Patent Description:
Supercapacitors, also known as an electrochemical capacitor (EC) or electronic double-layer capacitor (EDLC), is a unique electrical energy storage devices. Compared to the batteries, supercapacitors have the advantages in higher power density, faster charging-discharging, longer life span, and broader operating temperature.

Usually, supercapacitors have the potential used in the field of mid-range energy storage due to a lower energy density than batteries. Supercapacitors are physically storing the charges on the surface of the electrode and achieving the separation of charge in a Helmholtz double layer at the interface between the electrode surface and an electrolyte. One example of such a supercapacitor based on a silicon substrate is shown in <CIT>. Therefore, the corresponding capacitance and energy density of supercapacitors are proportional to the surface area of electrode materials. In order to increase the energy density of supercapacitors, two requirements are put forward on the active material: (<NUM>) a superb electrical conductivity, which a prerequisite condition to make sure the chargers can flow quickly during charging/discharging, and (<NUM>) a larger effective surface area, which is an essential condition to offer enough positions for chargers adherence.

Carbon nanotubes (CNTs), deriving from the development of nanoscience and nanotechnology, possess unique properties, such as extraordinary mechanical, excellent electrical conductivity, and nanoscale sizes making them suitable for a promising application in the field of energy storage. A typical method for a CNTs layer synthesized by chemical vapor deposition (CVD) is using Fe nanoparticles as the catalysts which are deposited on a barrier layer of Al<NUM>O<NUM> or SiO<NUM> (Reference: <NPL>); <NPL>. Other examples using nanotube on metal foil are discussed in <CIT>, <NPL>, and <NPL>. However, there are several drawbacks associated with such a CNTs layer for supercapacitor applications. First, the existence of a barrier increases the contact resistance between the CNTs layer and the current collector. Second, this CNTs layer perpendicular to the substrate, which is a loose structure with a small mass density that is not beneficial to improve the energy density of supercapacitors.

Other example of the prior art are discussed in <CIT> where aligned nanostructures are provided on a surface, where the surface has been patterned to provide catalyst island where the nanotubes as grown. In <CIT> presents a method for initiating nanostructure growth where a catalyst is deposited on a resistive element prior to a heating process. <CIT> describes a method for making a threedimensional network of nanotubes from an alumina template, such as a through hole, containing nickel sulfate particles, where the nanotubes are upright relative to the surface and includes further nanotubes linking the upright nanotubes.

In addition, several methods use CNTs ink or CNTs nanocomposites to form an electrode on a current collector (Reference: <NPL>, and <NPL>. Supercapacitor assembled with such electrodes shows poor equivalent series resistance (ESR) because a binder is often used to hold the CNTs layer on the current collector, resulting in increased contact resistance and further limiting the power density of supercapacitors. Besides, charge transfer across parallel CNTs generally is more resistive than that via inner tube paths in interconnected CNTs.

Pai Lu et al. reported a method to synthesize a carbon nanotube film on etched silicon for on-chip supercapacitor (Pub. No.: <CIT>, and <NPL>. Silicon is a good candidate substrate to develop on-chip supercapacitor due to compatible with intergrated circuits chip manufacturing. However, the silicon substrate is not flexible, and more expensive and poor conductivity comparing to metal film substrates.

Additional prior art disclosing synthesis or growth of nanostructures comprising nanotubes on a substrate are be found in <CIT> and in <CIT>.

It is therefore and object of the present invention to provide a method for fabricating a high-performance supercapacitor electrode without the above-described problems.

A further object of the present invention is to offer an electrode that can be mass-produced and used for energy storage devices.

The objects of the invention are solved by providing a method, electrode and supercapacitor as defined in the accompanying claims.

According to the invention a method is provided for directly growing cross-linked carbon nanotubes on a metal| current collector film without using a binder or a barrier layer, and also a method for synthesizing highly dense cross-linked carbon nanotubes with an interconnected structure and high mass loading.

