Enhanced electrical conductivity and stretchability of ionic-liquid PEDOT:PSS air-cathodes for aluminium-air batteries with long lifetime and high specific energy

A hydrogel film, poly-3,4-ethylenedioxythiophene (PEDOT):polystyrenesulfonate (PSS), containing an ionic liquid, is used as an air–cathode for a metal-air battery and its performance is investigated. This work presents the development of the air–cathode and the characterization of its physical, chemical and mechanical properties. Moreover, in view of wearable batteries, these air-cathodes are implemented within a flexible aluminium-air battery. It contains an aluminium anode, an electrolyte made of cellulose paper imbibed with an aqueous sodium chloride solution and the PEDOT:PSS air–cathode. Characterisation tests showed that the ionic liquid did not change the air–cathode chemically, while the electric conductivity increased considerably. The anode has an acceptable purity and was found to be resistant against self-corrosion. Discharge tests showed operating voltages up to 0.65 V, whereas two batteries in series could deliver up to 1.3 V at a current density of 0.9 mA cm(−2) for almost a day, sufficient for monitoring and medical devices. Several discharge tests with current densities from 0.25 up to 2.5 mA cm(−2) have presented operating lifetimes from 10 h up until over a day. At a current density of 2.8 mA cm(−2), the operating voltage and lifetime dropped considerably, explained by approaching the limiting current density of about 3 mA cm(−2), as evidenced by linear sweep voltammetry. The batteries showed high specific energies up to about 3140 Wh kg(−1). Mechanical tests revealed a sufficient stretchability of the air–cathode, even after battery discharge, implying an acceptable degree of wearability. Together with the reusability of the air–cathode, the battery is a promising route towards a low-cost viable way for wearable power supply for monitoring medical devices with long lifetimes and high specific energies. Optimization of the air–cathode could even lead to higher power applications.