Binder-free composite electrodes using carbon nanotube networks as a host matrix for activated carbon microparticles

In this research, networks of single-walled carbon nanotubes (SWNTs) were used to host activated carbon (aC) microparticles to fabricate freestanding composite electrodes without the use of polymer binders. The aC-SWNT composite electrodes with up to 50 wt. % aC showed specific surface areas approaching 1000 m²/g and electrical conductivities >36 S/cm. The composite electrodes possessed the properties of both pure SWNT electrodes (e.g. low ohmic drop and rapid ion diffusion) and activated carbon particles (e.g. high specific capacitance). With an interconnected mesoporous microstructure and high electrical conductivity, the CNT networks provide an attractive alternative to polymer binders for forming freestanding electrodes for electrical energy storage devices. Here we show that micron-sized particles can be supported in this framework to utilize the performance enhancement and robustness provided by CNTs. Symmetric electrochemical capacitors fabricated with the electrodes in 6 M potassium hydroxide (KOH) aqueous electrolyte maintained specific capacitances of more than 45 F/g after 30,000 constant-current charge–discharge cycles with a current of 3.6 mA/cm².