterised by a pore structure which is substantially predetermined by the structure of the template material. The template can for example be made from a silicon oxide. A process for producing a silicon oxide template known in the prior art is the so-called sol-gel process. The sol-gel route to preparation of silicon oxide is well known to the skilled person. For example, producing a monolithic silica body via the sol gel process is described in <CIT>.

Methods for preparing a porous carbon material without using a solid template is described in <CIT> and <CIT>. There, a prolonged polymerisation step is required prior to firing. A method for preparing porous carbon material using hemp fibre as a precursor is disclosed in <CIT>.

There persists a need to provide improved methods for making porous carbon materials, in particular by a polymerisation type process without employing a solid template and with a short polymerisation step. There also exists a need for porous carbon materials with improved properties.

Generally, it is an object of the present invention to at least partly overcome a disadvantage arising from the prior art.

The invention is as disclosed in the claims. Subject-matter falling outside the scope of the claims may be disclosed but is not according to the invention. Detailed Description.

Throughout this document disclosures of ranges are to be understood to include both end points of the range. Furthermore, each disclosure of a range in the description is to be understood as also disclosing preferred sub-ranges in which one end point is excluded or both end points are excluded. For example, disclosure of the range from <NUM> to <NUM> is to be understood as disclosing a range including the end points <NUM> and <NUM>. Furthermore, it is to be understood as also disclosing a range including the end point <NUM> but excluding the end point <NUM>, a range excluding the end point <NUM> but including the end point <NUM> and a range excluding both end points <NUM> and <NUM>.

Throughout this document, phrases in the form "A comprises only B" or "A is B" are to be understood as meaning that A comprises B and is essentially free of any other constituents. Preferably A in such case comprises less than <NUM> wt. %, more preferably less than <NUM> wt. %, further more preferably less than <NUM> wt. % of other constituents, based on the total weight of A. It is most preferred for A to be free of any constituents other than B. This concept generalises to an A having two or more constituents, such as in phrases of the general form "A comprises only B and C" and "A is B and C". In such a case, A preferably comprises less than <NUM> wt. %, more preferably less than <NUM> wt. %, further more preferably less than <NUM> wt. % of constituents other than B and C, based on the total weight of A. It is most preferred for A to be free of any constituents other than B or C.

Similarly, phrases of the general form "A does not comprise B" are to be understood as meaning that A is essentially free of B. Preferably A in such case comprises less than <NUM> wt. %, more preferably less than <NUM> wt. %, further more preferably less than <NUM> wt. % of B, based on the total weight of A. It is most preferred for A to be free of B. This concept generalises to an A which comprises none of a group of two or more specified constituents, such as a group of the general form "B and C". Preferably A in such a case comprises a total amount of B and C of less than <NUM> wt. %, more preferably less than <NUM> wt. %, further more preferably less than <NUM> wt. %, based on the total weight of A. It is most preferred for A to be free either B or C or both, preferably both.

The precursor of the present disclosure may comprise a solvent or a dispersant or both. In this document, the term solvent is used as a general term and in particular can refer to a solvent itself or to a dispersant or to both. In particular, preferred features described in the context of a solvent are also preferred features for a dispersant.

Compounds in the context of the present document preferably are describable as a stoichiometric combination of elements. Preferred compounds may be molecules or ions or molecular ions.

One aspect of the disclosure is a process for preparing a porous carbon material comprising the process steps:.

wherein the carbon source comprises a carbon source compound, wherein the carbon source compound comprises the following:.

The precursor comprises the carbon source and the amphiphilic species. In one embodiment, the precursor comprises one or more further constituents other than the carbon source and the amphiphilic species. In another embodiment, the precursor comprises just the carbon source and the amphiphilic species.

Further constituents for the precursor may be any which the skilled person considers appropriate in the context of the disclosure. Preferred further constituents are one or more selected from the group consisting of: a solvent and a cross-linking agent.

Where further constituents are present in the precursor, they are notionally considered to be separate from the carbon source and from the amphiphilic species, for example for the purposes of calculating proportions by mass. For example, where a carbon source is prepared in a solvent and introduced to the other constituent or other constituents of the precursor as a solution, the solvent is considered in the context of this disclosure to a further constituent and does not count as part of the carbon source.

The amphiphilic species of the present disclosure preferably serves to direct the formation of a three-dimensional structure from the carbon source. The amphiphilic species is preferably present in the precursor in the form of micelles and <NUM>-dimensional structures and preferably lead to the formation of pores in the resulting porous carbon material.

The amphiphilic species preferably comprises a first amphiphilic compound, the first amphiphilic compound comprising two or more adjacent ethylene oxide based repeating units. In one embodiment of the invention, the amphiphilic species comprises the first amphiphilic compound only. In another embodiment, the amphiphilic species comprises the first amphiphilic compound and one or more further amphiphilic compounds, or two or more, or three or more, or four or more further amphiphilic compounds. It is preferred that the further amphiphilic compounds each comprise two or more adjacent ethylene oxide based repeating units. Herein, preferred features disclosed in relation to the amphiphilic compound are preferred features for the first amphiphilic compound. Where one or more further amphiphilic compounds are present in the amphiphilic species, the preferred features disclosed in relation to the amphiphilic compound or to the first amphiphilic compound are also preferred features for one or more of, preferably all of, the further amphiphilic compounds.

Preferred amphiphilic compounds possess both hydrophilic and lipophilic behaviour.

One preferred hydrophilic group is the ethylene oxide based repeating unit. Other preferred hydrophilic groups are one or more selected from the group consisting of: a charged group and a polar uncharged group. Preferred polar uncharged groups comprise one or more selected from the group consisting of: O, S, N, P, F, Cl, Br and I. More preferred polar uncharged groups comprise O. Examples of preferred polar uncharged groups are: hydroxyl, carboxyl, carbonyl, aldehyde, ester, ether, peroxy, haloformyl, carbonate ester, hydroperoxyl, hemiacetal, hemiketal, acetal, ketal, orthoester, methylenedioxy, orthocarbonate ester, sulphhydryl, sulphide, disulphide, sulphinyl, sulphonyl, sulphino, sulpho, thiocyanate, isothiocyanate, carbono-thioyl, phosphino, phosphono, phosphate, carboxamide, amine, ketamine, adimine, imide, azide, azo, cyanate, isocyanate, nitrate, nitrile, isonitrile, nitrosooxy, nitro, nitroso, oxime, pyridyl, chloro, bromo and iodo. Preferred polar uncharged groups are hydroxyl and ester, more preferably hydroxyl. Preferred charged groups can be cationic or anionic. Examples of preferred anionic groups are: carboxylate, sulphate, sulphonate and phosphate, more preferably carboxylate. Preferred cationic groups are ammonium.

The lipophilic behaviour of the amphiphilic compound is preferably provided by one or more hydrocarbon moieties or one or more poly-ether moieties different to poly ethylene oxide or one or more of each.

Preferred hydrocarbon moieties may be saturated or unsaturated. A preferred saturated hydrocarbon is an alkane. Preferred alkanes may be linear, branched, cyclic or a mixture thereof. Preferred unsaturated hydrocarbon moieties comprises one or more carbon-carbon double bonds or one or more aromatic rings or one or more of each. A preferred hydrocarbon comprises a carbon chain or two or more carbon chains, each carbon chain preferably having <NUM> or more carbon atoms, more preferably <NUM> or more carbon atoms, most preferably <NUM> or more carbon atoms. The carbon chain preferably comprises one or more selected from the group consisting of: a straight carbon chain, a branched carbon chain and a carbon ring. The carbon chain preferably comprises a straight carbon chain, preferably is a straight carbon chain. Preferred carbon chains in this context may comprise one or more selected form the group consisting of: an alkane unit, an alkene unit, and an alkyne unit. The carbon chain preferably comprises an alkane unit, more preferably is an alkane.

