Coating-Engineered NiCo2O4/NiFeO//Mn-PC Thin-Film Electrodes for New Energy Electric Vehicle Supercapacitors

To address the application requirements of energy storage devices for new energy electric vehicles—including high energy density, high-power density, fast charging and discharging, and long-term cycling stability—traditional symmetric supercapacitors are often limited by low energy density and poor compatibility between the anode and cathode, making it difficult to meet the high-efficiency energy storage demands under the dynamic operating conditions of electric vehicles. This study focuses on the regulation of hierarchical thin-film structures and the innovative heterogeneous coating interface engineering with precise slurry coating and film-forming optimization and designs and fabricates NiCo2O4/NiFeO composite thin-film electrodes and Mn-doped porous carbon (Mn-PC) thin-film electrodes. The uniform, compact and stable coating formation on nickel foam substrates via controllable slurry coating facilitates the efficient integration of active materials and conductive supports. The electrode slurries were coated onto conductive nickel foam substrates, and high-performance aqueous supercapacitors were assembled using an asymmetric configuration. A systematic study was conducted covering material preparation, structural characterization, electrochemical testing, and full-device performance evaluation. Using techniques such as XRD, XPS, SEM, TEM, BET, and an electrochemical workstation, the study revealed the structure–activity relationships among material morphology, crystalline phases, pore structure, and electrochemical performance, elucidating the charge storage mechanisms of the composite electrode films and the principles of synergistic adaptation between the anode and cathode. The results indicate that NiCo2O4 nanowires decorated with in situ-grown NiFeO nanosheets to form a composite structure; when coated onto nickel foam, this forms a uniform, porous electrode film with a specific surface area of 171.3 m2/g, a specific capacitance as high as 1746 F/g at 1 A/g, and a capacity retention rate of 94.0% after 10,000 cycles. After coating and film formation, the Mn-PC anode introduced pseudocapacitive active sites through uniform Mn doping, resulting in a film electrode specific capacitance of 348 F/g and significantly improved rate and cycling performance. The assembled NiCo2O4/NiFeO//Mn-PC asymmetric supercapacitor exhibits a thin-film electrode specific capacitance of 153 F/g at 1 A/g, with a maximum energy density of 52 Wh/kg. Even at a power density of 9000 W/kg, it maintains 45 Wh/kg, and retains 89.5% of its capacity after 10,000 cycles, with overall performance outperforming most previously reported transition metal-based devices. This coating-engineered electrode fabrication strategy breaks through the interface mismatch and structural instability bottlenecks of traditional thin-film electrodes, providing a novel material system and an efficient coating assembly strategy for high-performance supercapacitor thin-film electrodes in new energy electric vehicles, and offers experimental evidence and technical references for the development and application of high-power energy storage coating devices for automotive use, as well as the innovative design of electrode coating engineering in energy storage fields.