The new funding will support a focused work package, the aims of which include:

  • Investigate the critical properties and limitations of lithium-rich oxygen-redox cathodes and novel anion-chemistry cathodes, and develop solutions to current scientific roadblocks that hinder wider use;
  • Develop new synthesis methods to facilitate scalable manufacturing routes for improved cathodes;
  • Carry out experimental, modelling and cell performance evaluation to select the most promising cathodes to be taken forward;
  • Synthesise cathode prototypes at small scales using scalable green synthesis routes and low energy manufacturing methods;
  • Assimilate materials in full battery cells and characterise their performance in proof-of-concept devices.

Nextrode – Lithium ion battery electrode manufacturing

Nextrode researchers are developing new tools, including pre-production design and manufacturing simulation, process diagnostics, and feedback control, to reduce the manufacturing costs of Li ion battery electrodes and to improve electrode performance.

 

Particles of a material are joined together with thin fibres.

The microstructure of a solvent-free Li ion battery cathode. Image credit: Guillaume Matthews, Oxford University.

Although battery electrode manufacturing capacity is rapidly expanding globally, principally to meet the growing electric vehicle market, some aspects of the manufacturing process are poorly understood. Consequently, manufacturing optimisation relies heavily on time-consuming and expensive trial and error. As a result, the actual performance of electrode designs is often significantly below the theoretical maximum and that obtained in laboratory testing. 

Nextrode using two approaches to develop smart manufacturing of electrodes for Li ion and related batteries. First, existing processes are being simulated with increased sophistication, with the separate process steps progressively explored for opportunities for real-time process control of electrode microstructure. New artificial intelligence tools are also being used to reveal the complex microstructure-process parameter links between successive manufacturing steps.

Second, researchers are inventing new manufacturing approaches that produce completely new electrode microstructures unachievable by today’s manufacturing plants. These smart structures are designed to allow much more of the performance of either existing or new energy storage materials to be achieved in practice. For example, a family of manufacturing processes that eliminates the use of solvents currently used in industrial manufacture are being developed with the potential to reduce cost, energy, and emissions, and provide new microstructures with higher energy storage performance.

Nextrode is led by Principal Investigator Professor Patrick Grant in the Department of Materials, University of Oxford. As well as Professor Grant’s team based at the University’s Begbroke Science Park, the Nextrode team includes researchers from the Department of Engineering Science and the universities of Birmingham, Sheffield, Southampton, Warwick and UCL, and newly joined by Imperial College London. The project partners collaborate closely with the UK Battery Industrialisation Centre.

We are tremendously excited by the continued investment of the Faraday Institution in our ideas and progress towards smarter Li ion battery manufacture. It is particularly timely given recent industrial commitments to battery manufacture in the UK. Although global competition is intense, we believe that by using a science-led approach to manufacturing we can help UK manufacturers develop novel, more sustainable and higher performing energy storage devices.

Nextrode Principal Investigator, Professor Patrick Grant, Department of Materials, University of Oxford

As part of the reshaping process, the Institution recently issued an open call for proposals for new research topics with tightly defined scopes that would strengthen the delivery of core research projects. The call was highly competitive. From that process Professor Stephen Duncan, from the University of Oxford’s Department of Engineering Science, was selected to investigate whether one or more stages in the electrode fabrication process could be brought within closed loop process control, where process variables could be altered in real time to control key properties and improve battery performance.

The majority of the funding for this programme, £17.1 million, will be provided by the Faraday Battery Challenge, which is delivered by Innovate UK for UK Research and Innovation. A further £1.1 million will be provided by the Department of Science, Innovation and Technology.

The full list of projects supported by the Faraday Institution can be found on the Faraday Institution’s website.