Recent Advances on Self‐Supported Arrayed Bifunctional Oxygen Electrocatalysts for Flexible Solid‐State Zn–Air Batteries

Flexible solid‐state Zn–air batteries have been rapidly developed benefiting from the uprising demand for wearable electronic devices, wherein the air electrode integrated with efficient bifunctional oxygen electrocatalysts plays an important role to achieve high performance. Binder‐free self‐supported bifunctional catalysts can provide large active surface area, fast electron transport path, easy ion diffusion, and excellent structural stability and flexibility, thus acting as promising flexible air cathodes. In this review, recent advances on the application of nanoarrayed electrocatalysts as air cathodes in flexible Zn–air batteries are reviewed. Especially, various types of bifunctional oxygen electrocatalysts, including carbonaceous material arrays, transition metal compound arrays, transition metal/carbon arrays, transition metal compound/carbon arrays, and other hybrid arrays, are discussed. The applications of flexible Zn–air batteries with two configurations (i.e., planar stacks and cable fibers) are also introduced. Finally, perspectives on the optimization of arrayed air cathodes for future development to achieve high‐performance flexible Zn–air batteries are shared.     

Recent Progress in Electrically Rechargeable Zinc–Air Batteries

Over the past decade, the surging interest for higher‐energy‐density, cheaper, and safer battery technology has spurred tremendous research efforts in the development of improved rechargeable zinc–air batteries. Current zinc–air batteries suffer from poor energy efficiency and cycle life, owing mainly to the poor rechargeability of zinc and air electrodes. To achieve high utilization and cyclability in the zinc anode, construction of conductive porous framework through elegant optimization strategies and adaptation of alternate active material are employed. Equally, there is a need to design new and improved bifunctional oxygen catalysts with high activity and stability to increase battery energy efficiency and lifetime. Efforts to engineer catalyst materials to increase the reactivity and/or number of bifunctional active sites are effective for improving air electrode performance. Here, recent key advances in material development for rechargeable zinc–air batteries are described. By improving fundamental understanding of materials properties relevant to the rechargeable zinc and air electrodes, zinc–air batteries will be able to make a significant impact on the future energy storage for electric vehicle application. To conclude, a brief discussion on noteworthy concepts of advanced electrode and electrolyte systems that are beyond the current state‐of‐the‐art zinc–air battery chemistry, is presented.     

Atomic Modulation and Structure Design of Carbons for Bifunctional Electrocatalysis in Metal–Air Batteries

With the extensive research and development of renewable energy technologies, there is an increasing interest in developing metal‐free carbons as a new class of bifunctional electrocatalysts for boosting the performance of metal–air batteries. Along with significant understanding of the electrocatalytic nature and the rapid development of techniques, the activities of carbon electrocatalysts are well‐tailored by introducing particular dopants/defects and structure regulation. Herein, the recent advances regarding the rational design of carbon‐based electrocatalysts for the oxygen reduction reaction and oxygen evolution reaction are summarized, with a special focus on the bifunctional applications in Zn–air and Li–air batteries. Specifically, the atomic modulation strategies to regulate the electrocatalytic activities of carbons and structure modification are summarized to gain deep insights into bifunctional mechanisms and boost advanced Zn–air and Li–air batteries. The current challenges and future perspectives are also addressed to accelerate the exploration of promising bifunctional carbon catalysts for renewable energy technologies, particularly metal–air batteries.     

Crosslinked Carbon Nanotube Aerogel Films Decorated with Cobalt Oxides for Flexible Rechargeable Zn–Air Batteries

Air electrodes with high catalytic activity are of great importance for rechargeable zinc–air batteries. Herein, a flexible, binder‐free composite air electrode for zinc–air batteries is reported, which utilizes a lightweight, conductive, and crosslinked aerogel film of carbon nanotubes (CNTs) functioned as a 3D catalyst‐supporting scaffold for bifunctional cobalt (II/III) oxides and as a current collector. The composite electrode shows high catalytic activities for both oxygen reduction reaction and oxygen evolution reaction, resulting from the synergistic effect of nitrogen‐doped CNTs and spinel Co₃O₄ nanoparticles. Solid‐state Zn–air batteries assembled using such free‐standing air electrodes (without the need of additional current collectors) are bendable and show low resistances, low charge/discharge overpotentials, and a high cyclic stability.     

