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 Advances toward the Rational Design of Efficient Bifunctional Air Electrodes for Rechargeable Zn–Air Batteries

Large‐scale application of renewable energy and rapid development of electric vehicles have brought unprecedented demand for advanced energy‐storage/conversion technologies and equipment. Rechargeable zinc (Zn)–air batteries represent one of the most promising candidates because of their high energy density, safety, environmental friendliness, and low cost. The air electrode plays a key role in managing the many complex physical and chemical processes occurring on it to achieve high performance of Zn–air batteries. Herein, recent advances of air electrodes from bifunctional catalysts to architectures are summarized, and their advantages and disadvantages are discussed to underline the importance of progress in the evolution of bifunctional air electrodes. Finally, some challenges and the direction of future research are provided for the optimized design of bifunctional air electrodes to achieve high performance of rechargeable 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.     

Amorphous Bimetallic Oxide–Graphene Hybrids as Bifunctional Oxygen Electrocatalysts for Rechargeable Zn–Air Batteries

Metal oxides of earth‐abundant elements are promising electrocatalysts to overcome the sluggish oxygen evolution and oxygen reduction reaction (OER/ORR) in many electrochemical energy‐conversion devices. However, it is difficult to control their catalytic activity precisely. Here, a general three‐stage synthesis strategy is described to produce a family of hybrid materials comprising amorphous bimetallic oxide nanoparticles anchored on N‐doped reduced graphene oxide with simultaneous control of nanoparticle elemental composition, size, and crystallinity. Amorphous Fe_0.5Co_0.5O_x is obtained from Prussian blue analog nanocrystals, showing excellent OER activity with a Tafel slope of 30.1 mV dec^?1 and an overpotential of 257 mV for 10 mA cm^?2 and superior ORR activity with a large limiting current density of ?5.25 mA cm^?2 at 0.6 V. A fabricated Zn–air battery delivers a specific capacity of 756 mA h g_Zn^?1 (corresponding to an energy density of 904 W h kg_Zn^?1), a peak power density of 86 mW cm^?2 and can be cycled over 120 h at 10 mA cm^?2. Other two amorphous bimetallic, Ni_0.4Fe_0.6O_x and Ni_0.33Co_0.67O_x , are also produced to demonstrate the general applicability of this method for synthesizing binary metal oxides with controllable structures as electrocatalysts for energy conversion.     

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.     

Co Nanoislands Rooted on Co–N–C Nanosheets as Efficient Oxygen Electrocatalyst for Zn–Air Batteries

Developing non‐precious‐metal bifunctional oxygen reduction and evolution reaction (ORR/OER) catalysts is a major task for promoting the reaction efficiency of Zn–air batteries. Co‐based catalysts have been regarded as promising ORR and OER catalysts owing to the multivalence characteristic of cobalt element. Herein, the synthesis of Co nanoislands rooted on Co–N–C nanosheets supported by carbon felts (Co/Co–N–C) is reported. Co nanosheets rooted on the carbon felt derived from electrodeposition are applied as the self‐template and cobalt source. The synergistic effect of metal Co islands with OER activity and Co–N–C nanosheets with superior ORR performance leads to good bifuctional catalytic performances. Wavelet transform extended X‐ray absorption fine spectroscopy and X‐ray photoelectron spectroscopy certify the formation of Co (mainly Co⁰) and the Co–N–C (mainly Co²⁺ and Co³⁺) structure. As the air‐cathode, the assembled aqueous Zn–air battery exhibits a small charge–discharge voltage gap (0.82 V@10 mA cm^?2) and high power density of 132 mW cm^?2, outperforming the commercial Pt/C catalyst. Additionally, the cable flexible rechargeable Zn–air battery exhibits excellent bendable and durability. Density functional theory calculation is combined with operando X‐ray absorption spectroscopy to further elucidate the active sites of oxygen reactions at the Co/Co–N–C cathode in Zn–air battery.     

Simultaneously Integrating Single Atomic Cobalt Sites and Co9S8 Nanoparticles into Hollow Carbon Nanotubes as Trifunctional Electrocatalysts for Zn–Air Batteries to Drive Water Splitting

The development of rechargeable metal–air batteries and water electrolyzers are highly constrained by electrocatalysts for the oxygen reduction reaction (ORR), oxygen evolution reaction (OER), and hydrogen evolution reaction (HER). However, the construction of efficient trifunctional electrocatalysts for ORR/OER/HER are highly desirable yet challenging. Herein, hollow carbon nanotubes integrated single cobalt atoms with Co₉S₈ nanoparticles (CoSA + Co₉S₈/HCNT) are fabricated by a straightforward in situ self‐sacrificing strategy. The structure of the CoSA + Co₉S₈/HCNT are verified by X‐ray absorption spectroscopy and aberration‐corrected scanning transmission electron microscopy. Theoretical calculations and experimental results embrace the synergistic effects between Co₉S₈ nanoparticles and single cobalt atoms through optimizing the electronic configuration of the CoN₄ active sites to lower the reaction barrier and facilitating the ORR, OER, and HER simultaneously. Consequently, rechargeable liquid and all‐solid‐state flexible Zn–air batteries based on CoSA + Co₉S₈/HCNT exhibit remarkable stability and excellent power density of 177.33 and 51.85 mW cm^?2, respectively, better than Pt/C + RuO₂ counterparts. Moreover, the as‐fabricated Zn–air batteries can drive an overall water splitting device assembled with CoSA + Co₉S₈/HCNT and achieve a current density of 10 mA cm^?2 at a low voltage of 1.59 V, also superior to Pt/C + RuO₂. Therefore, this work presents a promising approach to an efficient trifunctional electrocatalyst toward practical applications.     

