EP3044820A1 - Potential of zero charge modified carbon based electrode for desalination - Google Patents

Potential of zero charge modified carbon based electrode for desalination

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Publication number
EP3044820A1
EP3044820A1 EP14843583.7A EP14843583A EP3044820A1 EP 3044820 A1 EP3044820 A1 EP 3044820A1 EP 14843583 A EP14843583 A EP 14843583A EP 3044820 A1 EP3044820 A1 EP 3044820A1
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EP
European Patent Office
Prior art keywords
carbon
solution
electrode
film
formaldehyde
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP14843583.7A
Other languages
German (de)
French (fr)
Other versions
EP3044820A4 (en
Inventor
James Landon
Kunlei Liu
Xin Gao
Ayokunle Omosebi
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
University of Kentucky Research Foundation
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University of Kentucky Research Foundation
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Filing date
Publication date
Priority claimed from US14/230,668 external-priority patent/US20150166372A1/en
Application filed by University of Kentucky Research Foundation filed Critical University of Kentucky Research Foundation
Priority claimed from PCT/US2014/054947 external-priority patent/WO2015038612A1/en
Publication of EP3044820A1 publication Critical patent/EP3044820A1/en
Publication of EP3044820A4 publication Critical patent/EP3044820A4/en
Withdrawn legal-status Critical Current

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Classifications

    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00Electrodes
    • H01M4/02Electrodes composed of, or comprising, active material
    • H01M4/36Selection of substances as active materials, active masses, active liquids
    • H01M4/362Composites
    • H01M4/366Composites as layered products
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00Treatment of water, waste water, or sewage
    • C02F1/46Treatment of water, waste water, or sewage by electrochemical methods
    • C02F1/461Treatment of water, waste water, or sewage by electrochemical methods by electrolysis
    • C02F1/46104Devices therefor; Their operating or servicing
    • C02F1/46109Electrodes
    • HELECTRICITY
    • H01ELECTRIC ELEMENTS
    • H01MPROCESSES OR MEANS, e.g. BATTERIES, FOR THE DIRECT CONVERSION OF CHEMICAL ENERGY INTO ELECTRICAL ENERGY
    • H01M4/00Electrodes
    • H01M4/02Electrodes composed of, or comprising, active material
    • H01M4/13Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof
    • H01M4/133Electrodes based on carbonaceous material, e.g. graphite-intercalation compounds or CFx
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00Treatment of water, waste water, or sewage
    • C02F1/46Treatment of water, waste water, or sewage by electrochemical methods
    • C02F1/461Treatment of water, waste water, or sewage by electrochemical methods by electrolysis
    • C02F1/46104Devices therefor; Their operating or servicing
    • C02F1/46109Electrodes
    • C02F2001/46133Electrodes characterised by the material
    • C02F2001/46138Electrodes comprising a substrate and a coating
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F1/00Treatment of water, waste water, or sewage
    • C02F1/46Treatment of water, waste water, or sewage by electrochemical methods
    • C02F1/461Treatment of water, waste water, or sewage by electrochemical methods by electrolysis
    • C02F1/46104Devices therefor; Their operating or servicing
    • C02F1/46109Electrodes
    • C02F2001/46133Electrodes characterised by the material
    • C02F2001/46138Electrodes comprising a substrate and a coating
    • C02F2001/46142Catalytic coating
    • CCHEMISTRY; METALLURGY
    • C02TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02FTREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2103/00Nature of the water, waste water, sewage or sludge to be treated
    • C02F2103/08Seawater, e.g. for desalination
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E60/00Enabling technologies; Technologies with a potential or indirect contribution to GHG emissions mitigation
    • Y02E60/10Energy storage using batteries

Definitions

  • This document relates generally to the field of conductive carbon-based electrodes and, more particularly, to an electrode comprising a carbon sheet coated with a film. This film leads to the relocation of carbon's potential of zero charge (PZC).
  • PZC potential of zero charge
  • Charge efficiency is one of the important performance terms for a capacitive deionization (CDI) cell, which is given by the ratio of the equivalent charge of salt adsorbed to the charge passed during the adsorption step.
  • This efficiency value can be increased by variations in the applied voltage to the cell and the salt concentration, and the use of the membrane assisted electrodes. Beyond these physical variations/modifications, charge efficiency also can be alternatively elevated by chemically modifying the PZC of carbon-based electrodes. If the carbon's PZC is located in the electrode's working domain, a charge inefficiency will occur due to co-ion repulsion.
  • an electrode comprising a carbon sheet coated with a film.
  • This coated film results in the modification, or relocation, of the carbon's PZC.
  • the carbon sheet comprises a conductive carbon-based material.
  • the conductive carbon-based material is infiltrated with a solution comprising resorcinol and formaldehyde.
  • the carbon- based material is woven and may comprise, for example, carbon cloth, carbon felt, or carbon yarn.
  • a film is formed by dip-coating the carbon electrode in a solution followed by subsequent drying steps. The coating may have a thickness of between 1 A and 100 nm.
  • a method for making an electrode comprises the steps of: (a) infiltrating a carbon-based material with a solution containing resorcinol and formaldehyde; (b) polymerizing the solution infiltrated onto the carbon-based material to obtain a polymerized material; (c) subjecting the polymerized material to a solvent-exchange process; (d) carbonizing the polymerized material to obtain a carbonized material; and (e) coating the carbonized material with a film.
  • the subjecting step may include serially soaking the infiltrated carbon-based materialin deionized water and acetone followed by air drying.
