Progress in fiber-shaped zinc batteries: From structure, manufacturing, optimization to application

Abstract

Fiber-shaped batteries, distinguished by their unique one-dimensional architecture, offer ultra-high flexibility, remarkable stretchability, and excellent knittability, rendering them highly appealing as energy storage solutions for smart wearable fabrics. Among various fiber-shaped battery systems, aqueous zinc batteries stand out as one of the most promising candidates owing to their high specific capacity, inherent safety, and cost-effectiveness. However, the practical applicability of fiber-shaped zinc batteries (FZBs) is significantly hindered by challenges in scalable production, long-term operational stability, and seamless integration. Despite the growing interest in FZBs, a comprehensive and systematic review that critically examines the essential components, assembly configurations, manufacturing techniques, and performance-enhancing strategies is still lacking. This review aims to fill this gap by first summarizing the fundamental components of FZBs, including cathodes, anodes, electrolytes, current collectors, and encapsulation materials. It then compares the impact of various assembly configurations, including parallel, winding, coaxial, and weaving structures, on battery performance. Furthermore, it provides an in-depth analysis of diverse manufacturing techniques for fiber electrodes, including dip-coating, hydrothermal synthesis, and electrodeposition, as well as the assembly procedures ranging from manual to equipment-assisted and one-step assembly methods. In addition, this review highlights strategies for improving both electrochemical and wearable performance through material modification and structural design. It also underscores the multifunctional applications of FZBs, such as thermosensitive, fluorescent, and sweat-driven variants, along with their potential in physiological sensing and environmental monitoring. Finally, it identifies the existing barriers to FZBs commercialization, including limited energy density, complex integration processes, and unclear internal mechanisms. Based on these insights, it proposes future research directions and development initiatives to advance the field of FZBs, thereby promoting their transition from laboratory prototypes to commercial products.

Keywords

application / fiber-shaped zinc batteries / manufacturing / optimization / structure

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