Improving porous properties of activated carbon from carbon gel by the OTA method.

High-surface-area microporous-mesoporous carbons were produced from carbon gel by applying the three consecutive steps of air oxidation, thermal treatment, and activation (the OTA method) to the gel. The formation of mesopores occurs both inside and outside the nanoparticles which form the carbon gel, while micropores are predominantly created within the nanoparticles. The OTA method offered a greater increase in pore volume and BET surface area of the resulting activated carbon in comparison with conventional CO2 activation either under the same activation conditions or at the same degree of carbon burn-off. Under the best preparation conditions, the maximum values of micropore volume, mesopore volume, and BET surface area achievable using the OTA method were found to be 1.19 cm3 g-1, 1.81 cm3 g-1, and 2920 m2 g-1, respectively at a 72% carbon burn-off. The larger increase in porous properties of activated carbon gel prepared by the OTA method over those based on conventional activation stems from the effects of the oxidation and heat treatment steps of the OTA method that could produce a large number of reaction sites which lead to efficient pore formation during the following CO2 activation process.

Development of an efficient CVD technique to prepare TiO2/porous-carbon nanocomposites for high rate lithium-ion capacitors.

Titanium dioxide is a promising electrode material for lithium-ion capacitors. When using TiO2 as an electrode material, it is necessary to combine it with carbon at the nanometer level to improve its low electrical conductivity and low reactivity with Li+. However, preparation methods of reported TiO2/porous-carbon nanocomposites are generally not cost-effective, and their productivities are low. In this study, the vacuum liquid-pulse chemical vapor deposition (VLP-CVD) technique was developed to easily prepare TiO2/porous-carbon nanocomposites, where TiO2 nanoparticles with a diameter of ∼4 nm could be homogeneously deposited inside the pores of meso- or macroporous carbons. Because the deposited TiO2 nanoparticles had access to effective electrically conductive paths formed by the porous-carbon substrate, they showed a high discharge capacity of ∼200 mA h g-1-TiO2 (based on TiO2 weight). In particular, the composite prepared from macroporous carbon showed an extremely high rate performance, where 50% of the discharge capacity was retained at a current density of 15 000 mA g-1 when compared to that measured at 50 mA g-1. In addition, the composite also showed very high cyclability, where 80% of the discharge capacity was retained at the 10 000th cycle. Because the VLP-CVD technique can be performed using simple apparatus and commercially available starting materials, it can be expected to boost industrial production of TiO2/porous-carbon for lithium-ion capacitors.

Carbon Paper with a High Surface Area Prepared from Carbon Nanofibers Obtained through the Liquid Pulse Injection Technique.

To improve the performance of carbon paper used for applications such as electrodes for electrochemical devices and air filters, two types of long carbon nanofibers (CNFs) with average diameters of 20 and 49 nm were prepared by the liquid pulse injection (LPI) technique by adjusting reaction conditions. Carbon paper was made from the CNFs through a simple filtration process. The paper prepared from the CNFs with an average diameter of 20 nm (LPI-CNF(20) paper) was firm and flexible even though it was prepared without using any binders. LPI-CNF(20) paper also had a high surface area and showed a high electrical conductivity and a moderate gas permeability according to its void size. These properties are required for cathodes in the latest battery systems such as lithium-air batteries. In electrochemical experiments conducted to evaluate the performance of LPI-CNF(20) paper as a cathode, the paper showed a larger discharge capacity on the basis of the cathode weight than a conventional cathode (a commercially available carbon paper combined with a porous carbon), which indicated that it has a high potential to be used as a cathode in lithium-air batteries.

Development of TiO2-SiO2 Photocatalysts Having a Microhoneycomb Structure by the Ice Templating Method.

Immobilization of TiO2-based photocatalysts usually suffers from lowered surface area and mass transfer limitation compared with their suspended counterpart. In this work, TiO2-SiO2 monolithic photocatalysts having straight macropores, called microhoneycombs, were synthesized. The obtained samples had straight macropores with a diameter in the range of 15-40 µm formed by walls having a thickness up to 5 µm. The samples also contain micropores and small mesopores inside their walls, which contribute to high surface areas of more than 500 m2 g-1. Synthesized photocatalysts were tested in a continuous flow system using the decolorization of methylene blue as a model reaction. It was found that the unique morphology of the samples can be used to promote the uniform distribution of the target fluid while reducing the pressure drop across the photocatalyst to less than a hundredth compared with a packed bed system. In addition, calcination at 600-800 °C improved the strength and photocatalytic activity of the monoliths while preserving the high surface area of the samples.