  • the method may include completing the carbonizing step at about 800 - 1100°C for 30 - 360 min. In one embodiment the carbonizing step is completed at about 1,000°C for about 120 minutes. In any embodiment, the carbonizing step may further comprise using a ramp rate of about 1 to 5°C min "1 for heating from and cooling to room temperature. Further, the carbonizing step includes using a N 2 or Ar gas supply with flow greater than 300 mL min "1 during carbonizing in order to provide an inert atmosphere.
  • the solution used to infiltrate the carbon-based material has a mole ratio of resorcinol to formaldehyde of about 1:2.
  • the coating step may further comprise dipping the carbonized carbon-based woven material into a silica solution.
  • That silica solution may include tetraethyl orthosilicate.
  • the solution includes tetraethyl orthosilicate, ethanol and nitric acid with a volumetric ratio of from 1: 1: 1 to 1:50: 1.
  • the solution includes tetraethyl orthosilicate, ethanol and nitric acid with a volumetric ratio of from 1: 10: 1 to 1:30: 1.
  • the solution includes tetraethyl orthosilicate, ethanol and nitric acid with a volumetric ratio of 1:20: 1.
  • the coating step may comprise (a) dipping the carbonized woven carbon cloth into the silica solution, (b) drying the carbonized woven carbon cloth following dipping and (c) repeating steps (a) and (b).
  • the dipping may be done for three minutes followed by drying for thirty minutes.
  • the method may further comprise cutting the electrode to a desired shape.
  • methods described herein are applied to a carbon-based woven material.
  • the carbon-based woven material comprises carbon cloth, carbon felt, or carbon yarn.
  • the carbon-based woven material comprises carbon cloth.
  • the film is prepared from a solution comprising one or more of carbon nanotubes, silicon, organic-functionalized silicon, silica, organic-functionalized silica, copper, chitosan, alumina, titania, vanadia, zirconia, magnesia, any metal or metal oxide from any group 3 (IIIB) to group 12 (IIB) element, or any nonmetal.
  • the film is prepared from a solution comprising one or more nonmetals, which are selected from the group consisting of silicon, germanium, boron, antimony, or tellurium.
  • FIG. 2 indicates the use of TEOS modification (one of the modification methods) results in a significant change in the surface conditions. For instance, Si bonds were established on the carbon surface.
  • FIG. 3 gives the FTIR results to attest the change in the functional groups at the surface of a carbon material before and after the modifications.
  • FIG. 4 gives an example of relocation of the PZC for the treated sample by the use of sulfuric acid solution (SAS) and sulfanilic acid solution (SNAS). As indicated in the magnified plot, the degree of PZC shifting is -0.3 V when the unmodified (pristine) carbon is compared.
  • SAS sulfuric acid solution
  • SNAS sulfanilic acid solution
  • FIG. 5 shows that not only the use of sulfuric acid solution (SAS) but also the used of electro-oxidative method results in the PZC region for the treated carbon being positively shifted.
  • SAS sulfuric acid solution
  • FIG. 6 shows the PZC region of a carbon material can be detected by both cyclic voltammetry (CV) and electrochemical impedance spectroscopy (EIS). Both methods consistently suggest that the unmodified carbon (Pr) has a PZC region of ⁇ - 0.15 V vs SCE, and the treated sample (electro-oxidative) has a PZC region of -0.5 V vs. SCE.
  • CV cyclic voltammetry
  • EIS electrochemical impedance spectroscopy
  • FIG. 7 shows that the PZC shifting of a carbon material can be achieved by the use of HNO 3 acid.
  • the EIS spectra show the PZC region has been shifted from—0.2 V to -0.2 V after HNC -treatment.
  • FIG. 8 shows the possible location of the PZC region of a carbon electrode within the respective potential distribution. This representation suggests that the deionization performance can be substantially boosted when the PZC region is out of the corresponding electrode's working domain, and vice versa. For example, when a CDI cell employs the treated carbon as the cathode and the untreated carbon as the anode, the separation performance indicated in FIG. 9 can be significantly enhanced.
  • FIG. 1 illustrating a carbon sheet 10 which comprises a conductive woven carbon cloth infiltrated with a solution containing resorcinol and formaldehyde.
  • that solution includes a mole ratio of resorcinol to formaldehyde in the range of from 5: 1 to 1:5.
  • that solution includes a mole ratio of resorcinol to formaldehyde in the range of from 3: 1 to 1;3.
  • that solution includes a mole ratio of resorcinol to formaldehyde of about 1:2.
  • the infiltrated woven carbon cloth is subjected to polymerization. This is followed by subjecting the infiltrated woven carbon to a solvent exchange process. That solvent exchange process includes serially soaking the infiltrated woven carbon cloth with deionized water and acetone. This is then followed by air drying.
  • the carbonizing is subjected to carbonizing.
  • the carbonizing is completed at a temperature of between about 800 and about 1100°C for between about 30 and about 360 minutes.
  • the carbonizing is completed at a temperature of between about 900 and about 1100°C for between about 60 and about 240 minutes.
  • the carbonizing is completed at a temperature of between about 950 and 1050°C for between about 90 and about 180 minutes.
  • the carbonizing is completed at about 1,000°C for about 120 minutes.
  • the method may include using a ramp rate of about 1 to 5°C per minute for heating from and cooling to room temperature.
  • the carbonizing is completed in an inert atmosphere.
  • the inert atmosphere is provided by using a nitrogen gas supply with flow greater than 300 ml min "1 during carbonizing.