The amphiphilic compound may comprise ethylene oxide based repeating units, preferably adjacent. The ethylene oxide based repeating unit preferably has the formula -(CH<NUM>CH<NUM>O)-. The amphiphilic compound preferably comprises two or more, preferably <NUM> or more, more preferably <NUM> or more, more preferably <NUM> or more, more preferably <NUM> or more ethylene oxide based repeating units. In one aspect of this embodiment, the amphiphilic compound comprises one or more blocks of ethylene oxide based repeating units, each block comprising two or more, preferably <NUM> or more, more preferably <NUM> or more, more preferably <NUM> or more, more preferably <NUM> or more ethylene oxide based repeating units connected directly in a chain.

In one embodiment, a preferred amphiphilic compound comprises more than <NUM> wt. % of ethylene oxide based repeating units, based on the total weight of the first amphiphilic compound, preferably more than <NUM> wt. %, more preferably more than <NUM> wt. %, most preferably more than <NUM> wt. In some cases the compound may comprise up to <NUM> wt. % of ethylene oxide based repeating units. In one aspect of this embodiment, the amphiphilic compound comprises from <NUM> to <NUM> wt. % of ethylene oxide based repeating units, based on the total weight of the first amphiphilic species, preferably from <NUM> to <NUM> wt. %, more preferably from <NUM> to <NUM> wt. %, most preferably from <NUM> to <NUM> wt.

In one embodiment, it is preferred for the amphiphilic compound to comprise one or more of a further repeating unit, the further repeating unit being different to an ethylene oxide based repeating unit.

The further repeating unit is preferably a propylene oxide based repeating unit. The propylene oxide based repeating unit preferably has the formula -(CHCH<NUM>CH<NUM>O)-. The amphiphilic compound preferably comprises two or more, preferably <NUM> or more, more preferably <NUM> or more, more preferably <NUM> or more, more preferably <NUM> or more of the further repeating unit. In one aspect of this embodiment, the amphiphilic compound comprises one or more blocks of the further repeating unit, each block comprising two or more, preferably <NUM> or more, more preferably <NUM> or more, more preferably <NUM> or more, more preferably <NUM> or more of the further repeating unit connected directly in a chain.

The amphiphilic compound may comprises a butylene oxide based repeating unit, preferably two or more, preferably <NUM> or more, more preferably <NUM> or more, more preferably <NUM> or more, more preferably <NUM> or more of the butylene oxide based repeating unit. In one aspect of this embodiment, the amphiphilic compound comprises one or more blocks of the butylene oxide based repeating unit, each block comprising two or more, preferably <NUM> or more, more preferably <NUM> or more, more preferably <NUM> or more, more preferably <NUM> or more of the butylene oxide based repeating unit connected directly in a chain.

In one embodiment, it is preferred for the amphiphilic compound to comprise one or more ethylene oxide based repeating units and one or more of a further repeating unit, the further repeating unit being different to an ethylene oxide based repeating unit. The further repeating unit is preferably a propylene oxide based repeating unit. The propylene oxide based repeating unit preferably has the formula -(CHCH<NUM>CH<NUM>O)-. The amphiphilic compound preferably comprises two or more, preferably <NUM> or more, more preferably <NUM> or more, more preferably <NUM> or more, more preferably <NUM> or more ethylene oxide based repeating units. In one aspect of this embodiment, the amphiphilic compound comprises one or more blocks of ethylene oxide based repeating units, each block comprising two or more, preferably <NUM> or more, more preferably <NUM> or more, more preferably <NUM> or more, more preferably <NUM> or more ethylene oxide based repeating units connected directly in a chain. The amphiphilic compound preferably comprises two or more, preferably <NUM> or more, more preferably <NUM> or more, more preferably <NUM> or more, more preferably <NUM> or more of the further repeating unit. In one aspect of this embodiment, the amphiphilic compound comprises one or more blocks of the repeating unit, each block comprising two or more, preferably <NUM> or more, more preferably <NUM> or more, more preferably <NUM> or more, more preferably <NUM> or more of the further repeating unit connected directly in a chain. In a preferred aspect of this embodiment, the amphiphilic compound comprises one or more blocks of ethylene oxide based repeating units and one or more blocks of the further repeating unit. In one aspect of this embodiment, the amphiphilic compound comprises one or more ethylene oxide based repeating units and two or more further repeating units. One of the two or more further repeating units is preferably a propylene oxide based repeating unit. It is particularly preferred that the amphiphilic compound comprises one or more blocks of each of the ethylene oxide based repeating unit and the two or more further repeating units.

In one preferred embodiment the amphiphilic compound is a block copolymer comprising one or more hydrophilic blocks and one or more hydrophobic blocks. The preferred hydrophilic block is an ethylene oxide based repeat unit. Preferred hydrophobic blocks are a propylene oxide based block, a butylene oxide based block, or a hydrocarbon block, preferably a propylene oxide based block or a hydrocarbon block. Preferred block copolymers are diblock copolymers of the form AB or triblock copolymers of the form ABA or BAB.

In one embodiment, the amphiphilic compound is a triblock copolymer of the form ABA, wherein A is an ethylene oxide based block and B is either a propylene oxide based block or a hydrocarbon.

In one embodiment, the amphiphilic compound is a triblock copolymer of the form BAB, wherein A is an ethylene oxide based block and B is either a propylene oxide based block or a hydrocarbon.

In one embodiment, the amphiphilic compound is a diblock copolymer of the form AB, wherein A is an ethylene oxide based block and B is either a propylene oxide based block or a hydrocarbon.

In one embodiment, the amphiphilic compound is a mixed triblock copolymer of the form BAC, wherein A is an ethylene oxide based block, B and C are different and each chosen from the group consisting of: a propylene oxide based block and a hydrocarbon.

In one embodiment, the amphiphilic compound is a block copolymer, preferably as above, with one or more terminal groups, preferably selected from the group consisting of: a hydrocarbon, sulphate, phosphate, an amine, carboxylate and an ammonium salt.

In one embodiment, the amphiphilic species may be provided in a solvent. In this case, the solvent is notionally separate from the amphiphilic species for the purposes of calculating properties of the amphiphilic species, such content by weight in the precursor.

In one embodiment, a preferred amphiphilic compound has an HLB value measured by the Griffin Method in the range from <NUM> to <NUM>, preferably in the range from <NUM> to <NUM>, more preferably in the range from <NUM> to <NUM>, more preferably in the range from <NUM> to <NUM>, more preferably in the range from <NUM> to <NUM>. In one embodiment, preferred amphiphilic compounds have an HLB measured by the Griffin Method of <NUM> or more or more than <NUM> or <NUM> or more or more than <NUM> or <NUM> or more or more than <NUM>.

In one embodiment, a preferred amphiphilic compound has an HLB value measured by the Reference Method described in the test methods in the range from <NUM> to <NUM>, preferably in the range from <NUM> to <NUM>, more preferably in the range from <NUM> to <NUM>, more preferably in the range from <NUM> to <NUM>, more preferably in the range from <NUM> to <NUM>. In one embodiment, preferred amphiphilic compounds have an HLB measured by the Reference Method described in the test methods of <NUM> or more; or more than <NUM>; or <NUM> or more; or more than <NUM>; or <NUM> or more; or more than <NUM>.

