Ultrathin Al–air batteries by reducing the thickness of solid electrolyte using aerosol jet printing

Flexible Al–air batteries have great potential in the field of wearable electronic devices. However, how to reduce the thickness of the battery and improve their applicability in wearable applications is still an unresolved thorny problem. Therefore, this article focuses on the strategies to minimize the thickness of the solid electrolyte for flexible Al–air batteries. In this paper, an innovative aerosol jet printing method is used to prepare the ultrathin neutral electrolyte with a thickness of 18.3–74.5 μm. This study discusses the influence of the thickness and ion concentration on the conductance of the electrolyte in detail. The ultrathin electrolyte has been applied to the flexible Al–air battery, and the battery performance has been explored. The cell pack composed of single cells is light and thin, and can successfully drive small electrical equipment. This study provided new ideas for the preparation of ultrathin electrolyte for flexible energy products.