As the world increasingly relies on batteries—from phones and medical devices to electric cars and renewable energy systems—scientists are searching for safer and more affordable alternatives to today’s lithium-ion technology.
Now, researchers at the FAMU-FSU College of Engineering have developed a promising new type of rechargeable battery that could help meet those needs.
The team, led by Professor Petru Andrei and doctoral student Peng Wang, created a zinc-ion battery that uses water-based materials instead of flammable chemicals.
Their findings, published in ACS Omega, show that this new design is not only safer but also durable and easier to manufacture.
Lithium-ion batteries currently dominate the market, but they come with drawbacks.
They can overheat, catch fire, and rely on materials that are expensive and sometimes harmful to the environment. In response, scientists have been exploring alternatives such as aqueous zinc-ion batteries, which use water-based electrolytes and low-cost materials.
These batteries are naturally safer, but until now they have faced technical challenges that limit their performance.
One major issue is the formation of dendrites—tiny metal spikes that grow inside the battery during charging.
Over time, these structures can pierce internal components and cause short circuits or complete failure.
Another challenge is the complexity of manufacturing, which often involves multiple steps and strict quality control.
The new design tackles both problems at once. Instead of using traditional methods, the researchers developed a simplified process in which key battery components form directly inside the device during assembly. This approach uses a special hydrogel electrolyte made from poly(vinyl alcohol) and strong nanofibers derived from Kevlar, a material commonly used in protective gear.
This hydrogel plays an important role. It holds the liquid electrolyte in place, keeps the battery stable, and physically blocks the growth of dendrites. Because it is nonflammable and water-based, it also makes the battery much safer than conventional designs.
Another advantage of this system is how it is made. Traditional battery production involves mixing powders with solvents to create a paste, coating it onto metal surfaces, and then drying it—a time-consuming and energy-intensive process. The new method removes these steps entirely, allowing the battery to be assembled more simply and potentially at lower cost.
In testing, the battery showed impressive performance. It was able to charge and discharge quickly for more than 900 cycles while maintaining its capacity. This level of durability is especially important for applications that require long-lasting and reliable energy storage.
While these batteries may not store as much energy as lithium-ion versions, they are well suited for uses where safety, cost, and longevity matter most. For example, they could play a key role in storing energy from solar panels and wind farms, helping stabilize power grids. They could also be used in home backup systems or in devices where fire risk must be minimized, such as wearable medical equipment.
Overall, this new zinc-ion battery design represents an important step toward safer and more sustainable energy storage.
By simplifying manufacturing and improving reliability, it could help bring next-generation batteries closer to everyday use.
Source: Florida State University.
