An Overview and Future Perspectives of Rechargeable Flexible Zn-Air Batteries

Environmental friendliness and low-cost zinc-air batteries for flexible rechargeable applications have great potential in the field of flexible electronics and smart wearables owing to high energy density and long service life. However, the current technology of flexible rechargeable zinc-air batteries to meet the commercialization needs still facing enormous challenges due to the poor adaptability of each flexible component of the zinc-air batteries. This review focused on the latest progress over the past 5 years in designing and fabricating flexible self-standing air electrodes, flexible electrolytes and zinc electrodes of flexible Zn-air batteries, meanwhile the basic working principle of each component of flexible rechargeable zinc-air batteries and battery structures optimization are also described. Finally, challenges and prospects for the future development of flexible rechargeable zinc-air batteries are discussed. This work is intended to provide insights and general guidance for future exploration of the design and fabrication on high-performance flexible rechargeable zinc-air batteries.

Interface engineering of hierarchical flower-like N, P, O-doped NixPy self-supported electrodes for highly efficient water-to-hydrogen fuel/oxygen conversion

Rational construction of efficient bifunctional catalysts with robust catalytic activity and durability is significant for overall water splitting (conversion between water and hydrogen fuel/oxygen) using non-precious metal systems. In this work, the hierarchically porous N, P, O-doped transition metal phosphate in the Ni foam (NF) electrode (hollow flower-like NPO/NixPy@NF) was prepared through facile hydrothermal method coupled with phosphorization treatment. The hierarchical hollow flower-like NPO/NixPy@NF electrodes exhibited high bifunctional activity and stability for hydrogen evolution reaction (HER) and oxygen evolution reaction (OER) in alkaline solutions. The optimized electrode showed low overpotentials of 76 and 240 mV for HER and OER to reach a current density of 10 mA cm-2, respectively. Notably, the NPO/NixPy@NF electrode only required a low voltage of 1.99 V to reach the current densities of 100 mA cm-2 with long-term stability for overall water splitting using the NPO/NixPy@NF|| NPO/NixPy@NF cell, surpassing that of the Pt/C-RuO2 (2.24 V@ 100 mA cm-2). The good catalytic and battery performance should be attributed to i) the open hierarchical structure that enhanced the mass transfer; ii) a highly conductive substrate that accelerated the electron transfer; iii) the rich heterojunction and strong synergy between Ni2P and Ni5P4 that improved the catalytic kinetic; iv) the proper-thickness amorphous phosphorus oxide nitride (PON) shell that realized the stability. This work demonstrates a promising methodology for designing bifunctional transition metal phosphides with high performance for efficient water splitting.

Toward Quantitative Electrodeposition via In Situ Liquid Phase Transmission Electron Microscopy: Studying Electroplated Zinc Using Basic Image Processing and 4D STEM

High energy density electrochemical systems such as metal batteries suffer from uncontrollable dendrite growth on cycling, which can severely compromise battery safety and longevity. This originates from the thermodynamic preference of metal nucleation on electrode surfaces, where obtaining the crucial information on metal deposits in terms of crystal orientation, plated volume, and growth rate is very challenging. In situ liquid phase transmission electron microscopy (LPTEM) is a promising technique to visualize and understand electrodeposition processes, however a detailed quantification of which presents significant difficulties. Here by performing Zn electroplating and analyzing the data via basic image processing, this work not only sheds new light on the dendrite growth mechanism but also demonstrates a workflow showcasing how dendritic deposition can be visualized with volumetric and growth rate information. These results along with additionally corroborated 4D STEM analysis take steps to access information on the crystallographic orientation of the grown Zn nucleates and toward live quantification of in situ electrodeposition processes.