More in detail the present invention thus provides a process for fabricating an electrode by use of a direct growth cross-linked carbon nanotubes on a microstructured metal substrate, which can also act as a current collector. More specifically, the process begins to form the microstructures on the surface of a metal film substrate. Next, the microstructured substrate is coated with a metal layer or metal compounds which can convert into metal nanoparticles by subsequent heat treatment in a reducing gas atmosphere. Finally, the cross-linked carbon nanotubes are grown on the microstructured substrate under the catalysis of metal nanoparticles by atmospheric pressure chemical vapor deposition (APCVD) technique. A supercapacitor assembled with such electrodes exhibits an extremely high capacitance and an excellent equivalent series resistance (ESR).

The present invention provides a process for fabricating an electrode as well as the resulting electrode and supercapacitor utilizing said electrode, which composes a microstructured metal film substrate (current collector), metal nanoparticles, and cross-linked carbon nanotubes directly grown onto the current collector. The process comprises: (a) forming the microstructures on a metal film substrate for achieving surface gain and enabling cross-linked CNTs growth; (b) depositing metal or metal compounds layer on the surface of the microstructures; (c) converting metal or metal compounds layer into metal nanoparticles as the catalysts; (d) growing cross-linked carbon nanotubes on the microstructures in the presence of the catalysts. Specifically, the surface area of the microstructured metal film substrate is enlarged, offering larger space than the flat metal film substrate to deposit plenty of metal nanoparticles as catalysts for growing CNTs. Simultaneously, the irregular surface provides a scaffold template to grow CNTs along various directions to achieve CNTs interweaving together, eventually forming highly dense cross-linked carbon nanotubes with high mass loading coated onto the microstructured metal film substrate. More particularly, the highly-dense cross-linked carbon nanotubes are directly grown on the current collector without a binder or a barrier layer, which effectively reduces the contact resistance between the cross-linked carbon nanotubes and the current collector. Supercapacitors assembled with such electrodes could show a high capacitance and a low equivalent series resistance (ESR). Also, cross-linked carbon nanotubes are a superb scaffold structure for loading with pseudocapacitive materials to form a pseudocapacitive electrode. Typically, pseudocapacitive materials include transition metal oxides (manganese oxide, nickel oxide, cobalt oxide, and ruthenium oxide) and conductive polymers (polyaniline, polypyrrole, and Poly(<NUM>,<NUM>-ethylene dioxythiophene): poly(<NUM>-styrene sulfonate) (PEDOT: PSS)).

The metal film substrate involved in this invention could be any metals, which can be fabricated with a microstructured surface with corresponding fabricating methods. The microstructured surface can support metal nanoparticles as the catalysts and simultaneously offer a scaffold template to direct grow cross-linked carbon nanotubes on the metal film substrate. The metal film substrate includes any type of metals, such as aluminum, copper, nickel, titanium, chromium, or stainless steel. The metal film substrates should have impurity controlled for leakage current optimization. The metal film substrate should form a stable electrochemical system with the electrolyte. Both dry and wet etching can be applied to create the microstructures on these metal film substrates by physical or chemical ways, such as chemical etching, mechanical lapping, or laser etching, etc. The structures are with uniaxial open down to the substrate about sub-microns to tens microns deep and range from submicron to microns wider at the top, preferably within the range of <NUM> to <NUM> microns deep depending on the thickness of the metal film substrate and <NUM> to <NUM> microns wide.

According to the invention, aluminum (Al) is the preferred metal but not limited to Al based on its properties.

The metal film substrate in this invention is therefore preferable using aluminum foil as an example to grow directly cross-linked carbon nanotubes. Therefore, aluminum foil is involved in some embodiments as one of the metal substrates.

In some embodiments, the metal film substrate includes any structural type of metal products, such as: flat metal foil, porous metal foil.

According to the present invention, there is provided the methods to deposit metal or metal compounds layer on the microstructured metal film substrate by physical vapor deposition (PVD) or coating with metal compound precursors.

