Hierarchically porous carbon monoliths from commercial membrane templates

High surface area porous carbon materials have uses in electrochemical energy storage (EES) systems because of their transport properties, relatively low cost, and flexible architectures. In these materials, there is a tradeoff between smaller micro/mesopores for high surface area and larger macropores for fast transport, both of which are necessary for EES applications. An optimal material would balance a high surface area with efficient transport pathways by combining these different pore sizes. In this work, a single-step, low cost, scalable technique is demonstrated to access such hierarchically structured porous carbons where commercial nylon membranes are first infiltrated with carbon precursors and polymer additives and then heat treated. SEM imaging and nitrogen physisorption measurements of the final materials show small and large pores of about 10 nm and 400 nm, respectively. Nitrogen physisorption reveals a high surface area largely due to micropores. Four-point probe conductivity shows a conductivity of 9.25 S/cm, rendering these carbons suitable for EES applications. Electrochemical testing finally demonstrates an ability to act as a traditional carbon electrode when cycled against lithium metal. Results suggest that these polymer membrane-derived porous carbons may be a potential candidate for next generation EES systems.