Optimizing Electrodeposition of Polyaniline on Various Woven Steel Mesh Sizes for Enhanced Supercapacitor Performance

Abstract The development of efficient supercapacitors hinges on the innovation of superior electrodes, which are pivotal in augmenting their energy storage capabilities. Supercapacitors, recognized for their high‐power density and extended cycle life, play a crucial role as sustainable solutions in addressing energy storage challenges. A fundamental aspect of supercapacitor functionality involves the electrode material, which works in concert with other key components such as the current collector, separator, and electrolyte. This study focuses on evaluating the impact of the current collector material on the performance of symmetric supercapacitors. We investigated the electropolymerization of polyaniline on woven steel mesh current collectors of varying mesh sizes, ranging from 20 to 200 mesh per inch, using assorted deposition conditions. The electrochemically modified woven steel meshes were utilized to construct symmetric supercapacitors. The electrochemical performance of the assembled supercapacitors, configured in a two‐electrode system, was investigated using a variety of electrochemical techniques to better understand the kinetics of electrolyte ion migration. Notably, the 20‐mesh size, characterized by the fewest pores per inch, demonstrated superior performance with an optimum capacitance of 4730 mF/cm 2 , an energy density of 317.8 μWh/cm 2 , and a power density of 400 μW/cm 2 at a current density of 1 mA/cm 2 .