In some embodiments, a metal layer deposited by physical vapor deposition (PVD) may include electron-beam evaporation, thermal evaporation, or sputtering.

In some embodiments, metal compounds layer deposited by precursors may include dip coating or spray coating.

In some embodiments, the element of the metal layer includes nickel, iron, cobalt, or a mixture of any of the above; metal compounds have nickel compound, iron compound, cobalt compound, or a combination of any of the above.

In some embodiments, a metal compound precursor is prepared by dissolving the metal compounds into a soluble solvent (typically: water or organic solvents).

According to the present invention, there is provided the methods to form metal nanoparticles on the microstructured metal film substrate by heat treatment in a reducing atmosphere (typically: hydrogen) using a per se known process. The method preferably comprises the following steps: (a) oxidized metal layer is reduced to the metal layer, and further formed to metal nanoparticles; or (b) the formation of metal nanoparticles from the metal compounds is achieved by the simultaneous action of pyrolysis and reduction reactions. During heat treatment, surface energy plays a crucial role in the nucleation process. The size and number of metal nanoparticles are depended on the thickness of the metal layer or the concentration of the metal compound, heating rate, and holding temperature.

In some embodiments, the size of nickel nanoparticles is around <NUM>-<NUM>, and the nickel clusters have a larger size of <NUM>-<NUM> during heat treatment at <NUM>-<NUM> in a hydrogen atmosphere.

According to the present invention, there is provided a method to grow cross-linked carbon nanotubes on the microstructured metal film substrate. This method is a typical catalytic process for producing carbon material through the APCVD technique, which is well-known to the skilled person. Carbon-containing gas is decomposed into carbon atoms, which are further orderly assembled to form CNTs (more specifically, multi-walled carbon nanotubes (MWCNTs)) in the presence of the metal catalysts at the temperature of <NUM>~<NUM>. Ultimately, abundant CNTs are intertwined together to form highly dense cross-linked carbon nanotubes.

In some embodiments, the carbon-containing gas includes acetylene, methane, ethylene, propane, butane, or a mixture of any of the above.

In some embodiments, the thickness of the cross-linked carbon nanotubes can reach up to <NUM> (mass loading: up to~<NUM>/cm<NUM>).

In an embodiment of the present invention provides electrodes to assemble supercapacitor for electrical energy storage, wherein the supercapacitor structure comprises: at least two opposing electrodes, the separator between any two electrodes, and electrolyte permeated into the electrodes and the separators. The supercapacitor structure can further be packaged into a cylindrical, stacking, flat jellyroll cell, or surface mounting device.

In a variation on this embodiment, the electrode used in electrical energy storage devices include: capacitor, battery, or hybrid capacitor.

<FIG> illustrates a single-side electrode for supercapacitors in accordance with the present invention. Single-side electrode <NUM> comprises metal microstructures <NUM> formed on one side of the metal film substrate <NUM>, or "current collector" <NUM>, the deposited metal nanoparticles <NUM>, and cross-linked carbon nanotubes <NUM>. <FIG> depicts a double-side electrode for supercapacitors in accordance with the present invention. Double-side electrode <NUM> composes metal microstructures <NUM> formed on both sides of the metal film substrate <NUM>, or "current collector" <NUM>, the deposited metal nanoparticles <NUM>, and cross-linked carbon nanotubes <NUM>.

For any person skilled in the art, the illustrations of <FIG> are schematics only, in which layer thickness, aspect ratios, shapes, etc. are not necessarily correct.

<FIG> principally illustrates the process of fabricating metal microstructures <NUM>, deposited with metal nanoparticles <NUM>, and cross-linked carbon nanotubes <NUM> on the single-side electrode <NUM>, according to an embodiment of the present invention. <FIG> depicts the process of fabricating metal microstructures <NUM>, deposited with metal nanoparticles <NUM>, and cross-linked carbon nanotubes <NUM> on the double-side electrode <NUM>, according to an embodiment of the present invention.

