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Updated: Sep 23, 2025

Zinc-Sponge Battery Electrodes that Suppress Dendrites
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Zinc-Sponge Battery Electrodes that Suppress Dendrites.

Brandon J Hopkins1, Megan B Sassin2, Joseph F Parker2

  • 1Naval Research Laboratory, National Research Postdoctoral Associate, U.S. Naval Research Laboratory, Washington, DC, 20375, United States.

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Researchers developed novel zinc-sponge electrodes for rechargeable zinc batteries. These electrodes effectively suppress dendrite formation and shape change, enhancing battery performance and longevity.

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Area of Science:

  • Materials Science
  • Electrochemistry
  • Energy Storage

Background:

  • Rechargeable zinc batteries offer a promising alternative for energy storage due to zinc's abundance and high theoretical capacity.
  • Dendrite formation and shape change in zinc electrodes limit battery cycle life and pose safety risks.
  • Developing stable and efficient zinc electrodes is crucial for advancing battery technology.

Purpose of the Study:

  • To introduce two novel methods for fabricating zinc-sponge electrodes.
  • To investigate the suppression of dendrite formation and shape change in rechargeable zinc batteries.
  • To enable tunable electrode architecture for optimized battery performance.

Main Methods:

  • Fabrication of zinc-sponge electrodes via a paste of zinc particles, organic porogen, and a viscosity-enhancing agent.
  • Controlled heating of the paste under inert gas (annealing and decomposition) followed by air (fusion and burnout).
  • Tuning of electrode properties by adjusting zinc-to-porogen ratio, heating times, and particle characteristics.

Main Results:

  • Successful creation of open-cell zinc metal foam/sponge structures.
  • Demonstrated ability to tune mechanical and electrochemical properties by controlling fabrication parameters.
  • Achieved stable cycling up to 40% depth of discharge at relevant rates without dendrite formation.

Conclusions:

  • The developed methods provide a versatile approach to creating zinc-sponge electrodes with controlled architecture.
  • Zinc-sponge electrodes show significant potential for suppressing dendrites and improving the cycle life of rechargeable zinc batteries.
  • These electrodes are suitable for demanding applications such as grid storage, electric vehicles, and aviation.