Abstract: Methods and systems are provided for manufacturing and implementing solid-state electrolytes (SSEs) for aluminum-based rechargeable batteries and other secondary batteries. In some examples, a SSE composition may include a mixture including urea, sodium chloride, sodium borate, magnesium sulfate, and sodium silicate. In certain examples, the SSE composition may further include carboxymethyl cellulose. In some examples, an aluminum-based secondary battery may be formed by applying a first portion of the SSE composition to an aluminum-based anode via slot-die coating and a second portion of the SSE composition to a cellulose membrane to form a SSE layer, and combining the coated aluminum-based anode, the SSE layer, and a sulfur-based cathode. In certain examples, a current pulse may be applied to the aluminum-based secondary battery to activate in situ solid-electrolyte interphase layers.

Abstract: A zinc-air battery cell assembly comprising: a layer of anode material; one or more layers of cathode material; a separator directly between and engaging both the layer of anode material and the layer of cathode material that acts as both an electronic insulator and an ion conductive path between the layer of anode material and the layer of cathode material; and a diffusion member directly engaging the layer of cathode material.

Abstract: A zinc-air charger having a case defining a plurality of pass core vents, and an internal case cavity; a plurality of zinc-air cells that are electrically coupled and disposed within the internal case cavity; a coupling plug configured to couple with and provide electrical power generated by the plurality of zinc-air cells to a device that is separate from the zinc-air charger; and a system configured to: output electrical power generated by the plurality of zinc-air cells to the device; identify a state of the plurality of zinc-air cells, determine, based at least in part on the identified state of the plurality of zinc-air cells, that one or more of the plurality of zinc-air cells are air-starved, and in response to determining that the one or more of the plurality of zinc-air cells are air-starved, generate a power cut-off for a period of time that ceases electrical power output to the device.

Abstract: A zinc-air battery cell assembly comprising: a layer of anode material; one or more layers of cathode material; a separator directly between and engaging both the layer of anode material and the layer of cathode material that acts as both an electronic insulator and an ion conductive path between the layer of anode material and the layer of cathode material; and a diffusion member directly engaging the layer of cathode material.