Type of separators along with the properties of electrode material, electrolytes decide the performance and hence the utility of supercapacitor. Nylon as a separator material is investigated in this paper. Comparison of parameters of nylon separator supercapacitor and polyethylene separator supercapacitor is presented. The processing of electrode materials plays a significant role on the performance parameters of supercapacitor. Material processing method such as ball milling is the most commonly used in energy storage devices such as supercapacitors, batteries, and fuel cells. The effect of variation of the most significant ball milling parameters such as forward‐reverse time, total ball milling time and speed of ball mill machine on the performance of supercapacitor has been studied. Modeling of ball milling process on electrode material is done by using the statistical method design of the experiment. Pulse current density is taken as new output parameters which is more important than capacitance and internal resistance. Forward‐reverse time, total ball milling time, and speed of ball mill machine are taken as input parameters for statistical modeling. Capacitance and pulse current density is taken as output parameters for the modeling of nylon separator supercapacitor. The model values of output parameters of supercapacitor are validated with experimental values.
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