Industrial scale production of fibre batteries by a solution-extrusion method

Fibre batteries are of significant interest because they can be woven into flexible textiles to form compact, wearable and light-weight power solutions^1,2. However, current methods adapted from planar batteries through layer-by-layer coating processes can only make fibre batteries with low production rates, which fail to meet the requirements for real applications². Here, we present a new and general solution-extrusion method that can produce continuous fibre batteries in a single step at industrial scale. Our three-channel industrial spinneret simultaneously extrudes and combines electrodes and electrolyte of fibre battery at high production rates. The laminar flow between functional components guarantees their seamless interfaces during extrusion. Our method yields 1,500 km of continuous fibre batteries for every spinneret unit, that is, more than three orders of magnitude longer fibres than previously reported^1,2. Finally, we show a proof-of-principle for roughly 10 m² of woven textile for smart tent applications, with a battery with energy density of 550 mWh m^-2.