Large-Area Fabrication of Porous Graphene Networks on Carbon Fabric via Millisecond Photothermal Processing of Polyaniline for Supercapacitors.

Supercapacitors demonstrate promising potential for flexible, multi-functional energy storage devices; however, their widespread adoption is confronted by fabrication challenges. To access a combination of desirable device qualities such as flexibility, lightweight, structural stability, and enhanced electrochemical performance, carbon fiber (CF) can be utilized as a current collector, alongside graphene as an electrochemically active material. Yet achieving a cost-effective, large-scale graphene production, particularly on CF, remains challenging. Here, a rapid (<1 min) photothermal approach is developed for the large-scale production of graphene directly onto CF, utilizing polyaniline (PANI) as a polymer precursor. The in situ electropolymerization of PANI on CF facilitates its rapid synthesis on large areas, followed by conversion into graphene networks, enabling the binder-free fabrication of supercapacitor devices. These devices exhibit an areal capacitance of 180 mF cm-2 (at 2 mA cm-2 in 1 m H2SO4), an order of magnitude higher than other fabric-based devices. Moreover, the devised photothermal strategy allows for one-step preparation of supercapacitor devices on areas exceeding 100 cm-2, yielding an absolute areal capacitance of 4.5 F. The proportional increase in capacitance with device area facilitates scaling and indicates the commercial viability of this approach for low-cost, energy-efficient, and high-throughput production of lightweight, high-performance graphene-based multi-functional supercapacitor devices.

Ordered Nanoporous Carbons with Broadly Tunable Pore Size Using Bottlebrush Block Copolymer Templates.

We report the preparation of ordered porous carbon materials with tailored pore sizes selected between 16 and 108 nm using bottlebrush block copolymers (BBCPs) as templates. The nanoporous carbons are prepared via the cooperative assembly of polydimethylsiloxane-block-poly(ethylene oxide) (PDMS-b-PEO) BBCPs with phenol-formaldehyde resin yielding ordered precursor films, followed by carbonization. The assembly of PDMS-b-PEO BBCPs with the resin leads to films exhibiting a spherical morphology (PDMS as the minor domain) with uniform domain sizes between 18 and 150 nm in the bulk. The assembled PDMS sphere diameters scale linearly with BBCPs molecular weights, allowing precise control of domain size. Access to very large ordered domains is an enabling hallmark of BBCPs self-assembly, but reports of well-ordered spherical domains are not common. Carbonization of the ordered precursor films yields nanoporous carbon with uniform and tunable pore size. These nanoporous carbons are shown to exhibit excellent performance as supercapacitor electrodes with capacitance reaching up to 254 F g-1 at a current density of 2 A g-1.

Probing Electrocatalytic Synergy in Graphene/MoS2/Nickel Networks for Water Splitting through a Combined Experimental and Theoretical Lens.

The development of low-cost and active electrocatalysts signifies an important effort toward accelerating economical water electrolysis and overcoming the sluggish hydrogen or oxygen evolution reaction (HER or OER) kinetics. Herein, we report a scalable and rapid synthesis of inexpensive Ni and MoS2 electrocatalysts on N-doped graphene/carbon cloth substrate to address these challenges. Mesoporous N-doped graphene is synthesized by using electrochemical polymerization of polyaniline (PANI), followed by a rapid one-step photothermal pyrolysis process. The N-doped graphene/carbon cloth substrate improves the interconnection between the electrocatalyst and substrate. Consequently, Ni species deposited on an N-doped graphene OER electrocatalyst shows a low Tafel slope value of 35 mV/decade at an overpotential of 130 mV at 10 mA/cm2 current density in 1 M KOH electrolytes. In addition, Ni-doped MoS2 on N-doped graphene HER electrocatalyst shows Tafel slopes of 37 and 42 mV/decade and overpotentials of 159 and 175 mV, respectively, in acidic and alkaline electrolytes at 10 mA/cm2 current density. Both these values are lower than recently reported nonplatinum-group-metal-based OER and HER electrocatalysts. These excellent electrochemical performances are due to the high electrochemical surface area, a porous structure that improves the charge transfer between electrode and electrolytes, and the synergistic effect between the substrate and electrocatalyst. Raman spectroscopy, X-ray photoelectron spectroscopy, and density functional theory (DFT) calculations demonstrate that the Ni hydroxide species and Ni-doped MoS2 edge sites serve as active sites for OER and HER, respectively. Finally, we also evaluate the performance of the HER electrocatalyst in commercial alkaline electrolyzers.

