Scaling to practical pouch cell supercapacitor: Electrodes by electrophoretic deposition

The scale-up of supercapacitors by electrophoretic deposition (EPD) from coin cell to pouch cell with commercially relevant mass loadings and thicknesses is reported. The use of EPD in electrode fabrication mainly reduces the interfacial resistance and increases the mechanical flexibility of the electrodes. The cycling performance or conversion efficiency can also be improved due to the highly porous EPD coatings. An exemplary investigation of activated carbon (AC) electrodes with an electrolyte comprising of tetraethylammonium tetrafluoroborate in acetonitrile is carried out. According to the general literature, EPD of AC on metal substrates has not performed well for supercapacitor electrodes unless they were thinner and with lower mass loadings than commercial requirements. As a consequence, and to redress this research gap, all the electrodes prepared in this work demonstrate high mass loadings (8 mg cm⁻²) and practical layer thicknesses (125 µm) and contain polyvinylidene fluoride binders with electrically conductive carbon black particles. Research investigations include: (a) impact of EPD of AC onto small (10 cm²) and large areas (50 cm²) of aluminum foil current collectors, (b) scaling-up of coin to pouch cells, and (c) the preparation of electrode coatings on both sides of the current collector for the first time using EPD for pouch cell investigations. Our research learning shows the evidence of practical cell performance, including current loading (40 A g⁻¹), tens of thousands of successive charge and discharge operation (150,000 cycles), power (30 kW kg⁻¹) and energy densities (10 W h kg⁻¹), capacitance (154 F g⁻¹), capacitance retention (80%) and coulombic efficiency (relatively close to 100%). Based upon the success of the pouch cells investigated in this work, further research studies on the use of EPD for preparing energy storage electrodes for commercial cylindrical types of supercapacitors is envisaged.