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<p>The construction of fiber lithium-ion batteries with gel polymer electrolytes offers promising potential for wearable electronics, yet their multi-step assembly and hour-scale polymerization significantly limit manufacturing efficiency. Here we report a rapid, continuous fabrication method for high-safety fiber batteries with gel electrolytes, achieving minute-scale construction with a tenfold manufacturing efficiency by incorporating fast ultraviolet (UV) light-initiated, in-situ polymerization within the extrusion of one-dimensional fiber electrodes. This in-situ UV-initiated polymerization-extrusion method affords a conformal electrode–electrolyte interface that simultaneously accommodates dynamic deformation and is compatible with varying active electrode materials. The resulting fiber batteries exhibit high cycling stability, with 78% capacity retention after 400 cycles, and sustained operation under 100,000 bending cycles, highlighting their potential for rapid fabrication and practical deployment of fiber batteries.</p> Graphical abstract

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Rapid Fabrication of High-Safety Fiber Batteries via in-situ UV-Initiated Polymerization-Extrusion Method

  • 期刊论文

  • 发表日期：

    2026年5月20日

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  • Kun Zhang,
  • Yanfeng Zhang,
  • Runze Zhang,
  • You Pan,
  • Jiaxin Li,
  • Chen Zhao,
  • Meng Liao,
  • Huisheng Peng,
  • Bingjie Wang

摘要

The construction of fiber lithium-ion batteries with gel polymer electrolytes offers promising potential for wearable electronics, yet their multi-step assembly and hour-scale polymerization significantly limit manufacturing efficiency. Here we report a rapid, continuous fabrication method for high-safety fiber batteries with gel electrolytes, achieving minute-scale construction with a tenfold manufacturing efficiency by incorporating fast ultraviolet (UV) light-initiated, in-situ polymerization within the extrusion of one-dimensional fiber electrodes. This in-situ UV-initiated polymerization-extrusion method affords a conformal electrode–electrolyte interface that simultaneously accommodates dynamic deformation and is compatible with varying active electrode materials. The resulting fiber batteries exhibit high cycling stability, with 78% capacity retention after 400 cycles, and sustained operation under 100,000 bending cycles, highlighting their potential for rapid fabrication and practical deployment of fiber batteries.

Graphical abstract