Single-side electrode <NUM> and double-side electrode <NUM> have the same fabrication processes. Single-side electrode <NUM> is only fabricated with metal microstructures <NUM>, deposited with metal nanoparticles <NUM>, and coated with cross-linked carbon nanotubes <NUM> on one side of the metal film substrate <NUM>. Double-side electrode <NUM> is fabricated with metal microstructures <NUM>, deposited with metal nanoparticles <NUM>, and coated with cross-linked carbon nanotubes <NUM> on both sides of the metal film substrate <NUM>.

The preparation supercapacitor electrode in this invention involves four steps: (<NUM>) forming metal microstructures <NUM> on the metal film substrate <NUM>; (<NUM>) depositing metal or metal compounds layer on the surface of metal microstructures <NUM>; (<NUM>) converting metal or metal compounds layer into metal nanoparticles <NUM> as the catalysts; (<NUM>) growing cross-linked carbon nanotubes <NUM> on the metal microstructures <NUM> in the presence of the catalysts. Aluminum foil, one of the typical metal film substrate, is used as the current collector in supercapacitor. Therefore, aluminum foil is used as one example of a metal film substrate to show the detailed fabrication process.

Before etching, aluminum foil is sequentially cleaned by deionized water, acetone, and isopropanol. Then, aluminum foil is performed surface alkali treatment by NaOH solution (<NUM> mol/L) at <NUM>-<NUM> for <NUM>-<NUM> minutes. For a typical chemical acid etching, aluminum foil is etched by a mixed acid solution of <NUM> mol/L HCl and <NUM> mol/L H<NUM>SO<NUM> at the temperature of <NUM>~<NUM> for the etching time of <NUM>-<NUM> hours. The etching time is one of the parameters to control the shape size and aspect ratio of aluminum microstructures on aluminum foil. The following reactions are carried out in chemical acid etching.

2A1 + <NUM><NUM>SO<NUM> → Al<NUM>(SO<NUM>)<NUM> + <NUM><NUM>.

For a typical electrochemical acid etching, aluminum foil is performed in an electrochemical cell as the working electrode, and platinum foil is used as the counter electrode. Aluminum foil is etched under a constant current density of <NUM>-<NUM> mA/cm<NUM> in a mixed solution of <NUM> mol/L HCl and <NUM> mol/L H<NUM>SO<NUM> at the temperature of <NUM>-<NUM> for the etching time of <NUM>~<NUM> seconds. Similarly, the shape size and aspect ratio of aluminum microstructures are controlled by constant current density and etching time. For etching single-side aluminum microstructures, one side of aluminum foil is protected by tape and the other side is exposed to the mixed solution. For etching double-side aluminum microstructures, both sides of aluminum foil are without protection, which can contact and reaction with the mixed solution. The following equations take place during electrochemical acid etching.

Anode (aluminum foil):     Al → Al<NUM>+ + 3e-.

Cathode (platinum foil):     <NUM>+ + 2e- → H<NUM>.

As stated above this results in a microstructured surface having surface features with uniaxial open down to the substrate in the range of sub-microns to tens of microns deep and from submicron to microns wider at the top, preferably within the range of <NUM> To <NUM> microns deep depending on the thickness of the metal film substrate and <NUM> to <NUM> microns wide.

