Molecular Armor Encapsulation of Practical Layered Cathode Empowers Energetic Ah-Level Zn-MnO₂ Pouch and Prismatic...

The development of energetic zinc-manganese oxide (Zn-MnO₂) pouch and prismatic cells for energy storage applications is highly required, yet remains challenging especially in their Ah-level. To bridge the gap between laboratory-scale studies and commercial applications, this work encapsulates the practical layered MnO₂ cathode by a molecular armoring technique and then investigates its application potential in Ah-level Zn-MnO₂ pouch and prismatic cells. The molecular armor encapsulation not only enhances cathode conductivity but also remodels interfacial charge distribution, boosting redox kinetics and ion-storage reversibility. Simultaneously, it acts as a physical barrier that mitigates manganese dissolution while accommodating lattice strain from ion insertion/extraction to prevent cathode structural damage. As a result, based on the optimized MnO₂ cathode with molecular armor, the manufactured Ah-level pouch cell demonstrates a stable 120 cycles and a practical energy density of ∼58 Wh kg^-1. Systematic module integration tests and safety assessments in prismatic cells further validate the system's scalability and operational reliability, demonstrating its potential as a viable solution for future energy storage applications.