Structural Power Composites Based on High Mass Loading Zn-Ion Hybrid Supercapacitors with Metal Mesh Current Collectors and Aramid Nanofiber/Glass Fiber Composite Electrolytes

초록

A multifunctional electrode design is proposed for structural power composites (SPCs) by integrating high-mass-loading Zn-ion hybrid supercapacitor (ZHSC) components with stainless steel (SS) mesh current collectors. A combined wet-dry processing route was developed to overcome fabrication challenges in thick electrodes, such as compositional inhomogeneity and drying-induced cracking. The resulting freestanding activated carbon (AC) films were thermally laminated onto SS mesh to form ACSS electrodes with strong interfacial adhesion and improved electrical conductivity. A complementary ZnSS electrode was fabricated by calendering Zn foil onto SS mesh, enhancing mechanical robustness and electrical properties. The electrodes were assembled on opposite sides of an aramid nanofiber/glass fiber (ANFGF) composite electrolyte and subsequently protonated to enable strong interfacial bonding through the ANF network. The resulting ZHSC-SPC device demonstrates capacitive charge storage, with areal capacitance scaling linearly with electrode stacking while retaining gravimetric performance. The device delivers a specific capacitance of 72.2 F g-1, areal capacitance of 1284.3 mF cm-2, energy density of 516 & micro;Wh cm-2, and power density of 6.2 mW cm-2, with 76% retention after 500 cycles. Mechanical tests confirm high performance, with a tensile strength of 114 MPa and an elastic modulus of 2.8 GPa, demonstrating suitability for structural energy storage applications.

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