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Macroscopic ensembles of nanocarbons, such as fibres of carbon nanotubes (CNT), are characterised by a complex hierarchical structure combining coherent crystalline regions with a large porosity arising from imperfect packing of the large rigid building blocks. Such structure is at the centre of a wide range of charge storage and transfer processes when CNT fibres are used as electrodes and/or current collectors. This work introduces a method based on wide and small-angle X-ray scattering (WAXS/SAXS) to obtain structural descriptors of CNT fibres and which enables in situ characterisation during electrochemical processes. It enables accurate determination of parameters such as specific surface area, average pore size and average bundle size from SAXS data after correction for scattering from density fluctuations arising from imperfect packing of graphitic planes. In situ and ex situ WAXS/SAXS measurements during electrochemical swelling of CNT fibre electrodes in ionic liquid provide continuous monitoring of the increase in effective surface area caused by electrostatic separation of CNT bundles in remarkable agreement with capacitance changes measured independently. Relative contributions from quantum and Helmholtz capacitance to total capacitance remaining fairly constant. The WAXS/SAXS analysis is demonstrated for fibres of either multi- and single-walled CNTs, and is expected to be generally applicable to operando studies on nanocarbon-based electrodes used in batteries, actuators and other applications

This work presents a scalable method to produce robust all-solid electric double layer capacitors (EDLCs), compatible with roll-to-roll processes and structural laminate composite fabrication. It consists in sandwiching and pressing an ionic liquid (IL) based polymer electrolyte membrane between two CNT fiber sheet electrodes at room temperature, and laminating with ordinary plastic film. This fabrication method is demonstrated by assembling large area devices of up to 100 cm2 with electrodes fabricated in-house, as well as with commercial CNT fiber sheets. Free-standing flexible devices operating at 3.5 V exhibited 28 F g-1 of specific capacitance, 11.4 Wh kg-1 of energy density and 46 kW kg-1 of power density. These values are nearly identical to control samples with pure ionic liquid. The solid EDLC could be repeatedly bent and folded 180{\deg} without degradation of their properties, with a reversible 25% increase in energy density in the bent state. Devices produced using CNT fiber electrodes with a higher degree of orientation and therefore better mechanical properties showed similar electrochemical properties combined with composite specific strength and modulus of 39 MPa/SG and 577 MPa/SG for a fiber mass fraction of 11 wt.%, similar to a structural thermoplastic and with higher specific strength than copper.

This work presents a method to produce structural composites capable of energy storage. They are produced by integrating thin sandwich structures of CNT fiber veils and an ionic liquid-based polymer electrolyte between carbon fiber plies, followed by infusion and curing of an epoxy resin. The resulting structure behaves simultaneously as an electric double-layer capacitor and a structural composite, with flexural modulus of 60 GPa and flexural strength of 153 MPa, combined with 88 mF/g of specific capacitance and the highest power (30 W/kg) and energy (37.5 mWh/kg) densities reported so far for structural supercapacitors. In-situ electrochemical measurements during 4-point bending show that electrochemical performance is retained up to fracture, with minor changes in equivalent series resistance for interleaves under compressive stress. En route to improving interlaminar properties we produce grid-shaped interleaves that enable mechanical interconnection of plies by the stiff epoxy. Synchrotron 3D X-ray tomography analysis of the resulting hierarchical structure confirms the formation of interlaminar epoxy joints. The manuscript discusses encapsulation role of epoxy, demonstrated by charge-discharge measurements of composites immersed in water, a deleterious agent for ionic liquids. Finally, we show different architectures free of current collector and electrical insulators, in which both CNT fiber and CF act as active electrodes.