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JP-2026514391-A - Carbonaceous materials having modified physical and chemical properties, and methods for producing and using them.

JP2026514391AJP 2026514391 AJP2026514391 AJP 2026514391AJP-2026514391-A

Abstract

This specification discloses carbonaceous materials exhibiting properties and characteristics useful for their use in forming composite materials. In certain embodiments, the carbonaceous material includes a carbon content of 85% by weight or more, a surface area in the range of 150 m² /g to 500 m² /g, and an oil absorption value in the range of 50 g/100 g to 100 g/100 g. Methods for producing and using carbonaceous materials, including the formation of composite polymer compositions, are also disclosed.

Inventors

  • ドーナス，ポール
  • ウィリアムズ，ウィリアム・アール
  • マスノ，マコト・エヌ
  • スミス，ライアン・エル
  • オケイン，ルアイリ
  • ガオ，ユー
  • パテル，ヒマンシュ

Assignees

  • オリジン・マティアリアルズ・オペレーティング・インク

Dates

Publication Date
20260511
Application Date
20240328
Priority Date
20230329

Claims (20)

  1. A carbonaceous material produced from biomass raw materials, wherein the carbonaceous material is Carbon content of 85% by weight or more, The carbonaceous material includes a surface area in the range of 150 m² /g to 500 m² /g, and an oil absorption value in the range of 50 g/100 g to 100 g/100 g.
  2. The carbonaceous material according to claim 1, wherein the biomass supply raw material includes a lignin-free material, a lignin-containing material, or a combination thereof.
  3. The biomass supply raw material is a carbonaceous material according to any one of claims 1 to 2, comprising corn starch, wood material, or a combination thereof.
  4. The carbonaceous material according to any one of claims 1 to 3, wherein the biomass supply raw material is corn starch.
  5. A carbonaceous material according to any one of claims 1 to 4, further comprising a portion of unreacted biomass feedstock, macromolecular furan derivatives, cellulose compounds, lignin-based compounds, and/or lignin-derived compounds, or combinations thereof.
  6. The carbonaceous material according to claim 5, wherein the macromolecule furan derivative is a humic acid.
  7. The carbonaceous material according to any one of claims 1 to 6, wherein the oil absorption value is in the range of 65 g/100 g to 80 g/100 g.
  8. The carbonaceous material according to any one of claims 1 to 7, wherein the carbonaceous material is in the form of a particulate material, comprising (i) primary particles having a D50 value of 200 nm or more, or (ii) primary particles having a D50 value of 30 nm to 100 nm.
  9. The carbonaceous material is obtained by heat-treating a carbonophilic material at a temperature of 800°C to 1000°C, as described in any one of claims 1 to 8.
  10. The carbonaceous material is obtained by heat-treating a carbonophilic material at a temperature of 850°C, as described in any one of claims 1 to 8.
  11. A carbonaceous material according to claim 9 or claim 10, comprising less than 0.5 mg/kg of polycyclic aromatic hydrocarbons (PAHs).
  12. A carbonaceous material according to any one of claims 9 to 11, comprising less than 0.2 mg/kg of polycyclic aromatic hydrocarbons (PAHs).
  13. polymer matrix and A composite polymer composition comprising a filler material dispersed in the polymer matrix, wherein at least a portion of the filler material comprises a first filler component which is a carbonaceous material according to any one of claims 1 to 12.
  14. The composite polymer composition according to claim 13, wherein the filler material further comprises a second filler component that is chemically different from the first filler component.
  15. The composite polymer composition according to claim 14, wherein the second filler component comprises carbon black obtained from a non-biomass raw material.
  16. The composite polymer composition according to any one of claims 13 to 15, wherein the first filler component is present in an amount ranging from 0 to 60% by weight.
  17. A composite polymer composition according to any one of claims 13 to 16, having a tensile strength of 2500 psi or more.
  18. The composite polymer composition according to any one of claims 13 to 17, wherein the polymer matrix comprises a thermoplastic polymer or an elastomer.
  19. The composite polymer composition according to any one of claims 13 to 18, wherein the polymer matrix comprises one or more of styrene-butadiene rubber, butadiene rubber, ethylene propylene diene monomer rubber, isoprene rubber, butyl rubber, and natural rubber.
  20. The composite polymer composition according to any one of claims 13 to 19, wherein the first filler component is the carbonaceous material described in claim 4.