Cellulose Nanofiber as a Distinct Structure-Directing Agent for Xylem-like Microhoneycomb Monoliths by Unidirectional Freeze-Drying.

Honeycomb structures have been attracting attention from researchers mainly for their high strength-to-weight ratio. As one type of structure, honeycomb monoliths having microscopically dimensioned channels have recently gained many achievements since their emergence. Inspired by the microhoneycomb structure that occurs in natural tree xylems, we have been focusing on the assembly of such a structure by using the major component in tree xylem, cellulose, as the starting material. Through the path that finally led us to the successful reconstruction of tree xylems by the unidirectional freeze-drying (UDF) approach, we verified the function of cellulose nanofibers, toward forming xylem-like monoliths (XMs). The strong tendency of cellulose nanofibers to form XMs through the UDF approach was extensively confirmed with surface grafting or a combination of a variety of second components (or even a third component). The resulting composite XMs were thus imparted with extra properties, which extends the versatility of this kind of material. Particularly, we demonstrated in this paper that XMs containing reduced graphene oxide (denoted as XM/rGO) could be used as strain sensors, taking advantage of their penetrating microchannels and the bulk elasticity property. Our methodology is flexible in its processing and could be utilized to prepare various functional composite XMs.

Li-rich Li-Si alloy as a lithium-containing negative electrode material towards high energy lithium-ion batteries.

Lithium-ion batteries (LIBs) are generally constructed by lithium-including positive electrode materials, such as LiCoO2, and lithium-free negative electrode materials, such as graphite. Recently, lithium-free positive electrode materials, such as sulfur, are gathering great attention from their very high capacities, thereby significantly increasing the energy density of LIBs. Though the lithium-free materials need to be combined with lithium-containing negative electrode materials, the latter has not been well developed yet. In this work, the feasibility of Li-rich Li-Si alloy is examined as a lithium-containing negative electrode material. Li-rich Li-Si alloy is prepared by the melt-solidification of Li and Si metals with the composition of Li21Si5. By repeating delithiation/lithiation cycles, Li-Si particles turn into porous structure, whereas the original particle size remains unchanged. Since Li-Si is free from severe constriction/expansion upon delithiation/lithiation, it shows much better cyclability than Si. The feasibility of the Li-Si alloy is further examined by constructing a full-cell together with a lithium-free positive electrode. Though Li-Si alloy is too active to be mixed with binder polymers, the coating with carbon-black powder by physical mixing is found to prevent the undesirable reactions of Li-Si alloy with binder polymers, and thus enables the construction of a more practical electrochemical cell.

Conversion of silica nanoparticles into Si nanocrystals through electrochemical reduction.

The precise design of Si-based materials at the nanometer scale is a quite complex issue but of utmost importance for their present and potential applications. This paper reports the first attempt to address the electrochemical reduction of SiO2 at the nanometer scale. SiO2 nanoparticles are first covered with a uniform carbon layer with controlled thickness at an accuracy of a few nanometers, by pressure-pulsed chemical vapor deposition. With appropriate thickness, the carbon layer plays significant roles as a current path and also as a physical barrier against Si-crystal growth, and the SiO2 nanoparticles are successfully converted into extremely small Si nanocrystals (<20 nm) inside the shell-like carbon layer whose morphology is derived from the original SiO2 nanoparticles. Thus, the proposed electroreduction method offers a new synthesis strategy of Si-C nanocomposites utilizing the morphology of SiO2 nanomaterials, which are well known for a wide variety of defined and regular nanostructures. Owing to the volume difference of SiO2 and the corresponding Si, nanopores are generated around the Si nanocrystals. It has been demonstrated that the nanopores around the Si nanocrystals are effective to improve cycle performance of Si as a negative electrode for lithium-ion batteries. The present method is in principle applicable to various SiO2 nanomaterials, and thus, offers production of a variety of Si-C composites whose carbon nanostructures can be defined by their parent SiO2 nanomaterials.