High-performance flexible zinc-air batteries with layered Zn/C3N4-carbon nanotube/polyvinyl alcohol-epoxy resin composite: In-situ crosslinking and electrode-electrolyte integration

In this study, we have successfully developed a layered, porous anode-electrolyte integrated flexible solid-state zinc-air battery (ZAB) using a Zn/C3N4-CNT/PVA-ER composite. The solid electrolyte is synthesized by incorporating epoxy resin (ER) into PVA, and its morphology, microstructure, mechanical properties, and water absorption/retention capabilities are thoroughly characterized. The resulting PVA-ER solid electrolyte exhibits a porous, oriented structure with excellent mechanical properties, including a tensile strain of 170 % and a stress of 0.37 MPa. It also shows remarkable resilience, withstanding various deformations such as compression, bending, and twisting, along with a high-water absorption capacity of 223.5 g g−1 and a high OH− conductivity of 58.5 mS cm−1. The C3N4-carbon nanotube (CNT) composite membrane is successfully prepared and applied as the anode, forming efficient ion diffusion channels through cross-linking with PVA-ER chains. The flexible ZABs based on Zn/C3N4-CNT/PVA-ER demonstrated outstanding performance, including a long operational life of over 74 h, a high-power density of 112.6 mW cm−2, and a specific capacity of 770.8 mAh g−1. This work introduces innovative in-situ crosslinking and electrode-electrolyte integration strategies, advancing the development of high-performance flexible ZABs and paving the way for their application in wearable electronics and biologically inspired systems. [Display omitted] •Introduced in-situ crosslinking for advanced wearable zinc-air batteries.•PVA-epoxy resin (ER) electrolyte offers high tensile strength and ion conductivity.•C3N4-carbon nanotube (CNT) anode provides efficient ion diffusion and robust flexibility.•Developed flexible zinc-air batteries using Zn/C3N4-CNT/PVA-ER composite.•Achieved high-power density of 112.6 mW cm−2 and specific capacity of 770.8 mAh g−1.