Large Area Millisecond Preparation of High-Quality, Few-Layer Graphene Films on Arbitrary Substrates via Xenon Flash Lamp Photothermal Pyrolysis and Their Application for High-Performance Micro-supercapacitors.

We report a method for fast, efficient, and scalable preparation of high-quality, large area, few-layer graphene films on arbitrary substrates via high-intensity pulsed xenon flash lamp photothermal pyrolysis of thin precursor films at ambient conditions in millisecond time frames. The precursors comprised poly(2,2-bis(3,4-dihydro-3-phenyl-1,3-benzoxazine)), and cyclized polyacrylonitrile and possess significant absorption cross section within the bandwidth of the emission spectrum of a xenon flash lamp. By localizing light absorption to the precursor films, the process enabled the preparation of few-layer graphene films on any substrate, including thermally sensitive substrates without the need for any catalytic substrate as in chemical vapor deposition-based approaches or conductive electrodes as in electrochemical method-based approaches. The extent of conversion of the precursor films to graphene was strongly dependent on pulse energy and the local temperature achieved due to photothermal effect, which were controlled via pulse power modulation; it also depended on structural properties of the precursor and to a lesser extent on the substrate. The cPAN showed a higher efficiency for conversion to graphene, as confirmed by Raman spectra (ID/IG ∼ 0.3), and sheet resistance of 0.1 Ω cm. To demonstrate the utility of the process, graphene film electrodes prepared photothermally on carbon fiber current collector were used for the fabrication of micro-supercapacitors with a very high areal supercapacitance of 3.5 mF/cm2. Subsequent deposition of manganese oxide onto the fabricated electrodes significantly increased the energy storage capability of the supercapacitor, yielding a device with exceptionally high capacitance of 80 F/g at 1 mA current, good rate capability, and long cycle life.

Large-Pore Ordered Mesoporous Turbostratic Carbon Films Prepared Using Rapid Thermal Annealing for High-Performance Micro-pseudocapacitors.

Carbonization by rapid thermal annealing (RTA) of precursor films structured by a brush block copolymer-mediated self-assembly enabled the preparation of large-pore (40 nm) ordered mesoporous carbon (MPC)-based micro-supercapacitors within minutes. The large pore size of the fabricated films facilitates both rapid electrolyte diffusion for carbon-based electric double-layer capacitors and conformal deposition of V2O5 without pore blockage for pseudocapacitors. The pores were templated using bottlebrush block copolymers (BBCPs) via cooperative assembly of phenol-formaldehyde resin to produce microphase-segregated carbon precursor films on a variety of substrates. Ultrafast RTA processing (∼50 °C/s) at elevated temperatures (up to 1000 °C) then generated stable, conductive, turbostratic MPC films, resolving a significant bottleneck in rapid fabrication. MPC prepared on stainless steel at 900 °C demonstrated exceptionally high areal and volumetric capacitances of 6.3 mF/cm2 and 126 F/cm3 (at 0.8 mA/cm2 using 6 M KOH as the electrolyte), respectively, and 91% capacitance retention after 10,000 galvanostatic charge/discharge cycles. Post-RTA conformal V2O5 deposition yielded pseudocapacitors with 10-fold increase in energy density (20 µW h cm-2 µm-1) without adversely affecting the high power density (450 µW cm-2 µm-1). The use of RTA coupled with BBCP templating opens avenues for scalable, rapid fabrication of high-performance carbon-based micro-pseudocapacitors.