Considering
the low specific capacitance of structural solid supercapacitors,
which is due to the low ion diffusivity in solid electrolytes and
the small specific surface area of some structural electrodes such
as carbon fiber fabrics, novel structural supercapacitor designs are
proposed and evaluated in this study based on supercapacitor-functional
sandwich composite materials. Typical electrochemical double layer
capacitors (EDLCs) are proposed with liquid organic electrolyte 1
M TEABF4 in PC (propylene carbonate). In the innovative
sandwich structured composites, supercapacitors are embedded in the
skins and integrated in the honeycomb core where the aluminum faces
of the core constitute the current collectors of the supercapacitor-functional
core. The sandwich composite material exhibited a flexural modulus
of 5.07 GPa and a flexural strength of 413.9 MPa. The EDLCs embedded
in the skins increased the skin flexural modulus and strength by 47%
and 56%, respectively, for embedded lateral EDLCs, and by 91% and
106%, respectively, for embedded lateral and longitudinal EDLCs. Compared
to typical EDLCs with the same electrolyte, the structural supercapacitors
in this study demonstrated superior specific electrode capacitance, C
sp,el = 153 F g–1 for the
honeycomb supercapacitor and C
sp,el =
95.7 F g–1 for the skin supercapacitor, translating
to overall structural composite material performance of 0.68 Wh/m2
honeycomb and 30.5 W/m2
honeycomb for the supercapacitor-functional honeycomb, and 0.02 Wh/m2
skin and 5.4 W/m2
skin for the supercapacitor-functional
skin.