In one embodiment, a preferred amphiphilic compound has an HLB value measured by the Davies Method of <NUM> or more; or more than <NUM>; or <NUM> or more; or more than <NUM>; or <NUM> or more; or more than <NUM>; or <NUM> or more; or more than <NUM>; or <NUM> or more; or more than <NUM>. Some amphiphilic compounds can have an HLB value measured by the Davies Method of up to <NUM>.

In one embodiment, a preferred amphiphilic compound has an HLB value measured by the Effective Chain Length Method (<NPL>) of <NUM> or more; or more than <NUM>; or <NUM> or more; or more than <NUM>; or <NUM> or more; or more than <NUM>; or <NUM> or more; or more than <NUM>; or <NUM> or more; or more than <NUM>. Some amphiphilic compounds can have an HLB value measured by the Effective Chain Length Method of up to <NUM>.

In one embodiment, <NUM> of the amphiphilic species satisfies one or more of the following criteria immediately after shaking in <NUM> of distilled water, preferably determined according to the test method described herein:.

Clear in this context preferably means producing an obscuration of less than <NUM> % according to the method given herein. In the various aspects of this embodiment, the following combinations are satisfied: a, b, c, b+c, a+b, a+c or a+b+c. It is preferred for at least c to be satisfied.

Gas bubbles can be present within the body of another phase or may accumulate at the top of another phase to form a foam.

In one embodiment, <NUM> of the amphiphilic species satisfies one or more of the following criteria <NUM> minutes after shaking in <NUM> of distilled water, preferably determined according to the test method described herein:.

Clear in this context preferably means producing an obscuration of less than <NUM> % according to the method given herein. It is preferred for at least b to be satisfied.

In one embodiment, <NUM> of the amphiphilic species satisfies one or more of the following criteria <NUM> hour after shaking in <NUM> of distilled water, preferably determined according to the test method described herein:.

In one embodiment, <NUM> of the amphiphilic species satisfies one or more of the following criteria <NUM> day after shaking in <NUM> of distilled water, preferably determined according to the test method described herein:.

The carbon source of the present disclosure preferably provides the carbon material for the formation of a three-dimensional structure. This three-dimensional structure preferably has open pores and also preferably channels, preferably built by connecting open pores.

The carbon source of the present disclosure comprises a carbon source compound which comprises following:.

The carbon sources compound may comprise more than one aromatic ring i. In one aspect of this embodiment, the carbon source compound comprises <NUM> or more aromatic rings i. , preferably <NUM> or more, more preferably <NUM> or more, more preferably <NUM> or more. Where two or more aromatic rings i. are present in the carbon source compound, the aromatic rings i. may be the same or different. It is preferred for the aromatic rings within the same carbon source compound to be the same.

The aromatic ring i. preferably comprises adjacent OH groups. Adjacent OH group in the aromatic ring are connected to adjacent ring members. In one aspect of this embodiment, the aromatic ring has a first OH group and a second OH group and the first and second OH groups are adjacent to each other in the aromatic ring. It is preferred for <NUM> or more OH groups to each be adjacent to another OH group, preferably <NUM> or more OH groups, most preferably all OH groups.

The OH groups in the aromatic ring i. may be in protonated or de-protonated form. In one aspect of this embodiment, the carbon source compound is present as a salt, preferably comprising an organic anion and a metal cation.

Preferred aromatic rings have from <NUM> to <NUM> ring members. In one embodiment, the aromatic ring i. has <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM> members, preferably <NUM>, <NUM>, <NUM>, <NUM>, <NUM> or <NUM>, more preferably <NUM> or <NUM>, most preferably <NUM> members.

In one embodiment, the aromatic ring i. is a carbon ring. In another embodiment, the aromatic ring i. is a heterocycle comprising carbon and at least one other element, preferably selected form the group consisting of: P, N, O, S, and B. Carbon rings are preferred.

In the following, we describe the aromatic ring in terms of its base without substituents. For example, phenol is described as benzene because it is equivalent to a benzene ring having an attached OH group.

Preferred carbon rings in this context are the following: benzene, naphthalene, anthracene and pyrene.

Preferred aromatic rings comprising oxygen are the following: furan, benzofuran and isoben-zofuran. Preferred aromatic rings comprising one nitrogen atom are the following: pyrrole, indole, isoindole, imidazole, benzimidazole, purine, pyrazole, indazole, pyridine, quinoline, isoquinoline, pyrazine, quinoxaline, acridine, pyrimidine, quinazoline, pyradazine, cinnoline, phthalazine, <NUM>,<NUM>,<NUM>-triazine, <NUM>,<NUM>,<NUM>-triazine, and <NUM>,<NUM>,<NUM>-triazine. Preferred aromatic rings comprising sulphur are the following: thiophene, benzothiophene and benzo[c]thiophene. Preferred aromatic rings comprising both nitrogen and oxygen are the following: oxazole, benzoxazole, isoxazole, benzisoxazole. Preferred aromatic rings comprising both nitrogen and sulphur are the following: thiazole and benzothiazole.

The carbon source compound preferably comprises a polyalcohol structural unit. The polyalcohol structural unit preferably provides an anchoring point for further constituents of the compound, which are preferably linked to the polyalcohol via ester links.

In one embodiment, the polyalcohol structural unit has <NUM> or more, more preferably <NUM> to <NUM>, most preferably, <NUM> to <NUM> carbon atoms. In one aspect of this embodiment, the polyalcohol structural unit has <NUM> or more, more preferably <NUM> to <NUM>, more preferably, <NUM> to <NUM>, most preferably <NUM> to <NUM> OH groups. In one aspect of this embodiment, the polyalcohol structural unit is a sugar. Preferred sugars are mono-saccharides, preferably having a chemical formula of the general form CnH2nOn, wherein n is a whole number, preferably at least <NUM>, more preferably <NUM>. Preferred sugars are glucose, ribose, arabinose, xylose, lyxose, allose, altrose, mannonse, gulose, iodose, galactose and talose, preferably glusose. In one embodiment, the polyalcohol structural unit is glucose. In another embodiment, the polyalcohol structural unit is quinic acid.

Preferred carbon source compounds are polyphenols. In one embodiment, the carbon source is a polyphenol according to the White-Bate-Smith-Swain-Haslam (WBSSH) scheme.

In one embodiment, the carbon source compound satisfies one or more of the following features:.

Preferred carbon source compounds are tannins. Preferred tannins comprise one or more gallic acid structural units or one or more ellagic acid structural units or one or more gallic acid structural units and one or more ellagic acid structural units. Preferred tannins are so called gallotannins and ellagitannins. Preferred tannins are hydrolysable tannins. Preferred hydrolysable tannins comprise one or more ester structural units. Preferred hydrolysable tannins release gallic acid or ellagic acid when hydrolysed. Preferred tannins comprise one or more sugar structural units, preferably a single sugar structural unit. The preferred sugars in this context are glucose and quinic acid. In one embodiment, the carbon source compound comprises a gallic acid structural unit, preferably from <NUM> to <NUM>, more preferably from <NUM> to <NUM>, most preferably <NUM> to <NUM> gallic acid structural units. In embodiment, the carbon source compound comprises an ellagic acid structural unit, preferably from <NUM> to <NUM>, more preferably from <NUM> to <NUM>, most preferably <NUM> to <NUM> ellagic acid structural units. In one embodiment, the carbon source compound comprises both an ellagic acid structural unit and a gallic acid structural unit, preferably from <NUM> to <NUM>, more preferably from <NUM> to <NUM>, most preferably <NUM> to <NUM> ellagic acid and gallic acid structural units in total.

