Three-dimensional high-aspect-ratio microarray thick electrodes for high-rate hybrid supercapacitors

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Hybrid supercapacitors (HSCs) with facile integration and high process compatibility are considered ideal power sources for portable consumer electronics. However, as a crucial component for storing energy, traditional thin-film electrodes exhibit low energy density. Although increasing the thickness of thin films can enhance the energy density of the electrodes, it gives rise to issues such as poor mechanical stability and long electron/ion transport pathways. Constructing a stable three-dimensional (3D) ordered thick electrode is considered the key to addressing the aforementioned contradictions. In this work, a manufacturing process combining lithography and chemical deposition techniques is developed to produce large-area and high-aspect-ratio 3D nickel ordered cylindrical array (NiOCA) current collectors. Positive electrodes loaded with nickel–cobalt bimetallic hydroxide (NiOCA/NiCo-LDH) are constructed by electrodeposition, and HSCs are assembled with NiOCA/nitrogen-doped porous carbon (NiOCA/NPC) as negative electrodes. The HSCs exhibits 55% capacity retention with the current density ranging from 2 to 50 mA cm−2. Moreover, it maintains 98.2% of the initial capacity after long-term cycling of 15,000 cycles at a current density of 10 mA cm−2. The manufacturing process demonstrates customizability and favorable repeatability. It is anticipated to provide innovative concepts for the large-scale production of 3D microarray thick electrodes for high-performance energy storage system.