One unique property of supercapacitors relative to other energy storage devices is their exceptional lifetime, often reported in commercial devices as being over 1 million cycles. This cycle life is most often accompanied with a lifetime relating to a float at maximum voltage for a time of 1000 (or more) hours at a particular temperature, which gives a more practical indication of lifetime in terms of both time to assess and real life application. The end of life for such devices is taken as the point where the capacitance has decreased by 20% and/or the ESR has increased by 100%. In the early stages of use for a supercapacitor, a significant drop in capacitance and an accompanying increase in ESR, along with an increased level of gas generation are observed, the result of which would be a reduced lifetime by the conditions defined above. In order to maximise the lifetime and performance of supercapacitors, this early stage is taken care of through a pre-conditioning or ‘burn in’ stage during manufacture. The causes of the early stage issues mentioned are varied and include decomposition of carbon surface functional groups, solvent splitting (electrochemical decomposition, hydrogen and oxygen evolution reactions including decomposition of trace water) with gas evolution and current collector corrosion[1,2]. The typical burn-in procedure requires the cells to be held at a specific potential and temperature for an extended period of time, during which the capacitance fade, ESR increase and gas generation plateau, allowing the device to then exhibit excellent lifetime characteristics. Whilst the need for this step is clear, it is also costly and can be time consuming, requiring significant Capex and energy costs and also tying up significant inventory during the manufacturing process. Improvements and greater understanding of this process presents clear benefits to the manufacturing process and cost reductions. In this work, the burn-in process has been investigated at various scales, from coin cells through to 100F pouch cells, with differences in the requirements as the cell size increases discussed. Coin cells and small format pouch cells (70x50mm) have been constructed with YP50-F (Kuraray, Japan) activated carbon electrodes and TEABF4 in acetonitrile electrolyte and have been conditioned at 25oC and floating at 2.7V for 72 hours to ensure a lifetime of over 1000 hours. The temperature and potential of the burn-in has then been varied to shorten the process time and also reduce the total electrical energy required to achieve the same lifetime of device in terms of capacitance and ESR. Furthermore, the effect of water content of the electrolyte on the performance and burn-in process has been investigated. [1] S. Phadke, S. Amara and M. Anouti, Chem Phys Chem., 18, 2364, 2017 [2] M. He, K. Fic, E. Frackowaik, P. Novak and E. J. Berg, Energy Environ. Sci., 9, 623, 2016
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