A new silicon oxycarbide based gas diffusion layer for zinc-air batteries.

Rational material designs play a vital role in the gas diffusion layer (GDL) by increasing the oxygen diffusion rate and, consequently, facilitating a longer cycle life for metal-air batteries. In this work, a new porous conductive ceramic membrane has been developed as a cathodic GDL for zinc-air battery (ZAB). The bilayered structure with a thickness of 390 μm and an open porosity of 55% is derived from a preceramic precursor with the help of the freeze tape casting technique. The hydrophobic behaviour of the GDL is proved by the water contact angle of 137.5° after the coating of polytetrafluoroethylene (PTFE). The electrical conductivity of 5.59 * 10 S/cm is reached using graphite and MWCNT as filler materials. Tested in a ZAB system, the as-prepared GDL coated with commercial Pt-Ru/C catalyst shows an excellent cycle life over 200 cycles and complete discharge over 48 h by consuming oxygen from the atmosphere, which is comparable to commercial electrodes. The as-prepared electrode exhibits excellent ZAB performance due to the symmetric sponge-like structure, which facilitates the oxygen exchange rate and offers a short path for the oxygen ion/-electron kinetics. Thus, this work highlights the importance of a simple manufacturing process that significantly influences advanced ZAB enhancement.