Molten-Salt Media Synthesis of N-Doped Carbon Tubes Containing Encapsulated Co Nanoparticles as a Bifunctional Air Cathode for Zinc-Air Batteries

Cost efficient bifunctional air cathodes possessing high electrocatalytic activity are of great importance for the development of secondary Zn-air batteries. In this work, cobalt nanoparticles are encapsulated within a 3D N-doped open network of carbon tubes (Co@N-CNTs) by a molten-salt synthesis procedure conducted at a high temperature. Physical characterization demonstrates that Co@N-CNTs are comprised of Co particle inserted carbon tubes with mesoporous tube walls, providing significant active surface area for electrochemical reactions. High electrocatalytic activity of Co@N-CNTs towards both oxygen evolution and oxygen reduction reactions is due to its well-developed active surface and a synergistic effect between N-doped carbon and Co nanoparticles. Both primary and secondary Zn-air battery cells assembled using Co@N-CNTs as an air cathode show higher electrochemical performance than similar cells containing commercial Pt/C and Pt/C +RuO₂, making the newly developed material a promising alternative to existing metal-based air cathodes.