Tannic acid is the preferred carbon source compound. In one embodiment, the carbon source compound is a galloyl glucose. Preferred galloyl glucoses are the following: digalloyl glucose, trigalloyl glucose, tetragalloyl glucose, pentagalloyl glucose, hexagalloyl glucose, heptagalloyl glucose, octagalloyl glucose, nonagalloyl glucose, decagalloyl glucose, endecagalloyl glucose, dodecagalloyl glucose. In one embodiment, the carbon source compound is a galloyl quinic acid. Preferred galloyl quinic acids are the following: digalloyl quinic acid, trigalloyl quinic acid, tetragalloyl quinic acid, pentagalloyl quinic acid, hexagalloyl quinic acid, heptagalloyl quinic acid, octagalloyl quinic acid, nonagalloyl quinic acid, decagalloyl quinic acid, endecagalloyl quinic acid, dodecagalloyl quinic acid. In one embodiment, the carbon source compound is an ellagyl glucose. Preferred ellagyl glucoses are the following: diellagyl glucose, triellagyl glucose, tetraellagyl glucose, pentaellagyl glucose, hexaellagyl glucose, heptael-lagyl glucose, octaellagyl glucose, nonaellagyl glucose, decaellagyl glucose, endecaellagyl glucose, dodecaellagyl glucose. In one embodiment, the carbon source compound is an ellagyl quinic acid. Preferred ellagyl quinic acids are the following: diellagyl quinic acid, triellagyl quinic acid, tetraellagyl quinic acid, pentaellagyl quinic acid, hexaellagyl quinic acid, heptael-lagyl quinic acid, octaellagyl quinic acid, nonaellagyl quinic acid, decaellagyl quinic acid, endecaellagyl quinic acid, dodecaellagyl quinic acid. In one embodiment, the carbon source comprises a single carbon source compound selected form the above. In another embodiment, the carbon source comprises a mixture of two or more carbon source compounds selected from the above. The preferred tannic acid is decagalloyl glucose and has the chemical formula C<NUM>H<NUM>O<NUM>.

One or more solvents or dispersants may be present in the precursor. Solvents and dispersants are preferably liquids. Solvents and dispersants in this context preferably dissolve or disperse one or more of the constituents of the precursor, either prior to or after formation of the precursor. Preferred features of the solvent are described here and these features are also preferred features of a dispersant. A solvent may be introduced to the other constituents of the precursor as such or as a solvent for one or more of the other constituents of the precursor prior to formation of the precursor. If one or more solvents are employed, they are considered to be separate from other constituents of the paste for the purpose of calculating content by weight, even if they are employed as a solvent therefor prior to formation of the precursor. For example, if the carbon source is introduced to the other constituents of the precursor in the form of a solution or dispersion of the carbon source in a carbon source solvent, the content of carbon source in the precursor is calculated excluding the content of the carbon source solvent. This also applies, in particular, for the amphiphilic species and the co-ordinating species where one is present.

Solvents may be any solvent known to the skilled person and which he considers appropriate in the context of the disclosure, in particular solvents which are selected for their capability to dissolve or disperse one or more of the constituents of the precursor. Solvents may be organic or inorganic. A preferred solvent has a boiling point. Solvents preferably vaporise without leaving a residue when heated to above their boiling point. The preferred inorganic solvent is water. Preferred organic solvents are alcohols, ethers, aldehydes, esters or ketones, preferably alcohols. Preferred alcohols are methanol, ethanol or propanol, preferably ethanol. Another preferred organic solvent is acetone.

In one embodiment, the precursor does not comprise a solvent.

One or more cross-linking agents may be present in the precursor. Preferred cross-linking agents serve the purpose of facilitating the joining together of the carbon source into a <NUM>-dimensional structure in the porous carbon material. A cross-linking agent can be a catalyst, preferably a polymerisation catalyst for the carbon source.

Cross-linking agents may be any compound known to the skilled person which he considers appropriate in the context of the invention, in particular compounds which are selected for their capability for facilitating the joining together of the carbon source.

Preferred cross-linking agents comprise two or more functional groups. Preferred functional groups are able to form a link to the carbon source.

Preferred cross-linking agents are one or more selected from the group consisting of: para toluene sulphonic acid, hexamethylenetetramine, hexamethoxymethylmelamine and <NUM>-nitro-<NUM>-methyl-<NUM>-propanol.

In one embodiment, the cross-linking agent is a methylene donor.

In one embodiment of the disclosure, the precursor comprises a cross-linking agent, preferably in the range from <NUM> to <NUM> parts by weight, more preferably in the range from <NUM> to <NUM> parts by weight, more preferably in the range from <NUM> to <NUM> parts by weight, based on <NUM> parts of carbon source. In a preferred aspect of this embodiment, the cross-linking agent is a cross-linking agent for the carbon source. In one aspect of this embodiment, the cross-linking agent is a catalyst for polymerising the carbon source. In a preferred embodiment, the precursor does not comprise a cross-linking agent. In one embodiment, the precursor does not comprise more than <NUM> parts by weight of cross-linking agent, more preferably not more than <NUM> part, more preferably not more than <NUM> part, most preferably not more than <NUM> parts based on <NUM> parts of carbon source. In particular for a desired pore volume it is preferred to have less than <NUM> parts, preferably less than <NUM> part, more preferably less than <NUM> parts, more preferably less than <NUM> parts, or even no cross-linking agent present, based on <NUM> parts of carbon source.

The process of the disclosure preferably comprises a heating step. The heating step preferably serves to obtain a porous carbon material from the precursor, preferably through linking together of the carbon source.

In the heating step, one or more constituents other than the carbon source, preferably all constituents other than the carbon source, are removed from the precursor so as not to remain in the porous carbon material. Preferably one or more selected from the following group, preferably all of the members of the following group which are present in the precursor, are removed from the precursor during the heating step so as not to remain in the porous carbon material: the amphiphilic species; the solvent, if present; the cross-linking agent, if present; further constituents other than the carbon source, if present. Constituents removed from the precursor during the heating step can exit the precursor whole, for example by evaporation or sublimation, or can decompose inside the precursor whereupon the decomposition products exit the precursor.

The heating step preferably comprises a high temperature firing. The high temperature firing is preferably performed at a temperature in the range from <NUM> to <NUM>. The purpose of the high temperature firing step preferably serves to carbonize and potentially graphitise the carbon source, thereby obtaining the porous carbon material.

The precursor preferably does not require pre-polymerisation before the heating step. In one embodiment of the invention, the heating step of the precursor does not comprise a low temperature holding step of <NUM> minutes or more at a holding temperature in the range from <NUM> to <NUM>, preferably no low temperature holding step of <NUM> minute or more at a holding temperature in the range from <NUM> to <NUM>.

The process of the disclosure may comprise a mixing step, in which two or more constituents of the precursor, or the precursor itself, is mixed. In one embodiment, the process of the disclosure comprises a mixing step. In another embodiment, the process of the disclosure does not comprise a mixing step. In one embodiment, no longer than <NUM> hour are spent mixing, preferably no longer than <NUM> minutes, more preferably no longer than <NUM> minute. Where the process comprises a mixing step, it is preferably carried out prior to the heating step. Where the process comprises a high temperature heating step, a low temperature heating step and a mixing step, the mixing step is preferably performed prior to the low temperature heating step and the low temperature heating step is preferably carried out prior to the high temperature heating step.