After etching aluminum foil, aluminum microstructures are deposited and coated with nickel nanoparticles, as shown in <FIG>. Typically, there are two methods to load with nickel nanoparticles <NUM> on aluminum microstructures <NUM>, nickel electron beam evaporation, and nickel compound pyrolysis. Nickel electron beam evaporation is a physical vapor deposition. Specifically, the aluminum foil etched with aluminum microstructures is fixed in a vacuum chamber with a pressure of <NUM>×<NUM>-<NUM> to <NUM>×<NUM>-<NUM> Torr. The nickel atoms are simulated from nickel source by a constant current of <NUM>~<NUM> mA for the deposition time of <NUM> to <NUM> minutes. The electron beam deposition is performed under a pressure of <NUM>×<NUM>-<NUM> to <NUM>×<NUM>-<NUM> Torr with the argon flow of <NUM> sccm at the room temperature of <NUM>~<NUM>. The deposited nickel on the microstructured aluminum foil will expose in the air atmosphere after taking from the vacuum chamber, resulting in the formation of nickel oxide on the aluminum microstructures.

For the nickel compound pyrolysis method, various nickel precursors can be prepared by dissolving nickel compounds (NiCl<NUM>, Ni(NO<NUM>)<NUM>, or Ni(CH<NUM>CO<NUM>)<NUM>, etc.) in water, methanol, or ethanol. Then, these nickel precursors are sprayed on the microstructured aluminum foil. For the single-side electrode, nickel precursors only spray on one side of the microstructured aluminum foil, and both sides are sprayed for the double-sided electrode. Nickel compounds are well coated on the surface of aluminum microstructures as the solvent evaporation, and the following equations have described the formation of nickel compounds.

NiCl<NUM> solution → NiCl<NUM> · <NUM><NUM>O.

Ni(NO<NUM>)<NUM> solution → Ni(NO<NUM>)<NUM> · <NUM><NUM>O.

Ni(CH<NUM>CO<NUM>)<NUM> solution → Ni(CH<NUM>CO<NUM>)<NUM> · xH<NUM>O, where x can be <NUM>, <NUM>, and <NUM>.

Cross-linked carbon nanotubes are the primary activated material for electric double-layer capacitors (EDLC). <FIG> depict cross-linked carbon nanotubes <NUM> formed on aluminum microstructures <NUM> under the catalysis of nickel nanoparticles <NUM> by atmospheric pressure chemical vapor deposition (APCVD) technique. The forming mechanism of the APCVD process is known to the skilled person.

In a typical process, the microstructured aluminum foil deposited with nickel or nickel compounds is placed in the center of the tube furnace. The air in the tube furnace is bumped out and then filled with an Argon gas several times to reduce oxygen content. Then, <NUM>~<NUM> sccm of Ar and <NUM>-<NUM> sccm of H<NUM> is introduced into the tube to maintain atmospheric pressure. The tube furnace is heated up to <NUM>~<NUM> at the heating rate of <NUM>. When the temperature reached to <NUM>~<NUM>, <NUM>-<NUM> sccm C<NUM>H<NUM> carbon-containing gas is introduced into the tube and held at the temperature of <NUM>~<NUM> for <NUM> minutes to <NUM> hours. After that, C<NUM>H<NUM>, H<NUM>, and Ar supply are shut off, and the tube furnace is cooled down to room temperature (<NUM>) in a nitrogen atmosphere with a flow rate of <NUM> sccm. At the end of the APCVD process, the cross-linked carbon nanotubes are produced on the microstructured aluminum foil. In an APCVD process, the following reactions are taking place, forming cross-linked carbon nanotubes on microstructured aluminum foil.

<CHM>
<CHM>
<CHM>
<CHM>
where x can be <NUM>, <NUM>, and <NUM>.

<FIG> illustrates a typically basic supercapacitor structure based on single-side electrodes in accordance with an embodiment of the present invention. Supercapacitor comprises two single-side electrode <NUM>. Each single-sided electrode <NUM> further composes metal microstructures <NUM> fabricated on one side of a metal film substrate <NUM>, or "current collector" <NUM>, the deposited nickel nanoparticles <NUM>, and cross-linked carbon nanotubes <NUM>. Two single-side electrode <NUM> are typically separated by a solid separator <NUM>, which provides a physical barrier between two electrodes to prevent short circuits. Separator <NUM> is an ion-permeable membrane with high porosity to allow the flow of electrolyte <NUM> for charging and discharging. Typical separators used in supercapacitors are cellulose and glass fiber due to their chemical stability. Electrolyte <NUM> can fill into the gaps of cross-linked carbon nanotubes <NUM>, the gaps between metal microstructures <NUM> , and the pores of separator <NUM>. Note that electrolyte <NUM> can be neutral (Na<NUM>SO<NUM>), organic electrolytes, or ionic electrolytes. Any single-side electrode <NUM> can be selected as the positive or negative terminal of a supercapacitor.