  • the resulting carbon sheet 10 has a surface chemistry including carbon-carbon double bonds, carbon oxygen bonds and hydroxyl groups.
  • the carbon sheet 10 is subjected to coating with a film.
  • the carbon sheet 10 is dipped into a silica solution comprising tetraethyl orthosilicate (TEOS).
  • TEOS tetraethyl orthosilicate
  • the silica solution further comprises TEOS, ethanol and nitric acid with a volumetric ratio of 1:20: 1.
  • the pH of the solution is between about 2 and 8 pH.
  • the method includes (a) dipping the carbon sheet into the silica solution, (b) drying the carbon sheet following dipping and (c) repeating steps (a) and (b) until the silica coating is provided at a desired thickness. In one embodiment that thickness is between 1 A - 10 nm. In another embodiment that thickness is between 10 nm - 100 nm.
  • the coating step further comprises dipping said carbonized material into said solution for 1 to 30 minutes and drying said carbonized material for 5 to 500 minutes. In a further embodiment, the dipping may be for three minutes followed by drying for thirty minutes.
  • the dried film coated carbon sheet forms an electrode 12 (see Figure 2) including a unique surface chemistry. As illustrated in Figure 2, that surface chemistry includes -Si and -COOH functional groups which increase the negative charge on the surface of the electrode. This promotes cation absorption and thereby increases the wettability of the electrode 12 to provide for enhanced performance. This is particularly true for an electrode 12 utilized in capacitive deionization applications such as for the desalinition (e.g. , purification of salt water into drinking water.).
  • the electrode described herein may be used in supercapacitors and/or batteries.
  • the carbon sheets were composed of commercially conductive carbon cloth
  • a solvent-exchange process was performed for the polymerized samples, in which the samples were subjected to 2-hours of soaking in deionized water, 2-hours of soaking in acetone, and 2-hours of air-drying. Finally, the samples were carbonized at 1000°C for 2 hours using a ramp rate of 1 or 5°C min 1 for both heating and cooling from room temperature using a nitrogen gas supply with flow greater than 300 ml/min.
  • the quartz tube used here was 48 inches long with an external diameter of 3 inches and an internal diameter of 2.75 inches.
  • the carbon sheets were modified by the following steps in order to lead to a silica film being formed at the carbon surface: TEOS (Sigma-Aldrich), ethanol (Pharmco-Aaper), and HNO 3 (Acros) were vigorously mixed with a volumetric ratio of 1:20: 1 in a sealed glass bottle for 1 hour at room temperature.
  • the carbon sheets were dipped into the mixture for 3 min, and dried in an oven at 100°C for 30 min.
  • the carbon sheets were dipped repetitively into the TEOS mixture so as to vary the amount of silica deposited. All the received carbon sheets were kept in a vacuum desiccator before any characterization.
  • FTIR spectroscopy examined the chemical species at the carbon surface (FIG. 3).
  • Table 2 Effect of Na 2 C0 3 addition on carbon xerogel sheets' porosities and surface area. The porosities and surface areas were calculated using BJH method based upon desorption isotherms.
  • the PZC of the surface of an electrode as described herein may be modified to enhance deionization capability.
  • Treatments for xerogel materials are shown using sulfuric acid (FIG. 4), sulfanilic acid (FIG. 4), and electrochemical oxidation (FIG. 5).
  • Treatments for an activated carbon fiber cloth include electrochemical oxidation (FIG. 6) and nitric acid oxidation (FIG. 7). All of these treatments can be used with various carbon materials to shift the PZC and modify the salt removal capability of a capacitive deionization device.
  • PZC shifting and ideal locations are showin in FIG. 8 with salt removal experiments for both capacitive deionization and membrane capacitive deionization being shown in FIG. 9.
  • HNC -treatment The procedure for the HNC -treatment is as follows. A graduated cylinder with a film cover was used to heat 300 cm of -70% HNO 3 (Sigma- Aldrich) in a temperature-controlled coolant bath. When the temperature of HNO 3 was stable (at 20, 35, 50 and 80°C, selected by considering the principle of design of experiment), a carbon electrode, in one embodiment carbon xerogel (CX), with a geometric area of -70 cm was placed into the cylinder for 1 h. After treatment, to remove any residual HNO 3 on the surface of the carbon, the treated carbon was washed with a great amount of deionized water until the pH value approached neutral.
  • CX carbon xerogel
  • the wet carbon was post- treated at 160°C overnight in a vacuum oven before testing.
  • the treated carbon electrodes can be labeled as C-20, -35, -50 and -80, representing carbon sheet that was treated in HN0 3 at different temperatures, e.g., C-20 means that a carbon sheet was treated at 20°C.
  • C-20 means that a carbon sheet was treated at 20°C.
  • Organic sulfanilic acid was also used to treat the carbon electrode.
  • the procedure is as follows. A mixture of water (H 2 0), hydrochloric acid (HC1), sulfanilic acid (C 6 H 7 NO 3 S), sodium nitrite (NaN0 2 ), and acetone ((CH 3 ) 2 CO) in respective ratios of 39: 1.3: 1:0.4: 1.4 by weight was prepared in a beaker kept in a water bath with temperature at ⁇ 6°C.
  • a carbon electrode, in one embodiment a CX sheet was placed in the reaction product and left to sit for 12 hours. The CX sheet was withdrawn and repeatedly rinsed in deionized water until the solution pH was neutral.
