Activated carbon and electric double layer capacitor thereof

Abstract

An activated carbon composition having a relatively high transition metal content and a low covalent oxygen as defined herein. Also disclosed is a method of making and using the disclosed activated carbon composition, and an EDLC article incorporating the activated carbon composition.

1 - 12 . (canceled) 
     
     
         13 . A method of forming high-transition metal content, low-oxygen content activated carbon, comprising:
 pyrolyzing a carbon source starting material to obtain a char material;   activating the char material to form an activated carbon precursor; and   treating the activated carbon precursor to form the activated carbon.   
     
     
         14 . The method of  claim 13 , further comprising:
 reducing a particle size of the char material,   wherein reducing the particle size is conducted by at least one of grinding, ball milling, jet milling, pin milling, fluidized milling, or a combination thereof.   
     
     
         15 . The method of  claim 13 , wherein the activating is a steam activation comprising:
 heating the char material at a temperature in a range of 700° C. to 950° C. for a time in a range of 1 hr to 4 hrs.   
     
     
         16 . The method of  claim 13 , wherein the treating comprises:
 washing the activated carbon precursor to remove metal contaminants; and   heat treating the activating carbon precursor in a forming gas to reduce oxygen-containing functional groups on a surface of the activated carbon.   
     
     
         17 . The method of  claim 16 , wherein the washing comprises a first aqueous wash and a second acid-based wash. 
     
     
         18 . The method of  claim 13 , further comprising:
 reducing a particle size of the activated carbon.   
     
     
         19 . The method of  claim 18 , further comprising:
 mixing the reduced particle size activated carbon with carbon black and a binder;   calendaring the mixture to form a carbon paper;   laminating the carbon paper to form a carbon-based electrode.   
     
     
         20 . The method of  claim 13 , wherein the activated carbon comprises:
 a chemically bonded oxygen content of from 0.05 to 0.7 wt %; and   a total transition metal content of from 70 to 300 ppm.   
     
     
         21 . The method of  claim 20 , wherein the total transition metal content comprises:
 Fe of from 60 to 90 ppm;   Cu of from 50 to 70 ppm;   Cr of from 1 to 5 ppm;   Mn of from 1 to 5 ppm; and   Ni of from 1 to 5 ppm.