<FIG> depicts a typically multi-layer supercapacitor structure based on single-side electrodes and double-side electrodes in accordance with an embodiment of the present invention. Supercapacitor comprises two single-side electrode <NUM> and one double-side electrode <NUM>. Single-side electrode <NUM> and double-side electrode <NUM> has the same fabricating steps: forming metal microstructures <NUM>, depositing with nickel nanoparticles <NUM>, and growing with cross-linked carbon nanotubes <NUM>. The electrode layers are physically isolated by a separator <NUM>. Electrolyte <NUM> can permeate into the gaps of cross-linked carbon nanotubes <NUM>, the gaps between metal microstructures <NUM>, and the pores of separator <NUM>. The multi-layer supercapacitor structure has the same working principle as the basic supercapacitor structure. The separator <NUM> and electrolyte <NUM> used in basic supercapacitor structure are also usable to multi-layer supercapacitor structure. For any person skilled in the art, multi-layer supercapacitor structure can further be packaged into cylindrical, stacking, or flat jelly roll cells.

<FIG> presents the surface morphologies of the microstructured aluminum foil obtained by the chemical etching method in a mixed acid solution of <NUM> mol/L HCl and <NUM> mol/L H<NUM>SO<NUM> at the temperature of <NUM>~<NUM> for the etching time of <NUM> hours. In a typical chemical acid etching, the surface of aluminum foil is rough of irregular pits and plateaus, which are consistently distributed throughout the entire surface. In some embodiments, typical sizes of plateaus are <NUM>×<NUM>, and a specific depth of the pit is <NUM>-<NUM>.

<FIG> presents the surface morphologies of the microstructured aluminum foil fabricated by electrochemical acid etching method applying a constant current density of <NUM> mA/cm<NUM> in a mixed solution of <NUM> mol/L HCl and <NUM> mol/L H<NUM>SO<NUM> at the temperature of <NUM> for the etching time of <NUM> seconds. After performed electrochemical acid etching, aluminum foil is fully etched with pits, plateaus, and tunnels. The size of pits and plateaus are smaller than that etched by chemical acid etching, shown in <FIG>. In some embodiments, the tunnels are presented as a rectangle shape with a size of <NUM>-<NUM>. The typical depth of tunnels can reach up to ~<NUM>.

<FIG> illustrate the surface morphologies of nickel catalysts formed on etched aluminum foil by solution precursor spray technique. Nickel nanoparticles or clusters are formed on microstructured aluminum foil after heat treatment at <NUM>-<NUM> in a hydrogen atmosphere. In some embodiments, the size of nickel nanoparticles is around <NUM>-<NUM>, and the nickel clusters have a larger size of <NUM>-<NUM>. Note that nickel nanoparticles or clusters can fully form on the surface of microstructured aluminum foil because nickel solution precursors can permeate into all gaps among aluminum microstructures.

<FIG> present the surface morphologies of nickel nanoparticles deposited on etched aluminum foil by electron-beam evaporation technique. Nickel nanoparticles are uniformly deposited on the exposed surface of microstructured aluminum foil. Note that nickel nanoparticles can not deposit on the unexposed surfaces due to the shadowing effect.

<FIG> depicts the surface morphologies of the cross-linked carbon nanotubes on microstructured aluminum foil by atmospheric pressure chemical vapor deposition (APCVD) technique. In one embodiment of the present invention, the cross-linked carbon nanotubes are the carbon nanotubes (CNTs), more specifically, single-walled carbon nanotubes (SWCNTs), multi-walled carbon nanotubes (MWCNTs), or a mixture of above.