  • a carbon electrode is heated at 350°C for between 0.5 h and 4 h in an oven or furnace open to the air.
  • the corresponding samples can be denoted as C-Ox-(0.5h) and C-Ox-(4h).
  • This oxidation leads to the creation of oxide groups on the carbon electrode's surface which positively shifts the electrode's PZC.
  • Temperatures above 300°C and below 800°C can be used for various time durations to modify the extent to which the PZC is shifted which will affect the resulting deionization performance of a capacitive deionization (CDI) cell.
  • CDI capacitive deionization
  • the electrodes can be oxidized using electrochemical treatments.
  • carbon electrodes can be electrochemically oxidized at the anode using a cell potential of 1.5 V in a CDI cell for a period of 20 hours with a 4 mM NaCl electrolyte solution.
  • this cell potential can be anywhere from 0.4 V to 3 V for various time durations.
  • This anode or positive electrode in this cell will subsequently have a positively-modified PZC which can be used to enhance deionization capacity in an asymmetrically configured CDI cell.

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Abstract

An electrode is provided which includes a carbon-based material coated with a film which modifies the material's potential of zero charge. A method for producing the electrode includes steps of infiltrating a woven carbon cloth with a solution containing resorcinol and formaldehyde, polymerizing the solution infiltrated woven carbon cloth, subjecting the infiltrated and polymerized woven carbon cloth to a solvent-exchange process, carbonizing the woven carbon cloth and coating the carbonized woven carbon cloth with a film.

Description

POTENTIAL OF ZERO CHARGE MODIFIED CARBON BASED ELECTRODE FOR
DESALINATION
[0001] This utility patent application claims the benefit of priority in U.S. Provisional
Patent Application Serial Nos. 61/876,264, filed on September 11, 2013, and 61/915,794, filed December 13, 2013, and U.S. Nonprovisional Patent Application Serial No. 14/230,668, filed on March 31, 2014, the entirety of the disclosures of which are incorporated herein by reference.
TECHNICAL FIELD
[0002] This document relates generally to the field of conductive carbon-based electrodes and, more particularly, to an electrode comprising a carbon sheet coated with a film. This film leads to the relocation of carbon's potential of zero charge (PZC).
BACKGROUND
[0003] Charge efficiency is one of the important performance terms for a capacitive deionization (CDI) cell, which is given by the ratio of the equivalent charge of salt adsorbed to the charge passed during the adsorption step. This efficiency value can be increased by variations in the applied voltage to the cell and the salt concentration, and the use of the membrane assisted electrodes. Beyond these physical variations/modifications, charge efficiency also can be alternatively elevated by chemically modifying the PZC of carbon-based electrodes. If the carbon's PZC is located in the electrode's working domain, a charge inefficiency will occur due to co-ion repulsion. By coating a carbon material with a thin film, we are able to provide an electrode for CDI cell applications, which provides enhanced performance characteristics.
SUMMARY
[0004] In accordance with the purposes and benefits described herein, an electrode is provided comprising a carbon sheet coated with a film. This coated film results in the modification, or relocation, of the carbon's PZC. The carbon sheet comprises a conductive carbon-based material. In an embodiment, the conductive carbon-based material is infiltrated with a solution comprising resorcinol and formaldehyde. In a further embodiment, the carbon- based material is woven and may comprise, for example, carbon cloth, carbon felt, or carbon yarn. A film is formed by dip-coating the carbon electrode in a solution followed by subsequent drying steps. The coating may have a thickness of between 1 A and 100 nm.
[0005] In accordance with an additional aspect, a method is provided for making an electrode. That method comprises the steps of: (a) infiltrating a carbon-based material with a solution containing resorcinol and formaldehyde; (b) polymerizing the solution infiltrated onto the carbon-based material to obtain a polymerized material; (c) subjecting the polymerized material to a solvent-exchange process; (d) carbonizing the polymerized material to obtain a carbonized material; and (e) coating the carbonized material with a film. In accordance with the method, the subjecting step may include serially soaking the infiltrated carbon-based materialin deionized water and acetone followed by air drying. Further, the method may include completing the carbonizing step at about 800 - 1100°C for 30 - 360 min. In one embodiment the carbonizing step is completed at about 1,000°C for about 120 minutes. In any embodiment, the carbonizing step may further comprise using a ramp rate of about 1 to 5°C min"1 for heating from and cooling to room temperature. Further, the carbonizing step includes using a N2 or Ar gas supply with flow greater than 300 mL min"1 during carbonizing in order to provide an inert atmosphere.
[0006] In one possible embodiment the solution used to infiltrate the carbon-based material has a mole ratio of resorcinol to formaldehyde of about 1:2. The coating step may further comprise dipping the carbonized carbon-based woven material into a silica solution. That silica solution may include tetraethyl orthosilicate. In one embodiment the solution includes tetraethyl orthosilicate, ethanol and nitric acid with a volumetric ratio of from 1: 1: 1 to 1:50: 1. In another embodiment, the solution includes tetraethyl orthosilicate, ethanol and nitric acid with a volumetric ratio of from 1: 10: 1 to 1:30: 1. In another embodiment, the solution includes tetraethyl orthosilicate, ethanol and nitric acid with a volumetric ratio of 1:20: 1.
[0007] In an embodiment, the coating step may comprise (a) dipping the carbonized woven carbon cloth into the silica solution, (b) drying the carbonized woven carbon cloth following dipping and (c) repeating steps (a) and (b). The dipping may be done for three minutes followed by drying for thirty minutes. The method may further comprise cutting the electrode to a desired shape.
