A zinc-ion battery based machinable structure energy storage material with a high specific energy and good environmental adaptability

Developing structural energy storage materials (SESM) to address the range anxiety of aerial and aerospace vehicles is crucial. These materials must have a homogeneous, open structure, high specific energy, environmental adaptability, and ease of machining. Traditional capacitor-based or lithium-ion battery embedded structures fail to meet these demands simultaneously. In this study, the high energy density and environmental adaptability of zinc-ion batteries are integrated with the superior mechanical performance and ionic conductivity of a bi-continuous phase electrolyte, resulting in the creation of an open-structured composite. Through microphase separation simulation and optimization of mass transfer channels, the best formulation (MEP30) is achieved, featuring high mechanical strength (108   MPa Young’s modulus) and ionic conductivity (0.56 mS cm –1 ). An NH 4 V 4 O 10 @Carbon fiber (CF)||electrolyte||Zn@CF structure is developed, capable of multi-layer expansion. This design improves interlayer stress distribution and reduces weight, enhancing mechanical properties (408   MPa Young’s modulus) and system energy density (20 wh kg –1 ). The material can be machined into various shapes and remains functional after destructive processes like perforation and cutting. Under extreme conditions (low temperature, water immersion, low pressure) simulating aerial and aerospace environments, the multilayer material retains its energy density, offering a promising approach for SESM development.