20.500.12556/DiRROS-25180 Architecture-driven design of ZnO@C anodes in next-generation zinc-based batteries toward practical energy storage systems Zinc-based batteries are promising for sustainable energy storage due to their low cost and environmental friendliness. However, challenges such as passivation, low cycle life, and limited zinc utilization hinder practical commercialization. In this study, we address these challenges using ZnO@C nanoparticles (NPs) as anode active material, optimizing slurry formulation and electrode architectures. PTFE and CMC were employed as complementary binders to enhance mechanical integrity, wettability, and zinc utilization, while reducing the reliance on fluorinated binders. Two electrode fabrication methods — blade coating and hot pressing — were evaluated to assess the effects of active layer thickness on performance and durability. Full-cell Zn/Ni tests were run under harsh testing condition: closed cell, low amount of electrolyte and no additive or ZnO saturation. We found that thinner (ca. 100 μm), blade-coated ZnO@C anodes outperformed thicker (ca. 400 μm) hot-pressed electrodes in both cycle life and specific capacity. Blade-coated electrodes maintained a discharge-specific capacity exceeding 400 mAh g−1 for over 200 cycles and achieved a maximum of 524 mAh g−1, approximately 80 % of ZnO theoretical capacity. Post-mortem X-ray computed microtomography analyses revealed that the crucial electrode architecture parameters are ZnO particle accessibility and even utilization in the electrode bulk. These resulted to be optimal in blade-coated electrodes, while heterogeneities and untransformed ZnO volumes were found in the hot-pressed ones. Additionally, in view of concrete device implementation, the often overlooked role of cell casing materials was explicitly addressed. Specifically, the galvanic coupling among electrode material, current collector and cell casing was positively measured and rationalized. By integrating innovations in slurry formulations, electrode design, and practical testing setups, this work provides guidelines to transfer nanostructured Zn anodes to the practical device environment. Zn anode zinc-alkaline batteries nanostructured electrodes electrode architecture ZnO nanoparticle X-ray microtomography Zn anoda cink-alkalne baterije nanostrukturirane elektrode arhitektura elektrod ZnO nanodelci rentgenska računalniška mikrotomografija true false true Elsevier Angleški jezik Slovenski jezik © 2025 The Authors Neznano 2026-01-13 11:40:27 2026-01-13 11:44:42 2026-01-14 03:53:38 0000-00-00 00:00:00 2026 0 0 str. 1-10 [article no.] 119653 Vol. 1001 Jan. 2026 0000-00-00 Zaloznikova Objavljeno NiDoloceno 0000-00-00 0000-00-00 2025-11-15 544.5/.6 1873-2569 10.1016/j.jelechem.2025.119653 261134595 https://doi.org/10.1016/j.jelechem.2025.119653 0 47ed2858-f06c-11f0-94a7-001a4af901a5 https://dirros.openscience.si/Dokument.php?lang=slv&id=37955 RAZ_Emanuele_Elisa_2026.pdf RAZ_Emanuele_Elisa_2026.pdf 1 F13CDDD65535FF8B602CD5E1973FD6F8 e2922bc477d0f2237644365b7a97101a11eb60482e852ce740793cf59a40eb36 d2ad9237-f06c-11f0-94a7-001a4af901a5 https://dirros.openscience.si/Dokument.php?lang=slv&id=37956 RAZ_Emanuele_Elisa_2026.docx RAZ_Emanuele_Elisa_2026.docx 1 77A8DB3A4BAB89798F3D01060602C449 9de51e2d5498fda6474e2f500795ef2684dd7eacb2d57d5185851dc863202e24 db941ad5-f06c-11f0-94a7-001a4af901a5 https://dirros.openscience.si/Dokument.php?lang=slv&id=37957 Zavod za gradbeništvo Slovenije 0 0 0