[0008] In one embodiment, methods described herein are applied to a carbon-based woven material. In a further embodiment, the carbon-based woven material comprises carbon cloth, carbon felt, or carbon yarn. In another embodiment, the carbon-based woven material comprises carbon cloth.
[0009] In one embodiment, the film is prepared from a solution comprising one or more of carbon nanotubes, silicon, organic-functionalized silicon, silica, organic-functionalized silica, copper, chitosan, alumina, titania, vanadia, zirconia, magnesia, any metal or metal oxide from any group 3 (IIIB) to group 12 (IIB) element, or any nonmetal.
[0010] In one embodiment, the film is prepared from a solution comprising one or more nonmetals, which are selected from the group consisting of silicon, germanium, boron, antimony, or tellurium.
[0011] These and other embodiments of the present invention will be set forth in the description which follows, and in part will become apparent to those of ordinary skill in the art by reference to the following description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The accompanying drawings incorporated herein and forming a part of the specification, illustrate several aspects of the electrode made from a carbon-based material (e.g., carbon cloth) coated with a silica film and together with the description serve to explain certain principles thereof. In the drawings:
[0013] A schematic representation (FIGS. 1 and 2) shows the change in the functional groups at the surface of a carbon material before and after the modifications (e.g., TESO modification, HNO3 treatment, air-oxidation, and electrochemical oxidation). FIG. 1 represents that the unmodified carbon contains C=C, C-O, and O-H groups. FIG. 2 indicates the use of TEOS modification (one of the modification methods) results in a significant change in the surface conditions. For instance, Si bonds were established on the carbon surface.
[0014] FIG. 3 gives the FTIR results to attest the change in the functional groups at the surface of a carbon material before and after the modifications. By comparison of the unmodified carbon (dashed line), the use of TEOS medication leads to the C=0, S1-C6H5, N02, and Si-O-C being formed (solid line).
[0015] Potential of zero charge (PZC) region (dashed square) of a carbon material can be relocated by using one of the modification methods mentioned above. FIG. 4 gives an example of relocation of the PZC for the treated sample by the use of sulfuric acid solution (SAS) and sulfanilic acid solution (SNAS). As indicated in the magnified plot, the degree of PZC shifting is -0.3 V when the unmodified (pristine) carbon is compared.
[0016] FIG. 5 shows that not only the use of sulfuric acid solution (SAS) but also the used of electro-oxidative method results in the PZC region for the treated carbon being positively shifted.
[0017] FIG. 6 shows the PZC region of a carbon material can be detected by both cyclic voltammetry (CV) and electrochemical impedance spectroscopy (EIS). Both methods consistently suggest that the unmodified carbon (Pr) has a PZC region of ~ - 0.15 V vs SCE, and the treated sample (electro-oxidative) has a PZC region of -0.5 V vs. SCE.
[0018] FIG. 7 shows that the PZC shifting of a carbon material can be achieved by the use of HNO3 acid. The EIS spectra show the PZC region has been shifted from—0.2 V to -0.2 V after HNC -treatment.
[0019] FIG. 8 shows the possible location of the PZC region of a carbon electrode within the respective potential distribution. This representation suggests that the deionization performance can be substantially boosted when the PZC region is out of the corresponding electrode's working domain, and vice versa. For example, when a CDI cell employs the treated carbon as the cathode and the untreated carbon as the anode, the separation performance indicated in FIG. 9 can be significantly enhanced.
[0020] Reference will now be made in detail to the present electrode embodiments, examples of which are illustrated in the accompanying drawings. DETAILED DESCRIPTION
[0021] Reference is now made to Figure 1 illustrating a carbon sheet 10 which comprises a conductive woven carbon cloth infiltrated with a solution containing resorcinol and formaldehyde. In one embodiment, that solution includes a mole ratio of resorcinol to formaldehyde in the range of from 5: 1 to 1:5. In another embodiment, that solution includes a mole ratio of resorcinol to formaldehyde in the range of from 3: 1 to 1;3. In another embodiment, that solution includes a mole ratio of resorcinol to formaldehyde of about 1:2. After infiltration the infiltrated woven carbon cloth is subjected to polymerization. This is followed by subjecting the infiltrated woven carbon to a solvent exchange process. That solvent exchange process includes serially soaking the infiltrated woven carbon cloth with deionized water and acetone. This is then followed by air drying.
[0022] Next the carbon is subjected to carbonizing. In one embodiment the carbonizing is completed at a temperature of between about 800 and about 1100°C for between about 30 and about 360 minutes. In another embodiment, the carbonizing is completed at a temperature of between about 900 and about 1100°C for between about 60 and about 240 minutes. In another embodiment, the carbonizing is completed at a temperature of between about 950 and 1050°C for between about 90 and about 180 minutes. In another embodiment the carbonizing is completed at about 1,000°C for about 120 minutes. In any embodiment, the method may include using a ramp rate of about 1 to 5°C per minute for heating from and cooling to room temperature. In one embodiment the carbonizing is completed in an inert atmosphere. In one embodiment the inert atmosphere is provided by using a nitrogen gas supply with flow greater than 300 ml min"1 during carbonizing. As illustrated in Figure 1, the resulting carbon sheet 10 has a surface chemistry including carbon-carbon double bonds, carbon oxygen bonds and hydroxyl groups.