Framework‐Porphyrin‐Derived Single‐Atom Bifunctional Oxygen Electrocatalysts and their Applications in Zn–Air Batteries

High‐performance bifunctional oxygen electrocatalysis constitutes the key technique for the widespread application of clean and sustainable energy through electrochemical devices such as rechargeable Zn–air batteries. Single‐atom electrocatalysts with maximum atom efficiency are highly considered as an alternative of the present noble‐metal‐based electrocatalysts. However, the fabrication of transition metal single‐atoms is very challenging, requiring extensive attempts of precursors with novel design principles. Herein, an all‐covalently constructed cobalt‐coordinated framework porphyrin with graphene hybridization is innovatively designed and prepared as the pyrolysis precursor to fabricate single‐atom Co–N_x–C electrocatalysts. Excellent electrochemical performances are realized for both bifunctional oxygen electrocatalysis and rechargeable Zn–air batteries with regard to reduced overpotentials, improved kinetics, and prolonged cycling stability comparable with noble‐metal‐based electrocatalysts. Design principles from multiple scales are proposed and rationalized with detailed mechanism investigation. This work not only provides a novel precursor for the fabrication of high‐performance single‐atom electrocatalysts, but also inspires further attempts to develop advanced materials and emerging applications.     

Bifunctional Transition Metal Hydroxysulfides: Room‐Temperature Sulfurization and Their Applications in Zn–Air Batteries

Bifunctional electrocatalysis for oxygen evolution reaction (OER) and oxygen reduction reaction (ORR) constitutes the bottleneck of various sustainable energy devices and systems like rechargeable metal–air batteries. Emerging catalyst materials are strongly requested toward superior electrocatalytic activities and practical applications. In this study, transition metal hydroxysulfides are presented as bifunctional OER/ORR electrocatalysts for Zn–air batteries. By simply immersing Co‐based hydroxide precursor into solution with high‐concentration S^2?, transition metal hydroxides convert to hydroxysulfides with excellent morphology preservation at room temperature. The as‐obtained Co‐based metal hydroxysulfides are with high intrinsic reactivity and electrical conductivity. The electron structure of the active sites is adjusted by anion modulation. The potential for 10 mA cm^?2 OER current density is 1.588 V versus reversible hydrogen electrode (RHE), and the ORR half‐wave potential is 0.721 V versus RHE, with a potential gap of 0.867 V for bifunctional oxygen electrocatalysis. The Co₃FeS_1.5(OH)₆ hydroxysulfides are employed in the air electrode for a rechargeable Zn–air battery with a small overpotential of 0.86 V at 20.0 mA cm^?2, a high specific capacity of 898 mAh g^?1, and a long cycling life, which is much better than Pt and Ir‐based electrocatalyst in Zn–air batteries.     

Oxygen Vacancy–Rich In‐Doped CoO/CoP Heterostructure as an Effective Air Cathode for Rechargeable Zn–Air Batteries

An efficient and low‐cost electrocatalyst for reversible oxygen electrocatalysis is crucial for improving the performance of rechargeable metal?air batteries. Herein, a novel oxygen vacancy–rich 2D porous In‐doped CoO/CoP heterostructure (In‐CoO/CoP FNS) is designed and developed by a facile free radicals–induced strategy as an effective bifunctional electrocatalyst for rechargeable Zn–air batteries. The electron spin resonance and X‐ray absorption near edge spectroscopy provide clear evidence that abundant oxygen vacancies are formed in the interface of In‐CoO/CoP FNS. Owing to abundant oxygen vacancies, porous heterostructure, and multiple components, In‐CoO/CoP FNS exhibits excellent oxygen reduction reaction activity with a positive half‐wave potential of 0.81 V and superior oxygen evolution reaction activity with a low overpotential of 365 mV at 10 mA cm^?2. Moreover, a home‐made Zn–air battery with In‐CoO/CoP FNS as an air cathode delivers a large power density of 139.4 mW cm^?2, a high energy density of 938 Wh kg_Zn^?1, and can be steadily cycled over 130 h at 10 mA cm^?2, demonstrating great application potential in rechargeable metal–air batteries.     