Description

Cross-reference of related applications: This application claims the interests of U.S. Provisional Patent Application No. 63/455,522 filed on 29 March 2023 and U.S. Provisional Patent Application No. 63/525,306 filed on 6 July 2023, each of which is incorporated herein by reference in its entirety. This disclosure relates to carbonaceous materials, composite polymer compositions containing carbonaceous materials, rubber-containing products containing carbonaceous materials, compositions containing carbonaceous materials, and methods for producing carbonaceous materials. Carbon black can typically be produced by the thermal decomposition (e.g., incomplete combustion) of hydrocarbons from fuels/synthetic raw materials. Carbon black is a versatile material. Carbon black particles have a complex structure and can form aggregates and aggregated particles. However, such particles can have small diameters (e.g., in the nanometer range), which allows carbon black to absorb and scatter light, producing the "black" color from which its name derives. Depending on the color and concentration of carbon black, it can produce deep shades of dark black when used as a pigment in inks, paints, and other matrices. Carbon black can also function as a reinforcing filler in polymer products such as rubber tires, belts, and hoses. The aspect ratio and particle structure of carbon black create a reinforcing network of particles within the polymer matrix. This results in more durable materials and can improve the rigidity, dimensional stability, and load-bearing capacity of the polymer matrix. Conventional carbon black (including the methods used to produce it) is associated with environmental and health considerations. In some cases, carbon black is produced by the incomplete combustion of fossil fuels such as petroleum products, coal tar, or natural gas. This can contribute to greenhouse gas emissions and resource consumption. Fossil-based carbon black may also contain polycyclic aromatic hydrocarbons (PAHs), which are known carcinogens. Therefore, improved methods are needed to produce and use materials that avoid these drawbacks. The aspects disclosed in this disclosure advantageously provide carbonaceous materials produced from biomass feedstock. In some aspects of this disclosure, the carbonaceous materials produced from biomass feedstock contain a carbon content of 85% by weight or more. In some aspects, the carbonaceous materials further include a surface area in the range of 150 m² /g to 500 m² /g, and/or an oil absorption value in the range of 50 g/100 g to 100 g/100 g. Certain disclosed embodiments relate to methods for producing carbonaceous materials according to this disclosure. In some embodiments, the method includes obtaining a carbonophilic material from a biomass feedstock and post-treating the carbonophilic material, the carbonophilic material may include a portion of the unreacted biomass feedstock, macromolecular furan derivatives, cellulose compounds, lignin compounds, or combinations thereof. In some embodiments, the post-treating of the carbonophilic material involves at least partial deoxygenation of the carbonophilic material to provide the carbonaceous material according to this disclosure. In independent embodiments, the post-treating of the carbonophilic material does not include treating the carbonophilic material with an activator. The aforementioned purposes, features, and advantages of this disclosure, as well as other purposes, features, and advantages, will become more apparent from the following detailed description, which will proceed with reference to the accompanying drawings. Images A through F are SEM microscope images of carbonophilic materials manufactured from 100% Southern Pine raw materials.Images A through F are SEM microscope images of carbonophilic materials manufactured from 100% Southern Pine raw materials.Images A through F are SEM microscope images of carbonophilic materials manufactured from 100% Southern Pine raw materials.Images A through F are SEM microscope images of carbonophilic materials manufactured from 100% Southern Pine raw materials.Images A through F are SEM microscope images of carbonophilic materials manufactured from 100% Southern Pine raw materials.Images A through F are SEM microscope images of carbonophilic materials manufactured from 100% Southern Pine raw materials.A to I are SEM micrographs of examples of carbonophilic and carbonaceous materials (A to G) and comparative materials (H and I) according to embodiments of the present disclosure. A and C show SEM micrographs of carbonophilic materials produced from a lignin-free raw material (A) containing 100% corn starch and a lignin-containing raw material (C) containing 100% Southern pine wood. B and D to G show SEM micrographs of carbonaceous materials obtained from specific parent materials. H and I show images of comparative materials lacking the structural features shown by the materials of the present d