[0023] In accordance with an additional aspect of the present method, the carbon sheet 10 is subjected to coating with a film. In one embodiment, the carbon sheet 10 is dipped into a silica solution comprising tetraethyl orthosilicate (TEOS). In one embodiment the silica solution further comprises TEOS, ethanol and nitric acid with a volumetric ratio of 1:20: 1. The pH of the solution is between about 2 and 8 pH. In one embodiment the method includes (a) dipping the carbon sheet into the silica solution, (b) drying the carbon sheet following dipping and (c) repeating steps (a) and (b) until the silica coating is provided at a desired thickness. In one embodiment that thickness is between 1 A - 10 nm. In another embodiment that thickness is between 10 nm - 100 nm.
[0024] In accordance with an additional aspect of the present method, the coating step further comprises dipping said carbonized material into said solution for 1 to 30 minutes and drying said carbonized material for 5 to 500 minutes. In a further embodiment, the dipping may be for three minutes followed by drying for thirty minutes. The dried film coated carbon sheet forms an electrode 12 (see Figure 2) including a unique surface chemistry. As illustrated in Figure 2, that surface chemistry includes -Si and -COOH functional groups which increase the negative charge on the surface of the electrode. This promotes cation absorption and thereby increases the wettability of the electrode 12 to provide for enhanced performance. This is particularly true for an electrode 12 utilized in capacitive deionization applications such as for the desalinition (e.g. , purification of salt water into drinking water.). The electrode described herein may be used in supercapacitors and/or batteries.
[0025] Reference is made to the following example which further illustrates the electrode and the method of making the same.
Preparation of Silica- Coated Carbon Sheets
[0026] The fabrication of carbon sheets coated with a silica film consisted of two steps -
1) preparation of the carbon sheet and 2) dip-coating of the resulting carbon sheet within TEOS mixtures. In the following paragraphs, these steps will be detailed.
[0027] The carbon sheets were composed of commercially conductive carbon cloth
(untreated, Fuel Cell Store) infiltrated with solutions mainly containing resorcinol (Sigma- Aldrich), and formaldehyde (37 wt in methanol, Sigma- Aldrich) mixed in a 1 :2 mole ratio. The detailed preparation of the solution will be introduced separately. After infiltration, the wet substrates were immobilized between two glass slides and sealed overnight. The sheets were then heated at 85°C for a period of 24 hours in air, where the polymerization reaction was halted under such conditions. Subsequently, a solvent-exchange process was performed for the polymerized samples, in which the samples were subjected to 2-hours of soaking in deionized water, 2-hours of soaking in acetone, and 2-hours of air-drying. Finally, the samples were carbonized at 1000°C for 2 hours using a ramp rate of 1 or 5°C min 1 for both heating and cooling from room temperature using a nitrogen gas supply with flow greater than 300 ml/min. The quartz tube used here was 48 inches long with an external diameter of 3 inches and an internal diameter of 2.75 inches.
[0028] Following fabrication of the carbon sheets, the carbon sheets were modified by the following steps in order to lead to a silica film being formed at the carbon surface: TEOS (Sigma-Aldrich), ethanol (Pharmco-Aaper), and HNO3 (Acros) were vigorously mixed with a volumetric ratio of 1:20: 1 in a sealed glass bottle for 1 hour at room temperature. The carbon sheets were dipped into the mixture for 3 min, and dried in an oven at 100°C for 30 min. The carbon sheets were dipped repetitively into the TEOS mixture so as to vary the amount of silica deposited. All the received carbon sheets were kept in a vacuum desiccator before any characterization.
[0029] FTIR spectroscopy examined the chemical species at the carbon surface (FIG. 3).
By comparison, new bands at -1730, -1430 and -1100 cm"1 corresponding to C=0 stretching, S1-C6H5 stretching, and Si-O-C stretching, respectively were found (dashed and solid line). This assignment indicates that the modification resulted not only in a thin-film containing Si, but also in the attachment of -COOH functional groups to the carbon surface. This change is schematically illustrated in Figures 1 and 2. The addition of these -Si and -COOH functional groups increased the negative charge on the carbon surface (promoting cation adsorption) and increased the wettability of the carbon.
Preparation of Carbon Xerogel Sheets with Different Porosities and Surface Areas Effect of Na2C03 Concentration on Porosities and Surface Areas
[0030] The solutions were prepared by mixing 10 g resorcinol, 14.74 g formaldehyde (37 wt% in methanol), 3 g of X M Na2C03 solution (where X = 0.01, 0.02, 0.1, 0.25, and 0.5) in a sealed glass bottle. These chemical agents were vigorously mixed for 0.5 hours at room temperature. The resulting solutions were subsequently examined using a pH meter. As expected, we found that the pH of the solutions were strongly affected using the Na2C03 solutions with different concentrations. The corresponding results are listed in Table 1 (see below). It can be seen that an increase in the concentration of Na2C03 solutions results in an increase in the pH of the solutions.
[0031] Table 1. Effect of Na2C03 addition on pH of mixtures. In this study, the mass of resorcinol and formaldehyde (37 wt in methanol) is fixed at 10 g and 14.74 g, respectively, resulting in the mole ratio of resorcinol and formaldehyde being 1:2. Following this mixing, 3 g of X M Na2C03 solution was added, where X = 0.01, 0.02, 0.1, 0.25 and 0.5.