<FIG> illustrates the cross-section of the cross-linked carbon nanotubes on etched aluminum foil by atmospheric pressure chemical vapor deposition (APCVD) technique. The cross-linked carbon nanotubes are directly grown on the microstructured aluminum foil (current collector) to form an interconnecting structure, which is attached well on the current collector.

In one embodiment of the present invention, the thickness of the cross-linked carbon nanotubes can reach up to ~ <NUM> (mass loading: up to ~<NUM>/cm<NUM>), and which is adjusted by the number of nickel nanoparticles and the APCVD time. Supercapacitor with such electrodes has the outstanding impedance properties, (<NUM>) a reduced contact resistance because of CNT layer is directly grown on the current collector, it does not need a binder to fix carbon layer; (<NUM>) a reduced charge transfer resistance due to the superb the electrical conductivity of CNT and interweaved structure in the carbon layer.

A supercapacitor is assembled to investigate the capacitive performances of the cross-linked carbon nanotubes electrode. Two electrodes (each in the size of <NUM>×<NUM>, mass loading of <NUM>) are packaged into a stainless steel button cell (CR2032) by a digital pressure controlled electric crimper (MSK-160E). Tetraethylammonium tetrafluoroborate (Et<NUM>NBF<NUM>, <NUM> mol/L in acetonitrile) is used as the electrolyte, and the glass fiber filter is used as the separator. The cyclic voltammetry (CV) and electrochemical impedance spectroscopy (EIS) are performed by an electrochemical potentiostat (BioLogic VSP-<NUM>). The Kelvin connection clips are used during the tests to eliminate the effect of contact resistance.

<FIG> presents the cyclic voltammetry properties for the assembled supercapacitor at various scan rates from <NUM> mV/s to <NUM> mV/s in the voltage of <NUM>-<NUM> V according to the present invention. It is well known that the enclosed area of the CV curve presents the performance of the capacitor.

<FIG> illustrates the calculated capacitance normalized to the area and mass loading of cross-linked carbon nanotubes for the assembled supercapacitor according to the present invention. The areal and gravimetric capacitance is <NUM> mF/cm<NUM> and <NUM> F/g at the scan rate of <NUM> mV/s, respectively.

<FIG> depicts the Nyquist plot of the assembled supercapacitor obtained by electrochemical impedance spectroscopy (EIS) measurement from <NUM> to <NUM>. It is shown that Rcon (contact resistance), Rcht (charge transfer resistance), and Ridf (ion diffusion resistance) of the assembled supercapacitor are <NUM> Q, <NUM> Q, and <NUM> Q, respectively.

<FIG> illustrates the capacitance retention for the assembled supercapacitor in accordance with an embodiment of the present invention. The supercapacitor shows outstanding cycling stability of <NUM>% capacitance retention after <NUM> charge/discharge cycles.

Various electrodes are prepared by the APCVD technique. The prepared electrodes are loaded with different carbon mass from <NUM> to <NUM>, which are controlled by the number of nickel nanoparticles and the APCVD time (<NUM>~<NUM> minutes).

Several supercapacitors are packaged into stainless steel button cell (CR2032), shown as example1~example7. Tetraethylammonium tetrafluoroborate (Et<NUM>NBF<NUM>, 1mol/L in acetonitrile) and the glass fiber filter are used as the electrolyte and the separator, respectively. The corresponding CV and EIS of examples are tested by an electrochemical potentiostat (BioLogic VSP-<NUM>). The calculated capacitance normalized to the area of cross-linked carbon nanotubes are listed in TABLE <NUM>. The areal capacitance of examples is increased from <NUM> mF/cm<NUM> to <NUM> mF/cm<NUM> as the function of carbon mass loadings from <NUM> to <NUM>. The corresponding gravimetric capacitances are also calculated from <NUM> to <NUM> F/g.

