Carbon-based material and method of producing the same, and composite material and method of producing the same

Abstract

A method of producing a carbon-based material includes steps (a), (b) and (c). In the step (a), an elastomer and at least a first carbon material is mixed and the first carbon material is dispersed by applying a shear force to obtain a composite elastomer. In the step (b), the composite elastomer is heat-treated to vaporize the elastomer, and a second carbon material is obtained. In the step (c) the second carbon material is heat-treated together with a substance including an element Y to vaporize the substance including the element Y, a melting point of the element Y being low.

1 . A method of producing a carbon-based material, the method comprising: 
 (a) mixing an elastomer and at least a first carbon material and dispersing the first carbon material by applying a shear force to obtain a composite elastomer;    (b) heat-treating the composite elastomer to vaporize the elastomer included in the composite elastomer to obtain a second carbon material; and    (c) heat-treating the second carbon material together with a substance including an element Y and having a melting point lower than a melting point of the first carbon material to vaporize the substance including the element Y.    
     
     
         2 . The method of producing a carbon-based material as defined in  claim 1 , 
 wherein the step (b) is performed in the presence of a substance including an element X so that the element X bonds to a carbon atom of the first carbon material, and    wherein the element X includes at least one element selected from boron, nitrogen, oxygen, and phosphorus.    
     
     
         3 . The method of producing a carbon-based material as defined in  claim 2 , 
 wherein the composite elastomer includes the substance including the element X, and    wherein the element X bonds to the carbon atom of the first carbon material by the heat treatment in the step (b).    
     
     
         4 . The method of producing a carbon-based material as defined in  claim 2 , 
 wherein the step (b) is performed in an atmosphere containing the substance including the element X so that the element X bonds to the carbon atom of the first carbon material.    
     
     
         5 . The method of producing a carbon-based material as defined in  claim 2 , 
 wherein the element X is oxygen or nitrogen.    
     
     
         6 . The method of producing a carbon-based material as defined in  claim 1 , 
 wherein the composite elastomer includes the substance including the element Y.    
     
     
         7 . The method of producing a carbon-based material as defined in  claim 1 , 
 wherein, in the step (c), the substance including the element Y is disposed in a heat treatment furnace together with the second carbon material and vaporized by the heat treatment.    
     
     
         8 . The method of producing a carbon-based material as defined in  claim 1 , 
 wherein the carbon-based material is mixed into a matrix material including aluminum, and    wherein the substance including the element Y includes at least one element selected from magnesium, aluminum, silicon, calcium, titanium, vanadium, chromium, manganese, iron, nickel, copper, zinc, and zirconium.    
     
     
         9 . The method of producing a carbon-based material as defined in  claim 1 , 
 wherein the carbon-based material is mixed into a matrix material including magnesium, and    wherein the substance including the element Y includes at least one element selected from magnesium, aluminum, silicon, calcium, titanium, vanadium, chromium, manganese, iron, nickel, copper, zinc, and zirconium.    
     
     
         10 . The method of producing a carbon-based material as defined in  claim 8 , 
 wherein the substance including the element Y includes the element Y selected from magnesium, zinc, and aluminum.    
     
     
         11 . The method of producing a carbon-based material as defined in  claim 9 , 
 wherein the substance including the element Y includes the element Y selected from magnesium, zinc, and aluminum.    
     
     
         12 . The method of producing a carbon-based material as defined in  claim 1 , 
 wherein the first carbon material is carbon black.    
     
     
         13 . The method of producing a carbon-based material as defined in  claim 1 , 
 wherein the first carbon material is carbon fiber.    
     
     
         14 . The method of producing a carbon-based material as defined in  claim 13 , 
 wherein the carbon fiber is carbon nanofiber.    
     
     
         15 . The method of producing a carbon-based material as defined in  claim 14 , 
 wherein the carbon nanofibers have an average diameter of 0.5 to 500 nm.    
     
     
         16 . The method of producing a carbon-based material as defined in  claim 1 , 
 wherein the elastomer has a molecular weight of 5,000 to 5,000,000.    
     
     
         17 . The method of producing a carbon-based material as defined in  claim 1 , 
 wherein at least one of a main chain, a side chain, and a terminal chain of the elastomer includes at least one unsaturated bond or group having affinity to carbon nanofiber and selected from a double bond, a triple bond, and functional groups such as a-hydrogen, a carbonyl group, a carboxyl group, a hydroxyl group, an amino group, a nitrile group, a ketone group, an amide group, an epoxy group, an ester group, a vinyl group, a halogen group, a urethane group, a biuret group, an allophanate group, and a urea group.    
     
     
         18 . The method of producing a carbon-based material as defined in  claim 1 , 
 wherein a network component of the elastomer in an uncrosslinked form has a spin-spin relaxation time (T2n) measured at 30° C. by a Hahn-echo method using a pulsed nuclear magnetic resonance (NMR) technique of 100 to 3,000 μsec.    
     
     
         19 . The method of producing a carbon-based material as defined in  claim 1 , 
 wherein a network component of the elastomer in a crosslinked form has a spin-spin relaxation time (T2n) measured at 30° C. by a Hahn-echo method using a pulsed nuclear magnetic resonance (NMR) technique of 100 to 2,000 μsec.    
     
     
         20 . The method of producing a carbon-based material as defined in  claim 1 , 
 wherein the elastomer is natural rubber or nitrile butadiene rubber.    
     
     
         21 . The method of producing a carbon-based material as defined in  claim 1 , 
 wherein the step (a) is performed by using an open-roll method with a roll distance of 0.5 mm or less.    
     
     
         22 . The method of producing a carbon-based material as defined in  claim 21 , 
 wherein two rolls used in the open-roll method have a surface velocity ratio of 1.05 to 3.00.    
     
     
         23 . The method of producing a carbon-based material as defined in  claim 1 , 
 wherein the step (a) is performed by using an internal mixing method.    
     
     
         24 . The method of producing a carbon-based material as defined in  claim 1 , 
 wherein the step (a) is performed by using a multi-screw extrusion mixing method.    
     
     
         25 . The method of producing a carbon-based material as defined in  claim 1 , 
 wherein the step (a) is performed at 0 to 50° C.    
     
     
         26 . A carbon-based material obtained by the method as defined in  claim 1 .  
     
     
         27 . A carbon-based material which is mixed into a matrix material including aluminum or magnesium, 
 wherein a surface of a carbon material has a first bonding structure and a second bonding structure,    wherein the first bonding structure is a structure in which an element X bonds to a carbon atom of the carbon material,    wherein the second bonding structure is a structure in which an element Y bonds to the element X,    wherein the element X includes at least one element selected from boron, nitrogen, oxygen, and phosphorus, and    wherein the element Y includes at least one element selected from magnesium, aluminum, silicon, calcium, titanium, vanadium, chromium, manganese, iron, nickel, copper, zinc, and zirconium.    
     
     
         28 . A carbon-based material, 
 wherein a surface of a carbon material has a first bonding structure and a second bonding structure, and    wherein the first bonding structure is a structure in which oxygen bonds to a carbon atom of the carbon material, and    wherein the second bonding structure is a structure in which magnesium bonds to the oxygen.    
     
     
         29 . A method of producing a composite material, the method comprising: 
 (d) mixing the carbon-based material obtained by the method as defined in  claim 1  with a matrix material.    
     
     
         30 . A composite material obtained by the method as defined in  claim 29.