Robust Fe3Mo3C Supported IrMn Clusters as Highly Efficient Bifunctional Air Electrode for Metal–Air Battery

Catalysts at the air cathode for oxygen reduction and evolution reactions are central to the stability of rechargeable metal–air batteries, an issue that is gaining increasing interest in recent years. Herein, a highly durable and efficient carbide‐based bifunctional catalyst consisting of iron–molybdenum carbide (Fe₃Mo₃C) and IrMn nanoalloys is demonstratred. This carbide is chemically stable in alkaline media and over the potential range of an air cathode. More importantly, Fe₃Mo₃C is very active for oxygen reduction reaction (ORR) in alkaline media. Fe₃Mo₃C supported IrMn as a bifunictional catalysts exhibits superior catalytic performance than the state of the art ORR catalyst (Pt/C) and the oxygen evolution reaction catalyst (Ir/C). IrMn/Fe₃Mo₃C enables Zn–air batteries to achieve long‐term cycling performance over 200 h with high efficiency. The extraordinarily high performance of IrMn/Fe₃Mo₃C bifunictional catalyst provides a very promising alternative to the conventional Pt/C and Ir/C catalyst for an air cathode in alkaline electrolyte.     

Novel MOF‐Derived Co@N‐C Bifunctional Catalysts for Highly Efficient Zn–Air Batteries and Water Splitting

Metal–organic frameworks (MOFs) and MOF‐derived materials have recently attracted considerable interest as alternatives to noble‐metal electrocatalysts. Herein, the rational design and synthesis of a new class of Co@N‐C materials (C‐MOF‐C2‐T) from a pair of enantiotopic chiral 3D MOFs by pyrolysis at temperature T is reported. The newly developed C‐MOF‐C2‐900 with a unique 3D hierarchical rodlike structure, consisting of homogeneously distributed cobalt nanoparticles encapsulated by partially graphitized N‐doped carbon rings along the rod length, exhibits higher electrocatalytic activities for oxygen reduction and oxygen evolution reactions (ORR and OER) than that of commercial Pt/C and RuO₂, respectively. Primary Zn–air batteries based on C‐MOF‐900 for the oxygen reduction reaction (ORR) operated at a discharge potential of 1.30 V with a specific capacity of 741 mA h g_Zn^–1 under 10 mA cm^–2. Rechargeable Zn–air batteries based on C‐MOF‐C2‐900 as an ORR and OER bifunctional catalyst exhibit initial charge and discharge potentials at 1.81 and 1.28 V (2 mA cm^–2), along with an excellent cycling stability with no increase in polarization even after 120 h – outperform their counterparts based on noble‐metal‐based air electrodes. The resultant rechargeable Zn–air batteries are used to efficiently power electrochemical water‐splitting systems, demonstrating promising potential as integrated green energy systems for practical applications.     

Ultrathin Cobalt Oxide Layers as Electrocatalysts for High‐Performance Flexible Zn–Air Batteries

Synergistic improvements in the electrical conductivity and catalytic activity for the oxygen reduction reaction (ORR)/oxygen evolution reaction (OER) are of paramount importance for rechargeable metal–air batteries. In this study, one‐nanometer‐scale ultrathin cobalt oxide (CoO_x) layers are fabricated on a conducting substrate (i.e., a metallic Co/N‐doped graphene substrate) to achieve superior bifunctional activity in both the ORR and OER and ultrahigh output power for flexible Zn–air batteries. Specifically, at the atomic scale, the ultrathin CoO_x layers effectively accelerate electron conduction and provide abundant active sites. X‐ray absorption spectroscopy reveals that the metallic Co/N‐doped graphene substrate contributes to electron transfer toward the ultrathin CoO_x layer, which is beneficial for the electrocatalytic process. The as‐obtained electrocatalyst exhibits ultrahigh electrochemical activity with a positive half‐wave potential of 0.896 V for ORR and a low overpotential of 370 mV at 10 mA cm^?2 for OER. The flexible Zn–air battery built with this catalyst exhibits an ultrahigh specific power of 300 W g_cat ^?1, which is essential for portable devices. This work provides a new design pathway for electrocatalysts for high‐performance rechargeable metal–air battery systems.     