A particular contribution made by the present disclosure is process simplicity. In particular, the present disclosure can obviate the need for additional steps prior to firing, in particular low temperature heating steps or lengthy mixing steps. In one embodiment, the time between first contact between the carbon source and the amphiphilic species and the start of a firing step is less than <NUM> hours, preferably less than <NUM> hours, more preferably less than <NUM> hour, more preferably less than <NUM> minutes, more preferably less than <NUM> minutes. In one aspect of this embodiment, the start of a firing step is the first time the precursor is raised to a temperature above <NUM>, or above <NUM>, or above <NUM>, or above <NUM>, or above <NUM>.

The process may comprise a graphitisation step, designed to modify the properties of the porous carbon material. In one embodiment, the process comprises a graphitisation step following a firing step. The graphitisation step is preferably performed at a higher temperature to the firing step. In another embodiment, the process does not comprise separate firing and graphitisation steps. In one aspect of this embodiment, a high temperature step is employed for both carbonisation of the carbon source and graphitisation of the resultant porous carbon material.

Preferred temperatures for the graphitisation step are in the range from <NUM> to <NUM>, more preferably in the range from <NUM> to <NUM>, most preferably in the range from <NUM> to <NUM>. Where the process comprises a graphitisation step, the graphitisation step is preferably performed after the heating step.

A contribution to achieving at least one of the above mentioned objects is made by a porous carbon material according to the present invention. It is preferred according to the disclosure that the carbon source is carbonised in the heating step and the porous carbon material is obtained. The porous carbon material differs from the precursor in one or more, preferably all, of the following ways: constituents of the precursor other than the carbon source are removed from the precursor during heating and are no longer present in the porous carbon material; some atoms other than carbon are removed from the carbon source during heating and are no longer present in the porous carbon material, whereby the porous carbon material has a lower proportional content of atoms other than carbon than the carbon source; the porous carbon material is a contiguous solid, in contrast to the precursor which comprises a mixture of liquids and non-contiguous solids; the porous carbon material has a lower density than the carbon source or than the precursor or than both.

The term contiguous solid is used in reference to the porous carbon material to indicate that the carbon atom constituents of the porous carbon material are linked in collections of atoms which are immoveable relative to each other, wherein those collections are larger than the molecular scale, preferably having a largest dimension more than <NUM> Angstrom, more preferably more than <NUM> Angstrom, further more preferably more than <NUM> Angstrom, more preferably more than <NUM> Angstrom, more preferably more than <NUM>,<NUM> Angstrom. In one embodiment, the porous carbon material is present as a body having a largest dimension of at least <NUM>, preferably at least <NUM>, more preferably at least <NUM>. In another embodiment, the porous carbon material is present as a collection of particles, preferably following a step in which a single body is split into two or more bodies.

The porous carbon material can be employed in a number of technical applications. Preferred applications are the following: An electrochemical cell; a fuel cell, in particular a hydrogen fuel cell, and there in particular in proton exchange membrane; a capacitor; an electrode; and a catalyst. Preferred electrochemical cells in this context are lead acid cells and lithium ion cells. Preferred fuel cells in this context are hydrogen cells. Preferred capacitors in this context are electric double layer capacitors.

Process conditions and individual constituents can be selected to achieve desired properties of the porous carbon material whilst still working within the scope of the invention. For example, a graphitisation step following firing can be employed for decreasing the BET surface area of the porous carbon material.

The porous carbon material of the invention is as described in the claims.

In one embodiment, the porous carbon material has one or more, preferably all of the following features:.

In one aspect of this embodiment, it is preferred for one or more of the features a. to be fulfilled.

In another aspect of this embodiment, it is preferred for at least features c. to be fulfilled.

Porous carbon materials of this embodiment are particularly suitable for use in lithium ion cells, in particular as a cathode additive. A contribution is made towards at least one of the above mentioned objects by a lithium ion cell comprising the porous carbon material of the invention, preferably according to this embodiment.

Porous carbon materials of this embodiment are particularly suitable for use in lithium ion cells, in particular as an anode additive. A contribution is made towards at least one of the above mentioned objects by a lithium ion cell comprising the porous carbon material of the invention, preferably according to this embodiment.

Porous carbon materials of this embodiment are particularly suitable for use in lead acid electrochemical cells. A contribution is made towards at least one of the above mentioned objects by a lead acid electrochemical cell comprising the porous carbon material of the invention, preferably according to this embodiment.

Porous carbon materials of this embodiment are particularly suitable for use in electric capacitors, preferably electric double layer capacitors. A contribution is made towards at least one of the above mentioned objects by a capacitor, preferably an electric double layer capacitor, comprising the porous carbon material of the invention, preferably according to this embodiment.

Porous carbon materials of this embodiment are particularly suitable for use in electrochemical cells, preferably fuel cells, more preferably proton exchange membrane fuel cells. A contribution is made towards at least one of the above mentioned objects by a fuel cell, preferably a proton exchange membrane fuel cell, comprising the porous carbon material of the invention, preferably according to this embodiment.

A further aspect of this disclosure relates to a porous carbon product having a specified distribution of particle size, preferably of particle diameter, preferably as determined by the test method presented herein. A preferred particle size, preferably particle diameter, is preferably a particle size of contiguous bodies.

A contribution towards overcoming at least one of the above described technical objects is made by a porous carbon material |Y1| having a particle distribution d<NUM> in the range from <NUM> to <NUM>, preferably <NUM> to <NUM>, more preferably <NUM> to <NUM>, more preferably <NUM> to <NUM>, more preferably in the range from <NUM> to <NUM>, more preferably in the range from <NUM> to <NUM>. In one embodiment, the porous carbon material has a particle size d<NUM> above <NUM>, preferably above <NUM>, more preferably above <NUM>, more preferably above <NUM>, preferably above <NUM>, more preferably above <NUM>. In one embodiment, the porous carbon material has a particle size d<NUM> below <NUM>, preferably below <NUM>, more preferably below <NUM>, more preferably below <NUM>, more preferably below <NUM>, more preferably below <NUM>. In some cases the particle size d<NUM> may be up to about <NUM>. In one embodiment, it is preferred for the porous carbon material to satisfy one or more of the features described generally for porous carbon materials in this disclosure. In one embodiment, it is preferred for the porous carbon material to be obtainable, preferably obtained, by a process disclosed herein.

A contribution towards overcoming at least one of the above described technical objects is made by a process |Y2| comprising the following steps:.

In one embodiment, the porous carbon material has a particle size d<NUM> above <NUM>, preferably above <NUM>, more preferably above <NUM>, more preferably above <NUM>, preferably above <NUM>, more preferably above <NUM>. In one embodiment, the porous carbon material has a particle size d<NUM> below <NUM>, preferably below <NUM>, more preferably below <NUM>, more preferably below <NUM>, more preferably below <NUM>, more preferably below <NUM>. In some cases the particle size d<NUM> may be up to about <NUM>. In one embodiment, it is preferred for the porous carbon material to satisfy one or more of the features described generally for porous carbon materials in this disclosure. In one embodiment, it is preferred for the porous carbon material to be obtainable, preferably obtained, by a process disclosed herein.

A contribution towards overcoming at least one of the above described technical objects is made by a device comprising the porous carbon material according to |Y1| or obtainable by the process according to |Y2|. A preferred device in this context is a cell, preferably a cell comprising lead or an acid or both. The porous carbon material is preferably employed in or at an electrode, preferably an anode. In one embodiment, the device comprises an acid. A preferred acid is sulphuric acid. In one embodiment, the device comprises water. In one embodiment, the device comprises PbSO<NUM>. In one embodiment, the device comprises an electrolyte. Preferred constituents of the electrolyte are H<NUM>SO<NUM> and H<NUM>O. A preferred concentration of H<NUM>SO<NUM> in the electrolyte is in the range from <NUM> to <NUM>/cm<NUM>, preferably in the range from <NUM> to <NUM>/cm<NUM>, more preferably in the range from <NUM> to <NUM>/cm<NUM>.

