An accidental twist in semiconductor research has led to a breakthrough that could fix a common issue in zinc batteries.
A team of researchers at the Purdue Polytechnic Institute stumbled upon a way to improve zinc batteries while working on low-temperature semiconductors for flexible electronics.
Zinc batteries offer a safer, more affordable, and environmentally friendly alternative to lithium-ion systems, largely because they are non-flammable, made from abundant materials, and can be easily recycled.
The researchers, who were originally working on developing next-generation Complementary Metal-Oxide-Semiconductor (CMOS) devices, discovered that a p-type tin oxide semiconductor could effectively protect zinc anodes from corrosion and hydrogen evolution.
These two issues have posed major challenges in zinc battery technology, as they damage the zinc anode over time, reducing performance and shortening battery lifespan.
CMOS technology is widely used in the semiconductor industry to manufacture microchips found in processors, memory units, and image sensors, including those used in smartphones and digital cameras.
“Accidental” breakthroughs like this are not uncommon, said Sunghwan Lee, associate professor at Purdue’s School of Engineering Technology (SoET) and principal investigator of the study. He credits the lab’s cross-disciplinary environment for making such serendipitous advances possible.
“While testing semiconductor thin films, the team observed a spontaneous passivation effect that proved to be an ideal solution for the challenges of zinc battery corrosion and hydrogen evolution,” Lee said. “The innovative zinc anode strategy proved so effective that it resulted in a patent application.”
Accidental meets essential tech
Zinc batteries, commonly used in vehicles and stationary energy storage systems, are valued for their safety, affordability, and environmental benefits. However, their widespread adoption has been limited by relatively short lifespans and performance degradation over time.
The tin oxide coating could address these limitations by significantly enhancing the stability and durability of zinc anodes, potentially extending battery life and paving the way for broader commercial use.
“This zinc anode design strategy offers a sustainable solution for environmentally friendly, large-scale energy storage systems,” said Yuxuan Zhang, a SoET Ph.D. student, research assistant, and first author on the paper.
Zinc’s second life unlocked
The researchers believe their discovery will resonate with experts across a range of fields—including energy storage, battery technology, and semiconductor research—particularly those interested in the growing potential of cross-disciplinary innovation.
“This example of accidental innovation underscores how foundational knowledge, when coupled with curiosity, can unlock entirely new frontiers,” he said.
The discovery holds strong potential for both commercial and practical use, as it addresses key challenges in zinc battery performance—such as corrosion and short lifespan—while using materials and methods that can be scaled for real-world energy storage applications.
Other authors on the paper include Minyoung Kim, Dong Hun Lee, Fei Qin, Han-Wook Song, Chung Soo Kim, Jeongmin Park, Chohee Kim, and Fang Lian.
The accidental discovery has resulted in a patent application and a paper published in Energy & Environmental Science, one of the leading journals in the field.