Laboratory X-ray computed tomography imaging protocol allowing the operando investigation of electrode material evolution in various environments

A robust imaging protocol utilizing laboratory XCT is presented. Hybrid 2D/3D imaging at different scales with real-time monitoring allowed to assess, in operation, the evolution of zinc electrodes within three environments, namely alkaline, near-neutral, and mildly acidic. Different combinations of currents were used to demonstrate various scenarios exhibiting both dendritic and smooth deposition of active material. Directly from radiograms, the volume of the electrode and therefore its growth/dissolution rate was estimated and compared against tomographic reconstructions and theoretical values. The protocol combines simplistic cell design with multiple three-dimensional and two-dimensional acquisitions at different magnifications, providing a unique insight into electrode's morphology evolution within various environments.

Observation of Zn Dendrite Growth via Operando Digital Microscopy and Time-Lapse Tomography

The zinc-ion battery is one of the promising candidates for next-generation energy storage devices beyond lithium technology due to the earth's abundance of Zn materials and their high volumetric energy density (5855 mA h cm-3). To date, the formation of Zn dendrites during charge-discharge cycling still hinders the practical application of zinc-ion batteries. It is, therefore, crucial to understand the formation mechanism of the zinc dendritic structure before effectively suppressing its growth. Here, the application of operando digital optical microscopy and in situ lab-based X-ray computed tomography (X-ray CT) is demonstrated to probe and quantify the morphologies of zinc electrodeposition/dissolution under multiple galvanostatic plating/stripping conditions in symmetric Zn||Zn cells. With the combined microscopy approaches, we directly observed the dynamic nucleation and subsequent growth of Zn deposits, the heterogeneous transportation of charged clusters/particles, and the evolution of 'dead' Zn particles via partial dissolution. Zn electrodeposition at the early stage is mainly attributed to activation, while the subsequent dendrite growth is driven by diffusion. The high current not only facilitates the formation of sharp dendrites with a larger mean curvature at their tips but also leads to dendritic tip splitting and the creation of a hyper-branching morphology. This approach offers a direct opportunity to characterize dendrite formation in batteries with a metal anode in the laboratory.

Bridging nano- and microscale X-ray tomography for battery research by leveraging artificial intelligence

X-ray computed tomography (CT) is a non-destructive imaging technique in which contrast originates from the materials' absorption coefficient. The recent development of laboratory nanoscale CT (nano-CT) systems has pushed the spatial resolution for battery material imaging to voxel sizes of 50 nm, a limit previously achievable only with synchrotron facilities. Given the non-destructive nature of CT, in situ and operando studies have emerged as powerful methods to quantify morphological parameters, such as tortuosity factor, porosity, surface area and volume expansion, during battery operation or cycling. Combined with artificial intelligence and machine learning analysis techniques, nano-CT has enabled the development of predictive models to analyse the impact of the electrode microstructure on cell performances or the influence of material heterogeneities on electrochemical responses. In this Review, we discuss the role of X-ray CT and nano-CT experimentation in the battery field, discuss the incorporation of artificial intelligence and machine learning analyses and provide a perspective on how the combination of multiscale CT imaging techniques can expand the development of predictive multiscale battery behavioural models.

An operando spatially resolved study of alkaline battery discharge using a novel hyperspectral detector and X-ray tomography

An experimental technique is described for the collection of time-resolved X-ray diffraction information from a complete commercial battery cell during discharging or charging cycles. The technique uses an 80 × 80 pixel 2D energy-discriminating detector in a pinhole camera geometry which can be used with a polychromatic X-ray source. The concept was proved in a synchrotron X-ray study of commercial alkaline Zn-MnO2 AA size cells. Importantly, no modification of the cell was required. The technique enabled spatial and temporal changes to be observed with a time resolution of 20 min (5 min of data collection with a 15 min wait between scans). Chemical changes in the cell determined from diffraction information were correlated with complementary X-ray tomography scans performed on similar cells from the same batch. The clearest results were for the spatial and temporal changes in the Zn anode. Spatially, there was a sequential transformation of Zn to ZnO in the direction from the separator towards the current collector. Temporally, it was possible to track the transformation of Zn to ZnO during the discharge and follow the corresponding changes in the cathode.