X (concentration of Na2CQ3) / M pH
0.01 2.62
0.02 4.55
0.1 6.62
0.25 7.17
0.5 7.58
[0032] The use of the same carbon xerogel sheet preparation procedure but solutions with different pH values yielded different isotherms measured by a porosity and surface area analyzer (Micrometrics, ASAP 2020). Based upon the isotherms, the corresponding pore volumes and surface areas were calculated using the BJH method and BET method, respectively, and the corresponding results can be seen in Table 2 (see below). It was found that the addition of Na2C03 with different concentrations (the adjustment of solution's pH) has affected the porosities and surface areas of the resulting carbon sheets. In general, an increase in the Na2C03 concentration leads to a decrease in the pore volume but an increase in the surface area.
[0033] Table 2. Effect of Na2C03 addition on carbon xerogel sheets' porosities and surface area. The porosities and surface areas were calculated using BJH method based upon desorption isotherms.
Pore Volume
X (concentration of Na2C03) (M) 3 1 Surface Area (m g
0.01 0.57 150.11
0.02 0.40 171.31
0.1 0.26 211.36
0.25 0.15 203.79
0.5 0.047 106.9
Modification of PZC of Electrode Surface to Enhance Deionization Capability
[0034] In an aspect, the PZC of the surface of an electrode as described herein may be modified to enhance deionization capability. Treatments for xerogel materials are shown using sulfuric acid (FIG. 4), sulfanilic acid (FIG. 4), and electrochemical oxidation (FIG. 5). Treatments for an activated carbon fiber cloth include electrochemical oxidation (FIG. 6) and nitric acid oxidation (FIG. 7). All of these treatments can be used with various carbon materials to shift the PZC and modify the salt removal capability of a capacitive deionization device. PZC shifting and ideal locations are showin in FIG. 8 with salt removal experiments for both capacitive deionization and membrane capacitive deionization being shown in FIG. 9.
[0035] PZC Modification through Acid Treatments
[0036] The procedure for the HNC -treatment is as follows. A graduated cylinder with a film cover was used to heat 300 cm of -70% HNO3 (Sigma- Aldrich) in a temperature-controlled coolant bath. When the temperature of HNO3 was stable (at 20, 35, 50 and 80°C, selected by considering the principle of design of experiment), a carbon electrode, in one embodiment carbon xerogel (CX), with a geometric area of -70 cm was placed into the cylinder for 1 h. After treatment, to remove any residual HNO3 on the surface of the carbon, the treated carbon was washed with a great amount of deionized water until the pH value approached neutral. Subsequently, the wet carbon was post- treated at 160°C overnight in a vacuum oven before testing. The treated carbon electrodes can be labeled as C-20, -35, -50 and -80, representing carbon sheet that was treated in HN03 at different temperatures, e.g., C-20 means that a carbon sheet was treated at 20°C. The same procedures can also be used for sulfuric acid (H2S04) treatments at different temperatures and concentrations.
[0037] Organic sulfanilic acid was also used to treat the carbon electrode. The procedure is as follows. A mixture of water (H20), hydrochloric acid (HC1), sulfanilic acid (C6H7NO3S), sodium nitrite (NaN02), and acetone ((CH3)2CO) in respective ratios of 39: 1.3: 1:0.4: 1.4 by weight was prepared in a beaker kept in a water bath with temperature at ~6°C. A carbon electrode, in one embodiment a CX sheet, was placed in the reaction product and left to sit for 12 hours. The CX sheet was withdrawn and repeatedly rinsed in deionized water until the solution pH was neutral.
[0038] PZC Modification through Oxidation Treatment
[0039] The procedure for modifying a carbon electrode's PZC by oxidation treatments in the air is relatively straightforward. In one embodiment, a carbon electrode is heated at 350°C for between 0.5 h and 4 h in an oven or furnace open to the air. The corresponding samples can be denoted as C-Ox-(0.5h) and C-Ox-(4h). This oxidation leads to the creation of oxide groups on the carbon electrode's surface which positively shifts the electrode's PZC. Temperatures above 300°C and below 800°C can be used for various time durations to modify the extent to which the PZC is shifted which will affect the resulting deionization performance of a capacitive deionization (CDI) cell.
[0040] In addition, to thermal oxidation in air or oxygen, the electrodes can be oxidized using electrochemical treatments. In one embodiment, carbon electrodes can be electrochemically oxidized at the anode using a cell potential of 1.5 V in a CDI cell for a period of 20 hours with a 4 mM NaCl electrolyte solution. In another embodiment, this cell potential can be anywhere from 0.4 V to 3 V for various time durations. This anode or positive electrode in this cell will subsequently have a positively-modified PZC which can be used to enhance deionization capacity in an asymmetrically configured CDI cell.
[0041] The foregoing has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the embodiments to the precise form disclosed. Obvious modifications and variations are possible in light of the above teachings. All such modifications and variations are within the scope of the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled.

Claims

WHAT IS CLAIMED:
1. An electrode, comprising a carbon sheet coated with a film, wherein said film modifies a potential zero charge of carbon, and wherein said carbon sheet comprises a conductive carbon- based material.
2. The electrode of claim 1, wherein said carbon-based material is infiltrated with a solution containing resorcinol and formaldehyde.
3. The electrode of any of claims 1 or 2, wherein said carbon-based material comprises a carbon-based woven material.
4. The electrode of claim 3, wherein said carbon-based woven material comprises carbon cloth, carbon felt, or carbon yarn.
5. The electrode of any of claims 3 or 4, wherein said carbon-based woven material comprises carbon cloth.
6. The electrode of any of claims 1-5, wherein said film is prepared from a solution comprising one or more of carbon nanotubes, silicon, organic-functionalized silicon, silica, organic-functionalized silica, copper, chitosan, alumina, titania, vanadia, zirconia, magnesia, any metal or metal oxide from any group 3 (IIIB) to group 12 (IIB) element, or any nonmetal.
