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.     

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.     

Single Fe Atom on Hierarchically Porous S,N‐Codoped Nanocarbon Derived from Porphyra Enable Boosted Oxygen Catalysis for Rechargeable Zn‐Air Batteries

Iron–nitrogen–carbon materials (Fe–N–C) are known for their excellent oxygen reduction reaction (ORR) performance. Unfortunately, they generally show a laggard oxygen evolution reaction (OER) activity, which results in a lethargic charging performance in rechargeable Zn–air batteries. Here porous S‐doped Fe–N–C nanosheets are innovatively synthesized utilizing a scalable FeCl₃‐encapsulated‐porphyra precursor pyrolysis strategy. The obtained electrocatalyst exhibits ultrahigh ORR activity (E_1/2 = 0.84 V vs reversible hydrogen electrode) and impressive OER performance (E_{j = 10} = 1.64 V). The potential gap (ΔE = E_{j = 10} ? E_1/2) is 0.80 V, outperforming that of most highly active bifunctional electrocatalysts reported to date. Furthermore, the key role of S involved in the atomically dispersed Fe–Nx species on the enhanced ORR and OER activities is expounded for the first time by ultrasound‐assisted extraction of the exclusive S source (taurine) from porphyra. Moreover, the assembled rechargeable Zn–air battery comprising this bifunctional electrocatalyst exhibits higher power density (225.1 mW cm^?2) and lower charging–discharging overpotential (1.00 V, 100 mA cm^?2 compared to Pt/C + RuO₂ catalyst). The design strategy can expand the utilization of earth‐abundant biomaterial‐derived catalysts, and the mechanism investigations of S doping on the structure–activity relationship can inspire the progress of other functional electrocatalysts.     

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 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.     

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.     

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.     

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.     

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.     

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.     

Interfacing Manganese Oxide and Cobalt in Porous Graphitic Carbon Polyhedrons Boosts Oxygen Electrocatalysis for Zn–Air Batteries

Rational design and synthesis of highly active and robust bifunctional non‐noble electrocatalysts for both oxygen evolution reaction (OER) and oxygen reduction reaction (ORR) are urgently required for efficient rechargeable metal–air batteries. Herein, abundant MnO/Co heterointerfaces are engineered in porous graphitic carbon (MnO/Co/PGC) polyhedrons via a facile hydrothermal‐calcination route with a bimetal–organic framework as the precursor. The in situ generated Co nanocrystals not only create well‐defined heterointerfaces with high conductivity to overcome the poor OER activity but also promote the formation of robust graphitic carbon. Owing to the desired composition and formation of the heterostructures, the resulting MnO/Co/PGC exhibits superior activity and stability toward both OER and ORR, which makes it an efficient air cathode for the rechargeable Zn–air battery. Importantly, the homemade Zn–air battery is able to deliver excellent performance including a peak power density of 172 mW cm^?2 and a specific capacity of 872 mAh g^?1, as well as excellent cycling stability (350 cycles), outperforming commercial mixed Pt/C||RuO₂ catalysts. This work highlights the synergy from heterointerfaces in oxygen electrocatalysis, thus providing a promising approach for advanced metal–air cathode materials.     

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.     

MOF‐Based Metal‐Doping‐Induced Synthesis of Hierarchical Porous CuN/C Oxygen Reduction Electrocatalysts for Zn–Air Batteries

A transition‐metal–nitrogen/carbon (TM–N/C, TM = Fe, Co, Ni, etc.) system is a popular, nonprecious‐metal oxygen reduction reaction (ORR) electrocatalyst for fuel cell and metal–air battery applications. However, there remains a lack of comprehensive understanding about the ORR electrocatalytic mechanism on these catalysts, especially the roles of different forms of metal species on electrocatalytic performance. Here, a novel Cu?N/C ORR electrocatalyst with a hybrid Cu coordination site is successfully fabricated with a simple but efficient metal–organic‐framework‐based, metal‐doping‐induced synthesis strategy. By directly pyrolyzing Cu‐doped zeolitic‐imidazolate‐framework‐8 polyhedrons, the obtained Cu?N/C catalyst can achieve a high specific surface area of 1182 m² g^?1 with a refined hierarchical porous structure and a high surface N content of 11.05 at%. Moreover, regulating the Cu loading can efficiently tune the states of Cu(II) and Cu⁰, resulting in the successful construction of a highly active hybrid coordination site of N?Cu(II)?Cu⁰ in derived Cu?N/C catalysts. As a result, the optimized 25% Cu?N/C catalyst possesses a high ORR activity and stability in 0.1 m KOH solution, as well as excellent performance and stability in a Zn–air battery.     

An Oxygen‐Vacancy‐Rich Semiconductor‐Supported Bifunctional Catalyst for Efficient and Stable Zinc–Air Batteries

The highly oxidative operating conditions of rechargeable zinc–air batteries causes significant carbon‐support corrosion of bifunctional oxygen electrocatalysts. Here, a new strategy for the catalyst support design focusing on oxygen vacancy (OV)‐rich, low‐bandgap semiconductor is proposed. The OVs promote the electrical conductivity of the oxide support, and at the same time offer a strong metal–support interaction (SMSI), which enables the catalysts to have small metal size, high catalytic activity, and high stability. The strategy is demonstrated by successfully synthesizing ultrafine Co‐metal‐decorated 3D ordered macroporous titanium oxynitride (3DOM‐Co@TiO_xN_y). The 3DOM‐Co@TiO_xN_y catalyst exhibits comparable activities for oxygen reduction and evolution reactions, but much higher cycling stability than noble metals in alkaline conditions. The zinc–air battery using this catalyst delivers an excellent stability with less than 1% energy efficiency loss over 900 charge–discharge cycles at 20 mA cm^?2. The high stability is attributed to the strong SMSI between Co and 3DOM‐TiO_xN_y which is verified by density functional theory calculations. This work sheds light on using OV‐rich semiconductors as a promising support to design efficient and durable nonprecious electrocatalysts.