Space-based Carbon Nanotube Ultracapacitor

Luna Innovations will develop novel carbon nanosheet technology for space-based ultracapacitors. Our proven nanosheet manufacturing process will be optimized to enable capacitance >20,000 Farads at 3.3 V, a power density >8000 W/kg, a 20-year lifetime, an expanded -40 to +80°C temperature range, and radiation tolerance >106 rad.  Deposited by RF plasma enhanced chemical vapor deposition (PECVD), carbon nanosheet films are similar to vertically aligned carbon nanotubes, but nanosheets offer an open, two-dimensional, planar nanostructure rather than a closed, cylindrical tubular structure, and therefore a higher specific surface area.  In almost every metric, nanosheets offer potential advantages over nanotubes or activated carbon as an electrode material for ultracapacitors.  Preliminary testing of Lunas nanosheet-based ultracapacitors by John Miller at JME Incorporated determined a response time of <10-4 sec, indicating an extremely powerful capacitor. The data also indicate that the devices may already exceed the power density metric of 8000 W/kg. BENEFIT: Because nanosheet synthesis is compatible with roll-to-roll production directly onto metal foil, requires no special substrate pre-treatment or purification of catalyst materials, and can be easily post-treated in situ, high-volume production costs are expected to be comparable to other nanostructured electrode materials.  Using current deposition conditions, the materials cost for nanosheet electrodes is estimated at less $0.05 per square meter of substrate for a commercial roll-to-roll process.