Porous Fiber Processing and Manufacturing for Energy Storage Applications

Comparison of Pore Structures of Cellulose-Based Activated Carbon Fibers and Their Applications for Electrode Materials

This study presents the first investigation of cellulose-based activated carbon fibers (RACFs) prepared as electrode materials for the electric double-layer capacitor (EDLC) in lieu of activated carbon, to determine its efficacy as a low-cost, environmentally friendly enhancement alternative to nanocarbon materials. The RACFs were prepared by steam activation and their textural properties were studied by Brunauer–Emmett–Teller and non-localized density functional theory equations with N2/77K adsorption isotherms. The crystallite structure of the RACFs was observed by X-ray diffraction. The RACFs were applied as an electrode material for an EDLC and compared with commercial activated carbon (YP-50F). The electrochemical performance of the EDLC was analyzed using galvanostatic charge/discharge curves, cyclic voltammetry, and electrochemical impedance spectroscopy. The results show that the texture properties of the activated carbon fibers were influenced by the activation time. Crucially, the specific surface area, total pore volume, and mesopore volume ratio of the RACF with a 70-min activation time (RACF-70) were 2150 m2/g, 1.03 cm3/g and 31.1%, respectively. Further, electrochemical performance analysis found that the specific capacitance of RACF-70 increased from 82.6 to 103.6 F/g (at 2 mA/cm2). The overall high specific capacitance and low resistance of the RACFs were probably influenced by the pore structure that developed outstanding impedance properties. The results of this work demonstrate that RACFs have promising application value as performance enhancing EDLC electrode materials.

Porous Fibers Templated by Melt Blowing Cocontinuous Immiscible Polymer Blends

We report a scalable melt blowing method for producing porous nonwoven fibers from model cocontinuous polystyrene/high-density polyethylene polymer blends. While conventional melt compounding of cocontinuous blends typically produces domain sizes ∼1-10 μm, melt blowing these blends into fibers reduces those dimensions up to 35-fold and generates an interpenetrating domain structure. Inclusion of ≤1 wt % of a block copolymer compatibilizer in these blends crucially enables access to smaller domain sizes in the fibers by minimizing thermodynamically-driven blend coarsening inherent to cocontinuous blends. Selective solvent extraction of the sacrificial polymer phase yielded a network of porous channels within the fibers. Fiber surfaces also exhibited pores that percolate into the fiber interior, signifying the continuous and interconnected nature of the final structure. Pore sizes as small as ∼100 nm were obtained, suggesting potential applications of these porous nonwovens that rely on their high surface areas, including various filtration modules.