A contribution towards overcoming at least one of the above described technical objects is made by a use of a porous carbon material according to |Y1| or obtainable by the process according to |Y2| in a device. A preferred device in this context is a cell, preferably a cell comprising lead or an acid or both. The porous carbon material is preferably employed in or at an electrode, preferably an anode. In one embodiment, the device comprises an acid. A preferred acid is sulphuric acid. In one embodiment, the device comprises water. In one embodiment, the device comprises PbSO<NUM>. In one embodiment, the device comprises an electrolyte. Preferred constituents of the electrolyte are H<NUM>SO<NUM> and H<NUM>O. A preferred concentration of H<NUM>SO<NUM> in the electrolyte is in the range from <NUM> to <NUM>/cm<NUM>, preferably in the range from <NUM> to <NUM>/cm<NUM>, more preferably in the range from <NUM> to <NUM>/cm<NUM>. The use is preferably for improving cell performance. In one aspect, the use is for reducing water loss. In one aspect the use is for increasing charge acceptance.

The following test methods are used in the invention. In absence of a test method, the ISO test method for the feature to be measured published most recently before the earliest filing date of the present application applies. In absence of distinct measuring conditions, standard ambient temperature and pressure (SATP) as a temperature of <NUM> (<NUM>, <NUM> °F) and an absolute pressure of <NUM> kPa (<NUM> psi, <NUM> atm) apply.

The skeletal density measurements were performed according to DIN <NUM>-<NUM>. Between <NUM> and <NUM> of the powder sample were weighed in the sample cell and dried at <NUM> under vacuum for <NUM> prior to the measurement. The mass after drying was used for the calculation. A Pycnomatic ATC Helium Pycnometer from Themo Fisher Scientific, Inc. was used for the measurement, employing the "small" sample volume and the "small" reference volume. The pycnometer is calibrated monthly using the "extra small" sphere with a well-known volume of around <NUM><NUM>. Measurements were performed using Helium with a purity of <NUM>, at a temperature of <NUM> and a gas pressure of approx. <NUM> bar, according to the DIN standard and the SOP of the device.

The specific pore volume for different pore sizes, the cumulative pore volume, and the porosity were measured by mercury porosimetry. The mercury porosimetry analysis was performed according to ISO15901-<NUM> (<NUM>). A ThermoFisher Scientific PASCAL <NUM> (low pressure up to 4bar) und a PASCAL <NUM> (high pressure up to 4000bar) and SOLID Version <NUM>. <NUM> (<NUM>. <NUM>) software (all from Thermo Fisher Scientific, Inc. ) were calibrated with porous glass spheres with a modal pore diameter of <NUM> and pore volume of <NUM><NUM>/g (ERM-FD122 Reference material from BAM). During measurements the pressure was increased or decrease continuously and controlled automatically by the instrument running in the PASCAL mode and speed set to <NUM> for intrusion and <NUM> for extrusion. The Washburn method was employed for the evaluation and the density of Hg was corrected for the actual temperature. Value for surface tension was <NUM> N/m and contact angle <NUM>°. Sample size was between about <NUM> and <NUM>. Before starting a measurement, samples were heated to <NUM> in vacuum for <NUM> hour.

BET measurements to determine the specific surface area of particles are made in accordance with DIN ISO <NUM>:<NUM>. A NOVA <NUM> (from Quantachrome) which works according to the SMART method (Sorption Method with Adaptive dosing Rate), is used for the measurement. As reference material Quantachrome Alumina SARM Catalog No. <NUM> (<NUM><NUM>/g on multi-point BET method), and SARM Catalog No. <NUM> (<NUM><NUM>/g on multi-point BET method) available from Quantachrome are used. Filler rods are added to the reference and sample cuvettes in order to reduce the dead volume. The cuvettes are mounted on the BET apparatus. The saturation vapour pressure of nitrogen gas (N2 <NUM>) is determined. A sample is weighed into a glass cuvette in such an amount that the cuvette with the filler rods is completely filled and a minimum of dead volume is created. The sample is kept at <NUM> for <NUM> hour under vacuum in order to dry it. After cooling the weight of the sample is recorded. The glass cuvette containing the sample is mounted on the measuring apparatus. To degas the sample, it is evacuated at a pumping speed selected so that no material is sucked into the pump to a final pressure of <NUM> mbar.

The mass of the sample after degassing is used for the calculation. For data analysis the NovaWin <NUM> Software is used. A multi-point analysis with <NUM> measuring points is performed and the resulting total specific surface area (BETtotal) given in m<NUM>/g. The dead volume of each sample cell is determined once prior the measurement using Helium gas (He <NUM>, humidity <NUM> ppmv). The glass cuvettes are cooled to <NUM> using a liquid nitrogen bath. For the adsorptive, N<NUM> <NUM> with a molecular cross-sectional area of <NUM><NUM> at <NUM> is used for the calculation.

The empirical t-plot methodology is used according to ISO15901-<NUM>:<NUM> to discriminate between contributions from micropores and remaining porosity at relative pressures of more than <NUM> (i.e. mesoporosity, macroporosity and external surface area contributions) and to calculate the micropore surface (BETmicro) and micropore volume. The low pressure isotherm data points up to a cut-off p/p<NUM> , typically up to <NUM> p/p<NUM> are selected to determine the linear section of the t-plot. Data point selection is validated by obtaining a positive C constant. The micropore volume is determined from the ordinate intercept. The micropore specific surface area (BETmicro) can be calculated from the slope of the t-plot.

The external specific surface area BETexternal is defined by subtracting the micropore specific surface area from the total specific surface area, BETexternal = BETtotal - BETmicro.

For particle size determination of the particles a laser diffraction method was used according to ISO Standard <NUM>. A Mastersizer <NUM> from Malvern equipped with a He-Ne Laser (wave length of <NUM> with a maximum power of <NUM> mW) and a blue LED (wave length of <NUM> with a maximum power of <NUM> mW) and wet dispersing unit (Hydro MV) was employed for the measurements performed at ambient temperature of <NUM>. A mixture of isopropanol and deionized water (<NUM>% / <NUM>%) was used as measurement medium. The mixture was degassed in the dispersing unit by using the built-in stirrer at <NUM> rpm and ultrasonicate at maximum power for <NUM> seconds. The sample material is prepared as a concentrated dispersion in <NUM>% isopropanol (<NUM>). The quantity of material is sufficient to create a homogeneous mixture after the ultrasonic finger mixing for <NUM> seconds. The sample is added to the dispersing unit drop-wise with a pipette until the obscuration value is between <NUM>-<NUM>%. The values of D<NUM>, D<NUM> and D<NUM> (volume based) were determined using the Malvern software Mastersizer <NUM> Software <NUM>, and a form factor of <NUM>. The Fraunhofer theory is used for samples where the particles are > <NUM> and the Mie theory is applied to materials where the particles are < <NUM>.

Sieving for weight fractions with particles having a size larger than <NUM> were performed carefully with a sieve with an Air Jet RHEWUM LPS <NUM> MC sieving machine (RHEWUM GmbH) equipped with a sieve with <NUM> openings from Haver und Böcker (HAVER & BOECKER OHG).