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.     

Defective N/S‐Codoped 3D Cheese‐Like Porous Carbon Nanomaterial toward Efficient Oxygen Reduction and Zn–Air Batteries

Developing a facile and cost‐efficient method to synthesize carbon‐based nanomaterials possessing excellent structural and functional properties has become one of the most attractive topics in energy conversion and storage fields. In this study, density functional theory calculation results reveal the origin of high oxygen reduction reaction (ORR) activity predominantly derived from the synergistic effect of intrinsic defects and heteroatom dopants (e.g., N, S) that modulate the bandgap and charge density distribution of carbon matrix. Under the guidance of the first‐principle prediction, by using ultralight biomass waste as precursor of C, N, and S elements, a defect‐rich and N/S dual‐doped cheese‐like porous carbon nanomaterial is successfully designed and constructed. Herein, the intrinsic defects are artfully generated in terms of alkaline and ammonia activation. The electrochemical measurements display that such a material owns a comparable ORR activity (E_1/2 = 0.835 V) to the commercial Pt/C catalyst, along with splendid durability and methanol tolerance in alkali media. Furthermore, as cathode catalyst, it displays a high Zn–air battery performance. The excellent ORR activity of the catalyst can be attributed to its unique 3D porous architecture, abundant intrinsic defects, and high‐content active heteroatom dopants in the carbon matrix.     

Hollow Co3O4 Nanosphere Embedded in Carbon Arrays for Stable and Flexible Solid‐State Zinc–Air Batteries

Highly active and durable air cathodes to catalyze both the oxygen evolution reaction (OER) and oxygen reduction reaction (ORR) are urgently required for rechargeable metal–air batteries. In this work, an efficient bifunctional oxygen catalyst comprising hollow Co₃O₄ nanospheres embedded in nitrogen‐doped carbon nanowall arrays on flexible carbon cloth (NC‐Co₃O₄/CC) is reported. The hierarchical structure is facilely derived from a metal–organic framework precursor. A carbon onion coating constrains the Kirkendall effect to promote the conversion of the Co nanoparticles into irregular hollow oxide nanospheres with a fine scale nanograin structure, which enables promising catalytic properties toward both OER and ORR. The integrated NC‐Co₃O₄/CC can be used as an additive‐free air cathode for flexible all‐solid‐state zinc–air batteries, which present high open circuit potential (1.44 V), high capacity (387.2 mAh g^?1, based on the total mass of Zn and catalysts), excellent cycling stability and mechanical flexibility, significantly outperforming Pt‐ and Ir‐based zinc–air batteries.     

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.     

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.     

Oxygen Vacancies Dominated NiS2/CoS2 Interface Porous Nanowires for Portable Zn–Air Batteries Driven Water Splitting Devices

The development of highly active and stable oxygen evolution reaction (OER) electrocatalysts is crucial for improving the efficiency of water splitting and metal–air battery devices. Herein, an efficient strategy is demonstrated for making the oxygen vacancies dominated cobalt–nickel sulfide interface porous nanowires (NiS₂/CoS₂–O NWs) for boosting OER catalysis through in situ electrochemical reaction of NiS₂/CoS₂ interface NWs. Because of the abundant oxygen vacancies and interface porous nanowires structure, they can catalyze the OER efficiently with a low overpotential of 235 mV at j = 10 mA cm^?2 and remarkable long‐term stability in 1.0 m KOH. The home‐made rechargeable portable Zn–air batteries by using NiS₂/CoS₂–O NWs as the air–cathode display a very high open‐circuit voltage of 1.49 V, which can maintain for more than 30 h. Most importantly, a highly efficient self‐driven water splitting device is designed with NiS₂/CoS₂–O NWs as both anode and cathode, powered by two‐series‐connected NiS₂/CoS₂–O NWs‐based portable Zn–air batteries. The present work opens a new way for designing oxygen vacancies dominated interface nanowires as highly efficient multifunctional electrocatalysts for electrochemical reactions and renewable energy devices.     

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.     

Co Nanoparticles Confined in 3D Nitrogen‐Doped Porous Carbon Foams as Bifunctional Electrocatalysts for Long‐Life Rechargeable Zn–Air Batteries

Proper design and simple preparation of nonnoble bifunctional electrocatalysts with high cost performance and strong durability for the oxygen reduction reaction (ORR) and the oxygen evolution reaction (OER) is highly demanded but still full of enormous challenges. In this work, a spontaneous gas‐foaming strategy is presented to synthesize cobalt nanoparticles confined in 3D nitrogen‐doped porous carbon foams (CoNCF) by simply carbonizing the mixture of citric acid, NH₄Cl, and Co(NO₃)₂·6H₂O. Thanks to its particular 3D porous foam architecture, ultrahigh specific surface area (1641 m² g^?1), and homogeneous distribution of active sites (C–N, Co–N_x, and Co–O moieties), the optimized CoNCF‐1000‐80 (carbonized at 1000 °C, containing 80 mg Co(NO₃)₂·6H₂O in precursors) catalyst exhibits a remarkable bifunctional activity and long‐term durability toward both ORR and OER. Its bifunctional activity parameter (ΔE) is as low as 0.84 V, which is much smaller than that of noble metal catalyst and comparable to state‐of‐the‐art bifunctional catalysts. When worked as an air electrode catalyst in rechargeable Zn–air batteries, a high energy density (797 Wh kg^?1), a low charge/discharge voltage gap (0.75 V), and a long‐term cycle stability (over 166 h) are achieved at 10 mA cm^?2.     

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.     

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.