Efficient Bifunctional Catalytic Electrodes with Uniformly Distributed NiN2 Active Sites and Channels for Long‐Lasting Rechargeable Zinc–Air Batteries

Freestanding bifunctional electrodes with outstanding oxygen reduction reaction (ORR) and oxygen evolution reaction (OER) properties are of great significance for zinc–air batteries, attributed to the avoided use of organic binder and strong adhesion with substrates. Herein, a strategy is developed to fabricate freestanding bifunctional electrodes from the predeposited nickel nanoparticles (Ni‐NCNT) on carbon fiber paper. The steric effect of monodispersed SiO₂ nanospheres limits the configuration of carbon atoms forming 3D interconnected nanotubes with uniformly distributed NiN₂ active sites. The bifunctional electrodes (Ni‐NCNT) demonstrate ideal ORR and OER properties. The zinc–air batteries assembled with Ni‐NCNT directly exhibit extremely outstanding long term stability (2250 cycles with 10 mA cm^?2 charge/discharge current density) along with high power density of 120 mV cm^?2 and specific capacity of 834.1 mA h g^?1. This work provides a new view to optimize the distribution of active sites and the electrode structure.     

Nitrogen,Fluorine, and Boron Ternary Doped Carbon Fibers as Cathode Electrocatalysts for Zinc–Air Batteries

Zinc–air batteries with high‐density energy are promising energy storage devices for the next generation of energy storage technologies. However, the battery performance is highly dependent on the efficiency of oxygen electrocatalyst in the air electrode. Herein, the N, F, and B ternary doped carbon fibers (TD‐CFs) are prepared and exhibited higher catalytic properties via the efficient 4e⁻ transfer mechanism for oxygen reduction in comparison with the single nitrogen doped CFs. More importantly, the primary and rechargeable Zn–air batteries using TD‐CFs as air–cathode catalysts are constructed. When compared to batteries with Pt/C + RuO₂ and Vulcan XC‐72 carbon black catalysts, the TD‐CFs catalyzed batteries exhibit remarkable battery reversibility and stability over long charging/discharging cycles.     

Atomically Transition Metals on Self‐Supported Porous Carbon Flake Arrays as Binder‐Free Air Cathode for Wearable Zinc−Air Batteries

Metal single‐atom materials with their high atom utilization efficiency and unique electronic structures usually show remarkable catalytic performances in many crucial chemical reactions. Herein, a facile and easily scalable “impregnation‐carbonization‐acidification” strategy for fabricating a class of single‐atom‐anchored (including cobalt and nickel single atoms) monolith as superior binder‐free electrocatalysts for developing high‐performance wearable Zn–air batteries is reported. The as‐prepared single atoms, supported by N‐doped carbon flake arrays grown on carbon nanofibers assembly (M SA@NCF/CNF), demonstrate the dual characteristics of excellent catalytic activity (reversible oxygen overpotential of 0.75 V) and high stability, owing to the greatly improved active sites' accessibility and optimized single‐sites/pore‐structures correlations. Furthermore, wearable Zn–air battery based on Co SA@NCF/CNF air electrode displays superior stability under deformation, satisfactory energy storage capacity, and good practicality to be utilized as an integrated battery system. Theoretical calculations reveal a mechanism for the promotion of the catalytic performances on single atomic sites by lowering the overall oxygen reduction/evolution reaction barriers comparing to metal cluster co‐existing configuration. These findings provide a facile strategy for constructing free‐standing single‐atom materials as well as the engineering of high‐performance binder‐free catalytic electrodes.     

Defect Engineering toward Atomic Co–Nx–C in Hierarchical Graphene for Rechargeable Flexible Solid Zn‐Air Batteries

Rechargeable flexible solid Zn‐air battery, with a high theoretical energy density of 1086 Wh kg^?1, is among the most attractive energy technologies for future flexible and wearable electronics; nevertheless, the practical application is greatly hindered by the sluggish oxygen reduction reaction/oxygen evolution reaction (ORR/OER) kinetics on the air electrode. Precious metal‐free functionalized carbon materials are widely demonstrated as the most promising candidates, while it still lacks effective synthetic methodology to controllably synthesize carbocatalysts with targeted active sites. This work demonstrates the direct utilization of the intrinsic structural defects in nanocarbon to generate atomically dispersed Co–N_x–C active sites via defect engineering. As‐fabricated Co/N/O tri‐doped graphene catalysts with highly active sites and hierarchical porous scaffolds exhibit superior ORR/OER bifunctional activities and impressive applications in rechargeable Zn‐air batteries. Specifically, when integrated into a rechargeable and flexible solid Zn‐air battery, a high open‐circuit voltage of 1.44 V, a stable discharge voltage of 1.19 V, and a high energy efficiency of 63% at 1.0 mA cm^?2 are achieved even under bending. The defect engineering strategy provides a new concept and effective methodology for the full utilization of nanocarbon materials with various structural features and further development of advanced energy materials.     