7. The electrode of any of claims 1-6, wherein said film is prepared from a solution comprising silica.
8. The electrode of any of claims 1-6, wherein said film is prepared from a solution comprising one or more nonmetals, which are selected from the group consisting of silicon, germanium, boron, antimony, or tellurium.
9. The electrode of any of claims 1-7, wherein said solution further comprises tetraethyl orthosilicate (TEOS), ethanol and nitric acid.
10. The electrode of any of claims 1-9, wherein said film has a thickness of from 1 A to 100 nm.
11. A method of making an electrode, comprising:
infiltrating a carbon-based woven material with a solution comprising resorcinol and formaldehyde to obtain an infiltrated material;
polymerizing said solution infiltrated onto the carbon-based woven material to obtain a polymerized material;
subjecting said polymerized material to a solvent-exchange process;
carbonizing said polymerized material to obtain a carbonized material; and
coating said carbonized material with a film.
12. The method of claim 11, wherein said carbon-based woven material comprises carbon cloth, carbon felt, or carbon yarn.
13. The method of any of claims 11 or 12, wherein said carbon-based woven material comprises carbon cloth.
14. The method of any of claims 11-13, wherein said film is prepared from a solution comprising one or more of carbon nanotubes, silicon, organic-functionalized silicon, silica, organic-functionalized silica, copper, chitosan, alumina, titania, vanadia, zirconia, magnesia, any metal or metal oxide from any group 3 (IIIB) to group 12 (IIB) element, or any nonmetal.
15. The method of any of claims 11-14, wherein said film is prepared from a solution comprising silica.
16. The method of any of claims 11-14, wherein said film is prepared from a solution comprising one or more nonmetals, which are selected from the group consisting of silicon, germanium, boron, antimony, or tellurium.
17. The method of any of claims 11-16, wherein said subjecting step comprises serially soaking said infiltrated carbon in deionized water and acetone; and air drying.
18. The method of any of claims 11-17, wherein said carbonizing step is completed at about 800 - 1100 °C for 30 - 360 minutes.
19. The method of any of claims 11-18, wherein said carbonizing step is completed at about
900 - 1100 °C for 60 - 240 minutes.
20. The method of any of claims 11-19, wherein said carbonizing step is completed at about 950 - 1050 °C for 90 - 180 minutes.
21. The method of any of claims 11-20, wherein said carbonizing step is completed at about 1,000°C for about 120 minutes.
22. The method of any of claims 11-21, wherein said carbonizing step further comprises using a ramp rate of about 1°C to 5°C per minute for heating from and cooling to room temperature.
23. The method of any of claims 11-22, wherein said carbonizing step further comprises a nitrogen or argon gas supply with a flow rate greater than 300ml min"1 to provide an inert atmosphere during carbonizing.
24. The method of any of claims 11-23, wherein a mole ratio of resorcinol to formaldehyde in said solution containing resorcinol and formaldehyde is from about 5: 1 to 1:5.
25. The method of any of claims 11-24, wherein a mole ratio of resorcinol to formaldehyde in said solution containing resorcinol and formaldehyde is from about 3: 1 to 1:3.
26. The method of any of claims 11-25, wherein a mole ratio of resorcinol to formaldehyde in said solution containing resorcinol and formaldehyde is about 1:2.
27. The method of any of claims 11-26, wherein said coating step comprises dipping said carbonized material into a silica solution.
28. The method of any of claims 15 or 27, wherein said solution further comprises tetraethyl orthosilicate.
29. The method of any of claims 15, 27, or 28, wherein said solution further comprises tetraethyl orthosilicate, ethanol and nitric acid with a volumetric ratio of from 1: 1: 1 to 1:50: 1.
30. The method of any of claims 15 or 27-29, wherein said solution further comprises tetraethyl orthosilicate, ethanol and nitric acid with a volumetric ratio of from 1: 10: 1 to 1:30: 1.
31. The method of any of claims 15, or 27-30, wherein said solution further comprises tetraethyl orthosilicate, ethanol and nitric acid with a volumetric ratio of 1:20: 1.
32. The method of any of claims 11-32, wherein said coating step comprises
(a) dipping said carbonized material into a silica solution,
(b) drying said carbonized material following said dipping step, and
(c) repeating steps (a) and (b).
33. The method of any of claims 11-32, wherein said coating step further comprises dipping said carbonized material into said solution for 1 to 30 minutes and drying said carbonized material for 5 to 500 minutes.
34. The method of any of claims 11-33, further comprising cutting said electrode to a desired shape.
35. The method of any of claims 11-34, further comprising altering concentration of Na2C03 in said solution of resorcinol and formaldehyde to control porosity and surface area of resulting electrode.
36. Use of the electrode of any of claims 1-8 in desalination.
37. Use of the electrode of any of claims 1-8 in supercapacitors and/or batteries.
38. An electrode, comprising a carbon-based material coated with a film modifying the carbon's potential of zero charge, wherein the film may be prepared from a solution containing carbon nanotubes, silicon, organic functionalized silicon, silica, organic functionalized silica, copper, chitosan, alumina, titania, vanadia, zirconia, or magnesia, and wherein the film may also be prepared from metals and metal oxides from any group 3 (IIIB) to group 12 (IIB) elements or any nonmetals such as silicon, germanium, boron, antimony, or tellurium.
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