To summarize the present invention relates to a method for fabricating an electrode for a supercapacitor based on carbon nanotubes. The electrode composes a microstructured metal film substrate (current collector) and cross-linked carbon nanotubes grown onto the current collector. The method comprising the process of:.

This way an electrode may be fabricated with the method described above constituted by said metal microstructures, metal catalysts, and cross-linked carbon nanotubes, which can be formed on the single or double side of the metal film substrate.

The electrode may be used to assemble a supercapacitor structure comprising two single-side electrodes, separator, and electrolyte. The supercapacitor may also include a double-sided electrode, the supercapacitor structure comprising two single-side electrodes, one double-side electrode, separator, and electrolyte. The supercapacitor structure can further be packaged into cylindrical, stacking, flat jellyroll cells. or surface mounting device as the metal film substrate is flexible.

The metal film substrate includes any structural type of metal products, such as: flat metal foil; or porous metal foil suitable for being provided with the microstructures within the suitable size range adapted to receiving and maintaining the catalyst particles interacting with the carbon nanotubes.

The metal film substrate may be constituted by or include any type of material capable of receiving and containing the metal layer or compound, preferably one or more of aluminum, copper, nickel, titanium, chromium, or stainless steel. The microstructures in the metal film substrate can be fabricated by a physical or chemical method.

The deposion of the metal layer on the substrate can be achieved by electron-beam evaporation, thermal evaporation, or sputtering and may include nickel, iron, cobalt, or a mixture of any of the above.

The deposition of a metal compound layer can be achieved by dip coating or spray coating using a metal compound precursor and may include a nickel compound, iron compound, cobalt compound, or a mixture of any of the above. The metal compound precursors can be prepared by dissolving the metal compounds into a soluble solvent, such as: water, methanol, ethanol, acetone, diethyl ether, or ethyl acetate, etc..

The process of converting the metal or metal compounds layer into metal nanoparticles is performed at <NUM>-<NUM> in a hydrogen atmosphere, where the formed metal nanoparticles include nickel nanoparticles, iron nanoparticles, cobalt nanoparticles, or a mixture of any of the above.

The growing of cross-linked carbon nanotubes may be formed by the catalytic pyrolysis of carbon-containing gas by APCVD at <NUM>~<NUM>, where the carbon-containing gases include acetylene, methane, ethylene, propane, butane, or a mixture of any of the above.

The cross-linked carbon nanotubes may include at least one of the following: single-walled carbon nanotubes (SWCNTs); and multi-walled carbon nanotubes (MWCNTs).

The cross-linked carbon nanotubes can be acted as a scaffold structure for loading with pseudocapacitive materials to form a pseudocapacitive electrode. The pseudocapacitive electrode may include transition metal oxides such as at least one of manganese oxide, nickel oxide, cobalt oxide, and ruthenium oxide, and conductive polymers include at least one of polyaniline, polypyrrole, and Poly(<NUM>,<NUM>-ethylene dioxythiophene): poly(<NUM>-styrene sulfonate) (PEDOT: PSS). The pseudocapacitor may comprise: at least two opposing pseudocapacitive electrodes, the separator between any two pseudocapacitive electrodes, and electrolyte permeated into the pseudocapacitive electrodes and the separators.

Claim 1:
Method for fabricating an electrode (<NUM>;<NUM>) for a supercapacitor, the method includes the following process steps:
• in a surface of a metal film substrate (<NUM>), etching microstructures (<NUM>) with a predetermined roughness,
• depositing in said microstructures (<NUM>) a metal or metal compound layer,
• converting said metal or compounds layer into metal nanoparticles (<NUM>), constituting a catalyst,
• growing cross linked carbon nanotubes (<NUM>) in said microstructures (<NUM>) at said metal nanoparticle (<NUM>) acting as catalysts.