A <NUM> of amphiphilic molecule and <NUM> of deionized water are introduced into a <NUM> glass container with screw top lid. The closed container is vigorously shaken for <NUM> seconds. This <NUM> second shaking is repeated <NUM> further times separated by <NUM> minute intervals. After a <NUM> day interval, the closed container is again vigorously shaken for <NUM> seconds and the <NUM> second shaking is repeated <NUM> further times separated by <NUM> minute intervals. The container is inspected visually immediately after the final shaking. The dispersability is characterised by the following three features:.

Clear in this context preferably means producing an obscuration of less than <NUM> % according to the method given herein. The container is also inspected after the following periods of time following the final shaking: <NUM> minutes, <NUM> minutes, one hour and one day. In each further inspection, the dispersibility is characterised according to features b.

The powder test sample is compacted using uniaxial mechanical pressing with a pressure of <NUM>/cm<NUM>. An electrical current was applied to the compacted test sample using gold plated electrodes and the potential difference across the voltage drop measured. From this measurement the electrical resistance and thus the conductivity in S/cm are calculated. A value of more than <NUM>/cm is classed as being electrically conductive.

The clarity of a solution is determined by laser obscuration using the Malvern Mastersizer <NUM> instrument equipped with a He-Ne Laser (<NUM> wavelength) and a blue LED and wet dispersing unit (Hydro MV) and measurements are performed at ambient temperature of <NUM>. A mixture containing <NUM> of amphiphilic molecule in <NUM> of deionized water are introduced into a <NUM> glass container with a screw top lid. The Hydro MV dispersing unit is automatically filled with deionized water by the Malvern software Mastersizer <NUM> Software <NUM> and the background measurement is measured. The built-in stirrer is set at <NUM> rpm and the solution is continuously stirred. An aliquot of <NUM> is pipetted out of the <NUM> water / <NUM> amphiphilic molecule solution and added to the Hydro MV dispersing unit. The unit is stirred at <NUM> rpm for <NUM> minutes. Three measurements are taken, each of <NUM> seconds, and the average obscuration of the He-Ne laser is determined for each measurement by the software and is reported as a percent. The path length of light through the sample is <NUM>. An obscuration (I<NUM>-I)/I<NUM> of less than <NUM>% is considered to be clear.

The determination of the ethylene oxide (EO) content is determined using the ASTM standard test method (D4875-<NUM>). The test method B with carbon-<NUM> nuclear magnetic resonance spectroscopy (<NUM>C NMR) is used. A Bruker AC <NUM> spectrometer was used with deuterated acetone (NMR-grade with tetramethylsilane (TMS) as internal standard) and NMR sample tubes with diameter of <NUM>. Samples are prepared with <NUM> of amphiphilic molecule with <NUM> of deuterated acetone, mixtures are vigorously shaken for <NUM> seconds. The shaking is repeated <NUM> times at <NUM> minute intervals. The appropriate sample amount is transferred to an NMR tube.

The spectrometer parameters are set as in the ASTM method with: the lock on acetone d-<NUM>, pulse angle <NUM>°, acquisition time of <NUM> seconds, pulse delay of <NUM> seconds, spectral width of <NUM> ppm, and <NUM> data point acquisition and the H-<NUM> decoupler on. The signal is acquired with <NUM> transients and Fourier transformed from a weighted free induction decay signal to the frequency domain spectrum. The integrated areas of the PO (propylene oxide) methane and methylene carbon peaks (from <NUM> to <NUM> and <NUM> to <NUM> ppm (TMS reference)) and the EO carbon resonances (from <NUM> to <NUM> and <NUM> to <NUM> ppm) are obtained. For EO-capped polyols, the resonance at <NUM> ppm corresponds to the beta carbon of the terminal EO block and is subtracted from the PO peak area and added to the EO peak area. The PO and EO ratio is obtained by: <MAT> Where:.

The weight percent of EO is calculated from the PO/EO ratio (calculated above) by: <MAT>.

Where the molecular mass for EO is <NUM>/mol EO and for PO is <NUM>/mol PO. The EO percent is reported to the nearest tenth percent.

The method of <NPL>) is employed. The ions are detected with a micro-channel plate (MCP) detector. The mass spectrum is analysed to determine the presence of spectral features separated by <NUM>/z units which correspond to adjacent EO units.

An Effective HLB value is determined from the stability determination of an oil and water emulsion made with various blends of two surfactants. The emulsion is made with a canola oil [<NPL>] and deionized water. If the unblended surfactant to be tested makes a two-phase dispersion or a non-clear dispersion in the water dispersability test immmediately after shaking, it is considered a low HLB value dispersant and is blended with Tween® <NUM> (HLB value from Griffin Method of <NUM> and available from Croda GmbH, [<NPL>]). If the surfactant to be tested makes a single non-gas-phase dispersion with a clear phase in the water dispersability test, it is considered a high HLB value dispersant and is blended with Span® <NUM> (HLB value from Griffin Method of <NUM> and available from Croda GmbH, [<NPL>]).

The emulsions each made with <NUM> of oil and <NUM> of deionized water added to a glass vial with a screw top lid. In each case, a <NUM> sample of the blend of surfactants is added to the oil and water mixture. The closed vial containing the mixture is vigorously shaken for <NUM> seconds. The <NUM> second shaking is repeated <NUM> times at <NUM> minute intervals. After a <NUM> day interval the closed vial is again vigorously shaken for <NUM> seconds and the <NUM> second shaking is repeated <NUM> further times separated by <NUM> minute intervals. The stability of the emulsions is characterized by the height of the water component in the dispersions as measured with a ruler in centimetres. The stability is measured after <NUM> days from the last shaking. The two blends which produced the water component with smallest height are identified. Further blends at <NUM> wt. % increments are made and tested in the range between the two identified blends. The blend which yields the smallest height of the water component matches the required HLB of canola oil of <NUM>. The effective HLB can be calculated from the weight ratio in the blend and the known HLB of the Span® <NUM> or Tween® <NUM> in the blend assuming the blend has a combined HLB of <NUM>.

Ethanol is added to the carbon material powder to be tested until a homogeneous wetted mass is obtained (typical ratio carbon:ethanol <NUM>:<NUM> by weight). A suspension of <NUM> wt. % of PTFE in water (Purchased from Sigma Aldrich GmbH, <NPL>) is employed as binder. A minimum sufficient amount of binder is employed for forming a dough-like mass later (typically binder in the range <NUM>-<NUM>% wt. % is required with respect to the carbon in the mixture). While mixing for one hour, the slurry will transform into a dough-like mass. The moist electrode is rolled out with a rolling pin to a layer thickness of <NUM> when wet, and dried for <NUM> at <NUM>. If the dried electrode exhibits cracking, the test procedure must be restarted employing a higher content of binder.

An <NUM> × <NUM> rectangle sample from the prepared dried electrode sheet is cut. A clip sample holder (SH0601 sample holder from Krüss GmbH) is used to hang the electrode sample. A force tensiometer K100 from Krüss GmbH is used in the contact angle measurement mode and using a glass vessel (SV20 from Krüss GmbH, diameter of <NUM>) containing <NUM>-propanol <NPL>). The measurement is controlled by the Krüss Laboratory Desktop software, Version <NUM>. <NUM>, provided by Krüss GmbH and performed at ambient temperature of <NUM>. The sample is suspended above the solvent which is raised at a <NUM>/min rate to detect the surface of the liquid (sensitivity for detection is <NUM>). The electrode sample is further dipped in the solvent by raising the solvent vessel at a rate of <NUM>/min. If the electrode bends or curls during the dipping procedure, the test is restarted with a new electrode sample. The mass is recorded every <NUM> from a depth of <NUM> to a final depth of <NUM>. The electrode sample is held at <NUM> depth for <NUM> seconds, after which the mass is again recorded. The electrode is removed from the solvent at a rate of <NUM>/min with data measurements every <NUM>. The mass of the absorbed solvent during the <NUM> hold at <NUM> is determined by subtraction. The measurement is repeated three times and the average solvent uptake mass is determined. The absorbed solvent mass is directly related to the transport efficiency in the electrode.

