Carbon activation method and energy storage device thereof

Abstract

A method of making activated carbon including: compressing a mixture of an alkali metal hydroxide, a carbon source, and a solid thermosetting polymer precursor into a pellet; and a first heating of the compressed mixture, as defined herein; and optionally crushing, washing, or both, the resulting first heated mixture, as defined herein; and optionally a second heating, as defined herein.

What is claimed is: 
     
         1 . A method of making activated carbon comprising:
 compressing a mixture comprising an alkali metal hydroxide, a carbon source, and a solid thermosetting polymer precursor into a pellet; and   a first heating of the compressed mixture at from 600 to 1,000° C., for from 10 mins to 24 hours.   
     
     
         2 . The method of  claim 1  further comprising washing the resulting compressed and first heated mixture. 
     
     
         3 . The method of  claim 2  further comprising a second heating of the compressed, first heated, and washed mixture, at from 600 to 1000° C., for from 10 mins to 24 hours. 
     
     
         4 . The method of  claim 1  further comprising placing the compressed pellet into a closed container having a vent prior to the first heating. 
     
     
         5 . The method of  claim 2  further comprising crushing the compressed and first heated product prior to the washing. 
     
     
         6 . The method of  claim 1  wherein the first heating is accomplished in an container open to an external atmosphere. 
     
     
         7 . The method of  claim 1  wherein the alkali metal hydroxide is powdered KOH, the carbon source is powdered green coke, and the thermosetting polymer precursor is a mixture of a phenolic resin and a cross-linking agent. 
     
     
         8 . The method of  claim 7  wherein the alkali metal hydroxide and the carbon source is in a weight ratio of from 1:1 to 4:1. 
     
     
         9 . The method of  claim 7  wherein the mixture of a phenolic resin and a cross-linking agent to the mixture of the KOH and the powdered green coke is in a weight ratio of from 1:2 to 1:20. 
     
     
         10 . The method of  claim 1  wherein the second heating is accomplished in a forming gas, in an inert gas, or in a combination thereof. 
     
     
         11 . The method of  claim 2  wherein washing is accomplished successively with water, and a dilute aqueous acid, or concurrently with water and a dilute aqueous acid. 
     
     
         12 . The method of  claim 1  wherein carbon source has a median particle size of from 1 to 200 microns. 
     
     
         13 . The method of  claim 1  wherein carbon source has a median particle size of from 10 to 150 microns. 
     
     
         14 . The method of  claim 1  wherein carbon source has a median particle size of from 90 to 110 microns. 
     
     
         15 . The method of  claim 1  wherein compressing eliminates foaming of the mixture when heated.