Cold Sintering as a Cost-Effective Process to Manufacture Porous Zinc Electrodes for Rechargeable Zinc-Air Batteries

Zinc-air batteries (ZABs) offer a sustainable and safe pathway to low-cost energy storage. Recent research shows that thermally-sintered porous Zn electrodes with a three-dimensional network structure can enhance the performance and lifetime of ZABs, but they are expensive and energy-intensive to manufacture. In this work, monolithic porous Zn electrodes fabricated through an efficient cold sintering process (CSP) were studied for rechargeable ZABs. Electrochemical studies and extended charge-discharge cycling show good Zn utilization with no observable performance degradation when compared to Zn foil. Post-mortem analysis after 152 h of cycling reveals that the cold-sintered electrodes retain their original structure. A techno-economic assessment of the cold sintering process confirms significant reductions in both the time and energy required to manufacture Zn electrodes compared to a comparable thermal sintering process.

Implications of Testing a Zinc-Oxygen Battery with Zinc Foil Anode Revealed by Operando Gas Analysis

Zinc-oxygen batteries are seen as promising energy storage devices for future mobile and stationary applications. Introducing them as secondary battery is hindered by issues at both the anode and cathode. Research efforts were intensified during the past two decades, mainly focusing on catalyst materials for the cathode. Thereby, zinc foil was almost exclusively used as the anode in electrochemical testing in the lab-scale as it is easy to apply and shall yield reproducible results. However, it is well known that zinc metal reacts with water within the electrolyte to form hydrogen. It is not yet clear how the evolution of hydrogen is affecting the performance results obtained thereof. Herein, we extend the studies and the understanding about the evolution of hydrogen at zinc by analyzing the zinc-oxygen battery during operation. By means of electrochemical measurements, operando gas analysis, and anode surface analysis, we elucidate that the rate of the evolution of hydrogen scales with the current density applied, and that the roughness of the anode surface, that is, the pristine state of the zinc foil surface, affects the rate as well. In the end, we propose a link between the evolution of hydrogen and the unwanted impact on the actual electrochemical performance that might go unnoticed during testing. Thereof, we elucidate the consequences that arise for the working principle and the testing of materials for this battery type.

Correction approach of detector backlighting in radiography

In various kinds of radiography, deficient transmission imaging may occur due to backlighting inside the detector itself arising from light or radiation scattering. The related intensity mismatches barely disturb the high resolution contrast, but its long range nature results in reduced attenuation levels which are often disregarded. Based on X-ray observations and an empirical formalism, a procedure is developed for a first order correction of detector backlighting. A backlighting factor is modeled as a function of the relative detector coverage by the sample projection. Different cases of sample transmission are regarded at different backlight factors and detector coverage. The additional intensity of backlighting may strongly affect the values of materials' attenuation up to a few 10%. The presented scenario provides a comfortable procedure for corrections of X-ray or neutron transmission imaging data.

Influence of Al Alloying on the Electrochemical Behavior of Zn Electrodes for Zn-Air Batteries With Neutral Sodium Chloride Electrolyte

Zn alloy electrodes containing 10 wt. % Al were prepared to examine the applicability as anodes in primary Zn-air batteries with neutral 2M NaCl electrolyte. These electrodes were investigated by electrochemical measurements and microscopic techniques (SEM, LSM, AFM). Based on the cyclic voltammetry and intermediate term (24 h) discharge experiments, the only active element in the as-prepared alloy was found to be Zn. It was further confirmed by LSM that Zn rich areas dissolved while Al remained passive during discharge. The passive state of Al was also demonstrated by conductive AFM investigations on the as-cast alloy surfaces. The results on potentiodynamic polarization and weight loss measurements indicated that the alloy electrode was less prone to corrosion than pure Zn electrode. The electrochemical behavior of the electrodes was modified under certain cathodic polarization previous to measurements. Accordingly, originating from Al activation due to application of cathodic potentials, potentiodynamic polarization studies showed a clear shift on the corrosion potentials of the alloy toward more negative values. On the basis of these results, with the precondition of Al activation prior to discharge experiments, the effect of Al alloying on the Zn electrodes was revealed as temporarily enhanced potentials on the discharge profiles in comparison to pure Zn electrodes.