The disclosure is now further elucidated with reference to the figures. The figures and figure descriptions are exemplary and are not to be considered as limiting the scope of the invention.

<FIG> shows a process <NUM> for preparing a porous carbon material <NUM>. A carbon source <NUM>, in this case Tanex <NUM> (hydrolysable tannic acid mixture); an amphiphilic species <NUM>, in this case Synperonic PE/F127 (nonionic high HLB emulsifier); and optionally other constituents <NUM>, in this no further ingredients, were contacted in a contacting step <NUM> thereby obtaining a precursor <NUM>. A heating step <NUM> is performed to obtain a porous carbon material <NUM> from the precursor <NUM>.

<FIG> shows an SEM image of the surface of a material prepared according to the disclosure using Tanex <NUM> and Synperonic PE/F127 as starting materials. It can be seen that the carbon structure is formed of interconnected beads with hollow pores in between.

<FIG> shows an SEM image of the surface of a cross sectional cut through a material prepared according to the disclosure using Tanex <NUM> and Synperonic PE/F127 as starting materials. Here also the bead structure and pores of the carbon body are evident.

<FIG> shows an SEM image of the surface of a material prepared according to the disclosure using Tanex <NUM> and Synperonic PE/F127 as starting materials. Here also the long range porous structure of the carbon body is evident.

<FIG> shows an SEM image of the surface of a material prepared according to a comparative example using OmniVin 10R (condensed tannin) and Synperonic PE/F127 as starting materials. It can be seen that no long range porous structure in the carbon is formed.

<FIG> shows an SEM image of the surface of a material prepared according to a comparative example using Tanal QW (condensed tannin) and Synperonic PE/F127 as starting materials. It can be seen that no long range porous structure in the carbon is formed.

<FIG> shows the mercury porosimetry intrusion curve for the materials prepared according to the disclosure using Tanex <NUM> and Synperonic PE/F127 as starting materials.

The disclosure is now further elucidated with the aid of examples. These examples are for illustrative purposes and are not to be considered as limiting the scope of the invention. Commercial sources for materials employed are presented in table <NUM>.

<NUM> of tannic acid carbon source (according to table <NUM>) and a corresponding amount of an amphiphilic species (also according to table <NUM>) were introduced into a reaction vessel in proportions as indicated in table <NUM>. The reaction vessel and contents were immediately heated to <NUM> and maintained at that temperature for <NUM> hours. The properties of the resulting porous carbon material are also shown in table <NUM>.

Example <NUM> was repeated with the Synperonic PE/F127 amphiphilic species and the Tanex <NUM> carbon source, except that the reaction vessel also contained water. The weight ratio of amphiphilic species:carbon source:water was <NUM>:<NUM>:<NUM>. The properties of the resulting porous carbon material are shown in table <NUM>.

Example <NUM> was repeated with the Genapol X-<NUM> amphiphilic species and the Silvatech C carbon source. The weight ratio of amphiphilic species:carbon source is shown in table <NUM>. The properties of the resulting porous carbon material are shown in table <NUM>.

Example <NUM> was repeated with the Synperonic PE/F127 but with a condensed tannin in place of the tannic acid of the invention. Both OmniVin 10R and Tanal QW were employed as condensed tannin. No porous carbon product was formed. The weight ratio of carbon source : amphiphilic species and the results are shown in table <NUM>.

Hydrogen evolution tests and dynamic charge acceptance tests in a lead acid battery were performed using Lamp Black <NUM> (LB <NUM>) carbon black, available from Orion Engineered Carbons. The carbon black had a d<NUM> of <NUM> and a BET (NSA) value of <NUM><NUM>/g. Results are shown in table <NUM>.

Materials were prepared according to the recipes labelled as material <NUM> to <NUM> in table <NUM>. The obtained porous carbon material was resized to obtain particles having a particle size d<NUM> as given for the examples X1 to X7 in table <NUM>. The charge acceptance Id and the hydrogen evolution current IHER measured at -<NUM> V were determined according to the test method herein. The particle sizing was performed as follows:.

A coarse powder is obtained by crushing the material with a mortar and pestle to break the material mechanically to particles with a maximum diameter of <NUM>. Then, the coarse powder is processed to the target size using an Alpine Multi-processing system <NUM> ATP with a turboplex classifier (diameter <NUM>, Al2O3 material) and an Alpine Fluidised Bed Opposed Jet Mill <NUM> AFG from Hosokawa Alpine AG. The multi-processing system includes a cyclone (GAZ <NUM>) and a filter. The nitrogen gas used in the air jets of the mill has <NUM> bar of pressure and the feed rate of the material is <NUM>/hour. The sifter speed is <NUM> rpm. The material collected is in the cyclone fraction. The particle size is measured using the method described herein.

A coarse powder is obtained by crushing the material with a mortar and pestle to break the material mechanically to particles with a maximum diameter of <NUM>. Then, the coarse powder is process using a planetary ball mill such as the PM-<NUM> mill from Retsch GmbH with <NUM> grinding jars (Type "comfort") of zirconium oxide and <NUM> grinding balls, each ball with <NUM> diameter made from zirconium oxide (yttrium stabilized). The milling pots are filled with <NUM> of the coarse powder. The planetary ball mill is operated in "Manual mode" using the following parameters.

The bead mills are removed from the material by using the first mesh size in the sieving step. The oversize particles in the material are subsequently removed by a second sieving step with the given mesh size. Both sieving steps are done manually with the sieve placed on top of a bottom collecting pan, both with diameter of <NUM> and height of <NUM>. The material and balls are placed on top of the appropriate <NUM> sieve and slowly shaken in a rotary fashion until the material is collected in the collecting pan. The material is transferred from the collecting pan to another vessel, the sieve is changed to the given smaller mesh size and the material is again placed on the sieve and slowly shaken in a rotary fashion. The desired material is collected from the collecting pan and the particle size is measured using the method described herein.

Pastes for the negative electrode were prepared following the method described in the article by <NPL>) with the recipe given in the table <NUM>. <NUM> V laboratory test cells were prepared following the procedure in the same reference.

After construction of the batteries, the formation cycle was conducted also following the procedure as described in the same reference. The current @ -<NUM>. 5V vs. Ag/Ag<NUM>SO<NUM> gives an indication for the hydrogen evolution reaction and hence an indication for the water loss in the final battery. The measurements of the hydrogen evolution reaction were conducted as described in the article by <NPL>).

The DCA test protocol was adapted from EN-Norm <NUM>-<NUM>:<NUM> according to the qDCA protocol and following the method described in the same reference. Voltages in EN-Norm <NUM>-<NUM> were scaled by a factor of <NUM>/<NUM> as is appropriate for a 2V cell, and currents were downscaled to a 1Ah test cell regime. The values shown in Table <NUM> are the charging current Id after discharge as described in the reference.

Claim 1:
A porous carbon material characterized by
a. a total pore volume in the range from <NUM> to <NUM><NUM>/g for pores having a diameter in the range from <NUM> to <NUM>,<NUM>, with the total pore volume determined according to the mercury porosimetry method as described herein; and
b. a skeletal density in the range from <NUM> to <NUM>/cm<NUM>, with the skeletal density determined according to the skeletal density method as described herein.