Carbide‐Derived Carbon Monoliths with Hierarchical Pore Architectures

Abstract

Porous carbon materials are crucial components in catalysis, gas storage, electronics, and biochemistry. A hierarchical pore architecture in these materials is essential to achieve high surface areas combined with advanced mass transport kinetics. Widely used approaches for the generation of microor mesopores are activation and nanocasting. In contrast, macroporous carbon materials are primarily obtained by carbonization of polymeric precursor gels or replication of larger templates. A relatively new class of microand mesoporous carbon material with tunable porosity are carbide-derived carbon materials (CDCs). High-temperature chlorination of carbides leads to selective removal of metalor semi-metal atoms and allows control over the pore size of the resulting CDCs in a subngstrcm range by changing synthesis conditions or the carbide precursor. These materials have been studied for applications in gas storage and as electrode materials in supercapacitors because of their high specific surface areas. Recently, metal etching from pyrolyzed pre-ceramic components (polysilsesquioxanes or polysilazanes) was found to be a useful route towards carbide-derived carbon materials with enhanced porosity and gas-storage properties. A significant step towards ultrahigh specific surface area combined with a hierarchical mesoporous–microporous system was achieved using nanocasting of silica templates (SBA-15 or KIT-6) with polycarbosilane precursors and subsequent chlorine treatment of the resulting ordered mesoporous silicon carbides. These ordered mesoporous CDCs offer specific surface areas as high as 2800 mg 1 and total pore volumes of up to 2 cmg . Their mesostructure can be easily controlled by changing the silica hard template, resulting in excellent performance in protein adsorption, gas storage, and as electrodes for supercapacitors. However, such carbon materials are available only as nonstructured micrometer-sized powders and cannot be shaped into films without the addition of binders or the use of high mechanical stress, leading to structural deformation. Chlorine treatment of mechanically mixed Si/SiC precursors was found to be a useful route towards monolithic CDC with a hierarchical pore system. The presence of a free metal phase in the precursor system provides the opportunity to introduce a secondary macroporosity of 3 mm sized channels with a volume of 0.23 cmg 1 along with the microporous carbide-derived carbon material system. The introduction of large transport pores in polymerbased CDCs might be an alternative way to form materials that combine high surface areas with efficient fluid transport. The current literature describes a variety of routes for the production of highly macroporous ceramics from precursor polymers with controllable cell and window sizes. In particular, direct blowing of polycarbosilanes was found to be a useful approach for the generation of silicon carbide foams that might be suitable materials for the production of hierarchical CDCs. In the following, we describe a novel synthesis route for monolithic carbide-derived carbon materials, including micro-, meso-, and macroporous structures with extremely high specific surface area. They can be obtained by hightemperature chlorination of macroporous polymer-derived silicon carbide (SiC-PolyHIPE). A soft-templating approach starting from a high internal phase emulsion (HIPE) was used with an external oil phase consisting of liquid polycarbosilane SMP-10 and the cross-linker paradivinylbenzene. Using Span-80 as surfactant to stabilize the internal water phase, the application of oxidic or carbon hard templates and the corresponding template removal under harsh conditions is no longer necessary. After cross-linking the polymer chains, the resulting PolyHIPEs were pyrolyzed to silicon carbides at maximum temperatures of 700, 800, and 1000 8C and subsequently converted into CDCs by chlorine treatment at the maximum pyrolysis temperature (Supporting [*] M. Oschatz, L. Borchardt, Dr. I. Senkovska, N. Klein, Dr. R. Frind, Prof. Dr. S. Kaskel Department of Inorganic Chemistry Dresden University of Technology Bergstrasse 66, 01062 Dresden (Germany) E-mail: stefan.kaskel@chemie.tu-dresden.de