Discharge performance and dynamic behavior of refuellable zinc-air battery

Zinc-air batteries (ZABs) are considered a promising energy storage system. A model-based analysis is one of the effective approaches for the study of ZABs. This technique, however, requires reliable discharge data as regards parameter estimation and model validation. This work, therefore, provides the data required for the modeling and simulation of ZABs. Each set of data includes working time, cell voltage, current, capacity, power, energy, and temperature. The data can be divided into three categories: discharge profiles at different constant currents, dynamic behavior at different step changes of discharge current, and dynamic behavior at different random step changes of discharge current. Constant current discharge profile data focus on the evolution of voltage through time. The data of step changes emphasize the dynamic behavior of voltage responding to the change of discharge current. Besides, the data of random step changes are similar to the data of step changes, but the patterns of step changes are random. Such data support the modeling of a zinc-air battery for both theoretical and empirical approaches.

An X-ray Tomographic Study of Rechargeable Zn/MnO₂ Batteries

We present non-destructive and non-invasive in operando X-ray tomographic investigations of the charge and discharge behavior of rechargeable alkaline-manganese (RAM) batteries (Zn-MnO₂ batteries). Changes in the three-dimensional structure of the zinc anode and the MnO₂ cathode material after several charge/discharge cycles were analyzed. Battery discharge leads to a decrease in the zinc particle sizes, revealing a layer-by-layer dissolving behavior. During charging, the particles grow again to almost their initial size and shape. After several cycles, the particles sizes slowly decrease until most of the particles become smaller than the spatial resolution of the tomography. Furthermore, the number of cracks in the MnO₂ bulk continuously increases and the separator changes its shape. The results are compared to the behavior of a conventional primary cell that was also charged and discharged several times.

Rational Development of Neutral Aqueous Electrolytes for Zinc-Air Batteries

Neutral aqueous electrolytes have been shown to extend both the calendar life and cycling stability of secondary zinc-air batteries (ZABs). Despite this promise, there are currently no modeling studies investigating the performance of neutral ZABs. Traditional continuum models are numerically insufficient to simulate the dynamic behavior of these complex systems because of the rapid, orders-of-magnitude concentration shifts that occur. In this work, we present a novel framework for modeling the cell-level performance of pH-buffered aqueous electrolytes. We apply our model to conduct the first continuum-scale simulation of secondary ZABs using aqueous ZnCl₂ -NH₄ Cl as electrolyte. We first use our model to interpret the results of two recent experimental studies of neutral ZABs, showing that the stability of the pH value is a significant factor in cell performance. We then optimize the composition of the electrolyte and the design of the cell considering factors including pH stability, final discharge product, and overall energy density. Our simulations predict that the effectiveness of the pH buffer is limited by slow mass transport and that chlorine-containing solids may precipitate in addition to ZnO.

Visualizing Current-Dependent Morphology and Distribution of Discharge Products in Sodium-Oxygen Battery Cathodes

Synchrotron X-ray tomography and scanning electron microscopy were applied to elucidate the spatial distribution of discharge product (NaO2) in the carbon cathode of sodium-oxygen batteries. Various batteries were discharged galvanostatically and their cathodes were analyzed. We observe a particle density gradient along the cathode that scales with the current density applied. Besides, we show that the particle size and shape of discharge product strongly depend on current density, and on whether the particles are deposited close to the oxygen reservoir or near the separator. We correlate our findings to transport limitations for the supplied oxygen and gain crucial information for optimal operation of sodium-oxygen batteries. Our findings imply that for low current densities pore clogging might occur, and that for elevated current densities small high surface area particles with limited electric conductivity form; both phenomena can decrease the available discharge and charge capacity significantly.