Mass Produced Flexible Aramid Electrodes Via Delamination of Layered Aerogels for Cut-to-Fit Wearable Zinc–Air Batteries Encased in Aramid Protection

This study introduces a cut-to-fit methodology for customizing bulk aramid aerogels into form factors suitable for wearable energy storage. Owing to strong intercomponent bonds within aramid-based building blocks, it is possible to delaminate layered bulk aerogel into flexible and thinner sheets, enabling efficient mass production. This process allows for precise customization of aerogel dimensions, shape, and elasticity, ensuring high resilience to deformation along with excellent thermal and impact resistance. Incorporation of conductive carbon nanotubes on the surface significantly enhances electrical conductivity and multi-catalytic activity while retaining the inherent advantages of aramids. These advancements facilitate the use of flexible and conductive electrodes as air cathodes in solid-state zinc–air batteries (ZABs), which demonstrate superior cyclic performance and lifecycles exceeding 160 h. Furthermore, aramid-based packaging provides superior protection for pouch-type ZABs, ensuring a consistent power supply even in severe conditions. These batteries are capable of withstanding structural deformations and absorbing physical and thermal shocks, such as impacts and exposure to fire. Moreover, the innovative reassembly of custom-cut single-pouch cells into battery modules allows for enhanced power output, tailored to wearable applications. This highlights the potential of the technology for a wide array of wearable devices requiring dependable energy sources in demanding environments.