Method for producing carbon composite material and carbon composite material

Abstract

A method for producing a carbon composite material to reduce costs; and a carbon composite material includes a dealloying step of immersing a carbon-containing material composed of a compound, alloy or non-equilibrium alloy containing carbon in a metal bath, the metal bath having a solidification point lower than a melting point of the carbon-containing material, the metal bath being controlled to a lower temperature than a minimum value of a liquidus temperature within a compositional fluctuation range extending from the carbon-containing material to carbon by decreasing other non-carbon main components, to thereby selectively elute the other non-carbon main components into the metal bath to form a carbon member having microvoids; and a cooling step performed with the microvoids of the carbon member including a component of the metal bath to solidify the component. The carbon composite material combining carbon with the metal bath component that has solidified is thereby obtained.

1 . A method for producing a carbon composite material comprising a dealloying step of bringing a carbon-containing material composed of a compound, alloy or non-equilibrium alloy containing carbon into contact with a molten metal, the molten metal having a solidification point that is lower than a melting point of the carbon-containing material, the molten metal being controlled to a lower temperature than a minimum value of a liquidus temperature within a compositional fluctuation range extending from the carbon-containing material to carbon by decreasing other non-carbon main components, to thereby selectively elute the other non-carbon main components into the molten metal to form microvoids and allow the molten metal to penetrate the microvoids; and a cooling step performed with the microvoids including the molten metal to solidify the molten metal. 
     
     
         2 . The method according to  claim 1  for producing a carbon composite material, wherein the dealloying step is immersing the carbon-containing material into a metal bath composed of the molten metal thereby selectively eluting the other non-carbon main components into the metal bath. 
     
     
         3 . The method according to  claim 1  for producing a carbon composite material, comprising a pretreatment step of arranging a solid metal having a solidification point that is lower than a melting point of the carbon-containing material so as to contact the carbon-containing material, the pretreatment step followed by the dealloying step through heating the solid metal to turn the solid metal into the molten metal for selectively eluting the other non-carbon main components into the molten metal. 
     
     
         4 . The method according to  claim 1  for producing a carbon composite material, wherein the molten metal is composed of Ag, Bi, Cu, Ga, Ge, Hg, In, Ir, Pb, Pt, Rh, Sb, Sn, or Zn, or is composed of a mixture that is an alloy of at least one of those components as a main component, and wherein the other non-carbon main components are composed of any one or a mixture including more than one of Al, B, Be, Ca, Ce, Cr, Dy, Er, Eu, Fe, Gd, Hf, Ho, K, La, Li, Lu, Mg, Mn, Mo, Na, Nb, Nd, Pr, Sc, Se, Si, Sm, Sr, Ta, Ti, V, W and Zr. 
     
     
         5 . The method according to  claim 1  for producing a carbon composite material, wherein the dealloying step is performed in an inert atmosphere or a vacuum atmosphere, or performed in air with flux added to the molten metal. 
     
     
         6 . A carbon composite material comprising carbon and Ag, Bi, Cu, Ga, Ge, Hg, In, Ir, Pb, Pt, Rh, Sb, Sn or Zn, or an alloy including at least one of those components as a main component. 
     
     
         7 . A carbon composite material comprising carbon and Ag, Cu or Zn. 
     
     
         8 . The method according to  claim 2  for producing a carbon composite material, wherein the molten metal is composed of Ag, Bi, Cu, Ga, Ge, Hg, In, Ir, Pb, Pt, Rh, Sb, Sn, or Zn, or is composed of a mixture that is an alloy of at least one of those components as a main component, and wherein the other non-carbon main components are composed of any one or a mixture including more than one of Al, B, Be, Ca, Ce, Cr, Dy, Er, Eu, Fe, Gd, Hf, Ho, K, La, Li, Lu, Mg, Mn, Mo, Na, Nb, Nd, Pr, Sc, Se, Si, Sm, Sr, Ta, Ti, V, W and Zr. 
     
     
         9 . The method according to  claim 3  for producing a carbon composite material, wherein the molten metal is composed of Ag, Bi, Cu, Ga, Ge, Hg, In, Ir, Pb, Pt, Rh, Sb, Sn, or Zn, or is composed of a mixture that is an alloy of at least one of those components as a main component, and wherein the other non-carbon main components are composed of any one or a mixture including more than one of Al, B, Be, Ca, Ce, Cr, Dy, Er, Eu, Fe, Gd, Hf, Ho, K, La, Li, Lu, Mg, Mn, Mo, Na, Nb, Nd, Pr, Sc, Se, Si, Sm, Sr, Ta, Ti, V, W and Zr. 
     
     
         10 . The method according to  claim 2  for producing a carbon composite material, wherein the dealloying step is performed in an inert atmosphere or a vacuum atmosphere, or performed in air with flux added to the molten metal. 
     
     
         11 . The method according to  claim 3  for producing a carbon composite material, wherein the dealloying step is performed in an inert atmosphere or a vacuum atmosphere, or performed in air with flux added to the molten metal. 
     
     
         12 . The method according to  claim 4  for producing a carbon composite material, wherein the dealloying step is performed in an inert atmosphere or a vacuum atmosphere, or performed in air with flux added to the molten metal. 
     
     
         13 . The method according to  claim 8  for producing a carbon composite material, wherein the dealloying step is performed in an inert atmosphere or a vacuum atmosphere, or performed in air with flux added to the molten metal. 
     
     
         14 . The method according to  claim 9  for producing a carbon composite material, wherein the dealloying step is performed in an inert atmosphere or a vacuum atmosphere, or performed in air with flux added to the molten metal.