Scaling up pullulan-based supercapacitors: A sustainable approach to binder and separator integration in EDLCs
Year: 2025
Type: article
Abstract: Electrochemical double-layer capacitors (EDLCs) are essential for high-power energy storage, offering exceptional durability and longevity for diverse applications. Typically, they utilize activated carbon electrodes and organic electrolytes, produced through cost-effective roll-to-roll manufacturing, achieving ~2.7 V operating voltages. Replacing toxic materials in electrode fabrication is critical for transitioning towards sustainable manufacturing practices. A key component in their production is the binder, which must ensure uniform coating, thermal and mechanical stability, optimal microstructural properties, electrochemical inertness, and environmentally friendly processing. Pullulan (PUL), a water-soluble polysaccharide, is a promising green alternative, reducing environmental impact and costs. Our recent lab-scale studies have demonstrated the feasibility of pullulan as a binder for aqueous-processed EDLCs, but upscaling and validating it for large-scale EDLCs remain open challenges. This work presents the optimization of low-binder-content, high-mass-loading electrodes manufacturing at both laboratory and pre-industrial scales. Moreover, a PUL-based electrospun membrane was investigated as separator. The optimized electrode formulations are validated through detailed electrochemical measurements carried out in pouch cells with 20 cm² electrodes, providing critical insights into the feasibility and scalability of the proposed supercapacitor configuration. Notably, the cells containing the PUL-based separator demonstrated competitive results compared to the ones employing cellulose as separator.
Source: Journal of Power Sources
Language: English
Field: Materials Science
Domain: Physical Sciences
Open Access status: hybrid
Estimated APC paid: $4,230
OpenAlex ID: W4413627155