Precise regulation of zinc-anode interface stresses by digital-light-processed gel polymer electrolytes for ultralong-life zinc batteries
Yangfan Zhou, Wei Yuan, Xuyang Wu, Qing Liu, Xiaoqing Zhang, Tengjia Gao, Pei Wang, Chunzhong Li, Guanhua Zhang, Yubin Zeng, Yong Tang
Abstract
Abstract The development of robust anode-electrolyte interfaces (AEI) with enhanced compatibility and mechanical strength is critical for regulating zinc-ion nucleation kinetics, suppressing dendrite formation, and advancing zinc-ion battery commercialization. To address persistent interface degradation during battery cycling, we propose a novel manufacturing strategy utilizing digital-light-processing (DLP) 3D printing. This approach enables programmable regulation of gel-polymer electrolyte (GPE) structures through layer-by-layer photopolymerization, achieving precision regulation of macro-microstructures and interfacial stresses. The DLP-manufactured GPEs feature cross-scale structures combining dense porous networks with smooth surface topography, providing abundant electrochemical active sites and stable interfacial contact. Multiphase-field simulations integrated with in-situ/ex-situ characterizations reveal stress-enhanced zinc deposition mechanisms, where optimized interfacial stress eliminates AEI contact instability, ensuring rapid mass transfer between electrode and electrolyte. Under regulated interface stress, the symmetrical cell demonstrates stability exceeding 2 000 hours, and the full cell retains 91.72% capacity after 8 000 ultralong cycles, with reliable operation under extreme temperature conditions (−10 ℃/60 ℃). The precise regulation of interfacial stresses establishes stable AEI configurations, demonstrating a transformative approach to durable zinc-ion battery design.