Electrically Rechargeable Zinc–Air Batteries: Progress,Challenges, and Perspectives

Zinc–air batteries have attracted much attention and received revived research efforts recently due to their high energy density, which makes them a promising candidate for emerging mobile and electronic applications. Besides their high energy density, they also demonstrate other desirable characteristics, such as abundant raw materials, environmental friendliness, safety, and low cost. Here, the reaction mechanism of electrically rechargeable zinc–air batteries is discussed, different battery configurations are compared, and an in depth discussion is offered of the major issues that affect individual cellular components, along with respective strategies to alleviate these issues to enhance battery performance. Additionally, a section dedicated to battery‐testing techniques and corresponding recommendations for best practices are included. Finally, a general perspective on the current limitations, recent application‐targeted developments, and recommended future research directions to prolong the lifespan of electrically rechargeable zinc–air batteries is provided.     

Self‐Catalyzed Growth of Co–N–C Nanobrushes for Efficient Rechargeable Zn–Air Batteries

Highly efficient and stable bifunctional electrocatalysts for oxygen reduction and evolution are essential for aqueous rechargeable Zn–air batteries, which require highly active sites as well as delicate structural design for increasing effective active sites and facilitating mass/electron transfer. Herein, a scalable and facile self‐catalyzed growth strategy is developed to integrate highly active Co–N–C sites with 3D brush‐like nanostructure, achieving Co–N–C nanobrushes with Co,N‐codoped carbon nanotube branches grown on Co,N‐codoped nanoparticle assembled nanowire backbones. Systematic investigations suggest that nanobrushes deliver significantly improved electrocatalytic activity compared with nanowire or nanotube counterparts and the longer nanotube branches give the better performance. Benefiting from the increase of accessible highly active sites and enhanced mass transfer and electron transportation, the present Co–N–C nanobrush exhibits superior electrocatalytic activity and durability when used as a bifunctional oxygen catalyst. It enables a rechargeable Zn–air battery with a high peak power density of 246 mW cm^?2 and excellent cycling stability. These results suggest that the reported synthetic strategy may open up possibilities for exploring efficient electrocatalysts for diverse applications.     

Atomic Fe–Nx Coupled Open‐Mesoporous Carbon Nanofibers for Efficient and Bioadaptable Oxygen Electrode in Mg–Air Batteries

The recently emerging metal–air batteries equipped with advanced oxygen electrodes have provided enormous opportunities to develop the next generation of wearable and bio‐adaptable power sources. Theoretically, neutral electrolyte‐based Mg–air batteries possess potential advantages in electronics and biomedical applications over the other metal–air counterparts, especially the alkaline‐based Zn–air batteries. However, the rational design of advanced oxygen electrode for Mg–air batteries with high discharge voltage and capacity under neutral conditions still remains a major challenge. Inspired by fibrous string structures of bufo‐spawn, it is reported here that the scalable synthesis of atomic Fe–N_x coupled open‐mesoporous N‐doped‐carbon nanofibers (OM‐NCNF‐FeN_x) as advanced oxygen electrode for Mg–air batteries. The fabricated OM‐NCNF‐FeN_x electrodes present manifold advantages, including open‐mesoporous and interconnected structures, 3D hierarchically porous networks, good bio‐adaptability, homogeneously coupled atomic Fe–N_x sites, and high oxygen electrocatalytic performances. Most importantly, the assembled Mg–air batteries with neutral electrolytes reveal high open‐circuit voltage, stable discharge voltage plateaus, high capacity, long operating life, and good flexibility. Overall, the discovery on fabricating atomic OM‐NCNF‐FeN_x electrode will not only create new pathways for achieving flexible, wearable, and bio‐adaptable power sources, but also take a step towards the scale‐up production of advanced nanofibrous carbon electrodes for a broad range of applications.     

