A Study Of 3D Printed Activated

Carbon(AC) Electrode For The

Manufacture Of Electric Double-layer
Capacitors(EDLCs) Using Dual Nozzle
Deposition System

Presented By:-
Satendra Kumar
PhD Scholar(32EE18A35006)
CSIR-AMPRI-Bhopal
TABLE OF CONTENTS
 Introduction to
 Additive Manufacturing
 Concept of EDLCs
 Materials
 Preparation of 3D AC electrode
 Preparation of 3D gel electrolyte
 Fabrication of EDLCs
 Characterization
 Experimental results
 Conclusion
 References
Additive Manufacturing(AM)
Additive Manufacturing(AM), generally referred as 3D printing, is a 3D objects
fabrication technique constructed on a layer by layer process.

The 3D printing technology allows us the following

 Manufacturing of complex internal structures.
 Able to build various thickness of thin layers.
 Able to generate good level of internal porosity.
 Rapid production and smooth operations.
 Development of multi-material structures.
 Provides the possibility of building complete functional electronic devices.
 Very cost effective.

Nozzle
Substrate
 Concept Of EDLCS Separator
+ Electrode - Electrode

C= [KεoA/d]*(N-1)
Current
Collector

C= εoA/{d-t+(t/K)}
Where,
K=dielectric constant
εo=permitivity of free space
A=plate area
d= plate separarion
N= number of plates
t= thickness of separator
It stores energy electro-statically by
polarizing electrolytic solution.
Unlike batteries no chemical reaction Charged
takes place. Liquid
electrolyte
Can go hundreds of thousands of electrolyte
ions
charging cycles without degradation.
Non-faradaic reaction.
Redox reaction should not occur
Materials
Electrode Materials(Carbon based)
 Graphene/AC composite
 SWNTs electrodes
 AC nanowhiskers
 AC microporous
 AC fibers
 AC slurry
Activcated Carbon
forms:-
1. Carbon black
2. Carbon fiber
cloth
3. Carbon
aerogel
4. Graphene
 Continued….
Electrolyte Materials

1. PVA powder 1. PVA powder 1. Activated carbon

2. Binder(distilled water) 2. Binder(distilled water) 2. CMC binder
3. Aqueous H2SO4 3. CMC binder 3. Ethanol
4. CMC binder 4. H3PO4 4. H3PO4
5. Magnetic stirrer 5. Magnetic stirrer 5. PVA powder

Separator
The choice of separator is defined by the properties of the electrolyte ---
good impregnation of the separator material, separator must be thermally
stable at the working temperature range and it must be
chemically/electrochemically inert. Its thickness must be thin as possible
and porosity must be higher.
 Continued….

Current collector Paste

1. Specially Silicon is used as a substrate material
2. PVDF-HFP(polyvinylidene flouride-co-hexafluoropropylene)
3. NMP(1-methyl-2-pyrrolidinone)
4. Zn+Ag powder
5. Magnetic stirrer
Current Collector & Electrodes
must have
Good Conductivity
High Temperature Stability
Long-term Chemical Stability (Inertness)
High Corrosion Resistance And
High Surface Areas Per Unit Volume And Mass.
AC Slurry Preparation For Electrode
Method#1 72Hr
Dry at
100g AC 50mL carbon- 100mL distilled 150Ċ 5g ball-milled
powder based chinese ink water AC powder

PVA gel powder

Stirrer at RT for
24Hr
2.6g PVA powder
+ 20mL distilled
To ensure the homogeneity of the AC slurry, water stirrered
add 8mL H3PO4 and 1g of 5% CMC at 50Ċ for 1Hr
 Continued…

Method#2
at 50C for 1Hr
2g AC powder already
2g PVA + 40mL
pre-heated to 100C
distilled water
for 1Hr

24Hr stirrer for

making it
homogeneous
Electrolyte gel Preparation
2.5g PVA
powder 30mL 1.5g CMC of 5% 18mL 6M H3PO4
distilled
water

at 50C for 1Hr

Magnetic stirred
over night until
completely
homogeneous

.
Design Of The Structure Of EDLC
170mm
163mm Current collector

2mm AC layer
Separator
Gel electrolyte

Silicon substrate
Due to the working mechanisms, there
are four layers of materials on each side
of an EDLC, i.e.
. 1. Silicon substrate
2. Current collector
3. AC material
4. Gel electrolyte
Electrode Fabrication Techniques
Fused Deposition Modeling
Paste deposition by 3D printing is a promising manufacturing
method for controlling the deposition layers and it can provide
accurate and complex structures.

Plastic tube
Paste
PLA filament spool material
PLA filament
Different techniques
1. FDM or Fused Filament
Fabrication
Printed 2. Dip coating
object
3. Doctor blade coating
4. Screen printing
5. Masking
Nozzle 6. Spraying
7. Roll-to-Roll printing
Syringe
Base platform 8. Selective laser melting
Characterization Techniques
1. Scanning electron microscopy(SEM)
2. X-ray diffraction(XRD)
3. Brunauer–Emmett–Teller(BET)
4. Bending test
5. Electrochemical performances
 Galvanostatic Charge-discharge (GCD)
 Cyclic Voltammetry (CV)
 Electrochemical Impedance Spectroscopy
(EIS)
Expected Experimental Results

Cyclic voltammograms curves Galvanostatic charge/discharge curves

Qtotal
C1 = ΔV
C2 = i · Δt
Cs1 = C1/m ΔV

Cs2 = C2/m
 Expected Experimental Results

S.N. Total Mass C1(mF) Cs1(mF C2(mF) Cs2(m Energy Power

mass(mg) loading(m /g) F/g) density( density(
g/cm2) mWs/g) mW/g)
1 942 45.99 182 193.20 224.59 238.42 76.29 95.36
Conclusion
1. 3D printing provides the fabrication of a freestanding electrochemical
platform.
2. FDM/paste deposition is a very versatile, cost effective and open source
printing technique.
3. Flexible and stable EDLC layer can be produced in one continuous process
by 3D printer
4. Able to fabricate geometrically intricate EDLCs
5. Good reproducibility
References
[1]. M. Areir, Y. Xu, R. Zhang, D. Harrison, J. Fyson, E. Pei, A study of 3D printed
active carbon electrode for the manufacture of electric double-layer
capacitors, J. Manuf. Process. 25 (2017) 351–356,
http://dx.doi.org/10.1016/j.jmapro.2016.12.020.
[2]. F. Qiu, D. Harrison, J. Fyson, D. Southee, Fabrication and characterisation of
flexible coaxial thin thread supercapacitors, Smart Sci. 2 (2014) 107–115,
http://dx.doi.org/10.1080/23080477.2014.11665613.
[3]. A. Tanwilaisiri, Y. Xu, R. Zhang, D. Harrison, J. Fyson, Milad A, Design and
fabrication of modular supercapacitors using 3d printing, Journal of Energy
Storage 16(2018) 1-7, http://doi.org/10.1016/j.est.2017.12.020.