Atomically Thin Mesoporous Co3O4 Layers Strongly Coupled with N‐rGO Nanosheets as High‐Performance Bifunctional Catalysts for 1D Knittable Zinc–Air Batteries

Under development for next‐generation wearable electronics are flexible, knittable, and wearable energy‐storage devices with high energy density that can be integrated into textiles. Herein, knittable fiber‐shaped zinc–air batteries with high volumetric energy density (36.1 mWh cm^?3) are fabricated via a facile and continuous method with low‐cost materials. Furthermore, a high‐yield method is developed to prepare the key component of the fiber‐shaped zinc–air battery, i.e., a bifunctional catalyst composed of atomically thin layer‐by‐layer mesoporous Co₃O₄/nitrogen‐doped reduced graphene oxide (N‐rGO) nanosheets. Benefiting from the high surface area, mesoporous structure, and strong synergetic effect between the Co₃O₄ and N‐rGO nanosheets, the bifunctional catalyst exhibits high activity and superior durability for oxygen reduction and evolution reactions. Compared to a fiber‐shaped zinc–air battery using state‐of‐the‐art Pt/C + RuO₂ catalysts, the battery based on these Co₃O₄/N‐rGO nanosheets demonstrates enhanced and stable electrochemical performance, even under severe deformation. Such batteries, for the first time, can be successfully knitted into clothes without short circuits under external forces and can power various electronic devices and even charge a cellphone.     

Defect Engineering of Chalcogen‐Tailored Oxygen Electrocatalysts for Rechargeable Quasi‐Solid‐State Zinc–Air Batteries

A critical bottleneck limiting the performance of rechargeable zinc–air batteries lies in the inefficient bifunctional electrocatalysts for the oxygen reduction and evolution reactions at the air electrodes. Hybridizing transition‐metal oxides with functional graphene materials has shown great advantages due to their catalytic synergism. However, both the mediocre catalytic activity of metal oxides and the restricted 2D mass/charge transfer of graphene render these hybrid catalysts inefficient. Here, an effective strategy combining anion substitution, defect engineering, and the dopant effect to address the above two critical issues is shown. This strategy is demonstrated on a hybrid catalyst consisting of sulfur‐deficient cobalt oxysulfide single crystals and nitrogen‐doped graphene nanomeshes (CoO_0.87S_0.13/GN). The defect chemistries of both oxygen‐vacancy‐rich, nonstoichiometric cobalt oxysulfides and edge‐nitrogen‐rich graphene nanomeshes lead to a remarkable improvement in electrocatalytic performance, where CoO_0.87S_0.13/GN exhibits strongly comparable catalytic activity to and much better stability than the best‐known benchmark noble‐metal catalysts. In application to quasi‐solid‐state zinc–air batteries, CoO_0.87S_0.13/GN as a freestanding catalyst assembly benefits from both structural integrity and enhanced charge transfer to achieve efficient and very stable cycling operation over 300 cycles with a low discharge–charge voltage gap of 0.77 V at 20 mA cm^?2 under ambient conditions.     

Boosting Bifunctional Oxygen Electrocatalysis with 3D Graphene Aerogel‐Supported Ni/MnO Particles

Electrocatalysts for oxygen‐reduction and oxygen‐evolution reactions (ORR and OER) are crucial for metal–air batteries, where more costly Pt‐ and Ir/Ru‐based materials are the benchmark catalysts for ORR and OER, respectively. Herein, for the first time Ni is combined with MnO species, and a 3D porous graphene aerogel‐supported Ni/MnO (Ni–MnO/rGO aerogel) bifunctional catalyst is prepared via a facile and scalable hydrogel route. The synthetic strategy depends on the formation of a graphene oxide (GO) crosslinked poly(vinyl alcohol) hydrogel that allows for the efficient capture of highly active Ni/MnO particles after pyrolysis. Remarkably, the resulting Ni–MnO/rGO aerogels exhibit superior bifunctional catalytic performance for both ORR and OER in an alkaline electrolyte, which can compete with the previously reported bifunctional electrocatalysts. The MnO mainly contributes to the high activity for the ORR, while metallic Ni is responsible for the excellent OER activity. Moreover, such bifunctional catalyst can endow the homemade Zn–air battery with better power density, specific capacity, and cycling stability than mixed Pt/C + RuO₂ catalysts, demonstrating its potential feasibility in practical application of rechargeable metal–air batteries.