This EPSRC First Grant project will concentrate on the use of so-called 'Electrophoretic Deposition (EPD)' to manufacture energy storage electrodes with spatially distributed properties; in order to further advance the performance of electrochemical power devices. The research is aimed at realising a full capacity utilisation while meeting all relevant power extractions. This will be achieved by developing new electrode designs, manufacture them at a meaningful scale, microstructural characterisation and energy storage measurement. Electrodes built in this way will have their energy storage functions met more rationally than conventional monolithic design. Whilst in-depth investigation of materials chemistry is beyond the scope of this manufacturing centred project, the research will perform exemplary experiments involving Nb2O5 and C, in Li-ion battery context. The improved electrodes will be designed, manufactured and validated in the UK's first full battery prototyping lines in a non-commercial environment at the WMG Energy Innovation Centre. Specifically, this project directly challenges the existing manufacturing paradigm in which electrode designs are driven by outdated manufacturing considerations, such as the casting and calendaring of powder-based viscous slurry. The existing technologies, which are clearly scalable and robust, dominate today's electrode manufacturing for batteries and supercapacitors devices. But, the manufacturing approach greatly limit the 'usable' energy density (Wh/kg) and 'usable' capacity (Ah) at device cell level and creates an undesirable viscous circle. This is because calendaring powder-based electrodes for high fraction of active materials results in pore networks with high tortuosity, filled with undesirable quantity of inactive materials such as polymeric binders and electrical conductivity enhancer carbon black particles. In this context, the electrodes must then be thin for high rate. But, thin electrodes result in high fraction of inactive materials; which consequently lowers the maximum achievable 'usable' energy density and 'usable' capacity. A real-world need therefore persists to expand our knowledge about realising high density active material electrodes, whilst having low pore tortuosity and of adequate electrical conductivity, but is less affected by the demanding manufacturing requirements and engineering constraints. The proposed EPD approach is sufficiently generic that it can be applied for any energy storage materials and their chemistries, and the developed tools, processes and methodologies are common across scale can be of direct relevance for systematic optimisation of any existing Li-ion batteries, beyond Li-ion chemistries (e.g., Na-ion, Mg-ion) and higher energy density electrochemical capacitors (based on metal oxides). In short, this project will explore a new direction: the scientific challenges and technological opportunities enabled by the design of 'high density active material electrodes of spatially distributed properties' through modern approaches in electrochemical manufacturing. The project outcomes are expected to impact scientific understandings of how charged materials and electric field interact, and will create improved electrode designs for future energy storage.

Coatings are ubiquitous throughout day to day life and ensure the function, durability and aesthetics of millions of products and processes. The use of coatings is essential across multiple sectors including construction, automotive, aerospace, packaging and energy and as such the industry has a considerable value of £2.7 billion annually with over 300,000 people employed throughout manufacturers and supply chains. The cars that we drive are reliant on advanced coating technology for their durability and aesthetics. Planes can only survive the harsh conditions of flight through coatings. These coatings are multi-material systems with carefully controlled chemistries and the development and application of coatings at scale is challenging. Most coatings surfaces are currently passive and thus an opportunity exists to transform these products through the development of functional industrial coatings. For example, the next generation of buildings will use coating technology to embed energy generation, storage and release within the fabric of building. Photocatalytic coated surfaces can be used to clean effluent streams and anti-microbial coatings could revolutionise healthcare infrastructure. This means that this new generation of coatings will offer greater value-added benefits and product differentiation opportunities for manufacturers. The major challenges in translating these technologies into industry and hence products are the complex science involved in the development, application and durability of these new coatings systems. Hence, through this CDT we aim to train 50 EngD research engineers (REs) with the fundamental scientific expertise and research acumen to bridge this knowledge gap. Our REs will gather expertise on coatings manufacture regarding: - The substrate to be coated and the inherent challenges of adhesion - the fundamental chemical and physical understanding of a multitude of advanced functional coatings technologies ranging from photovoltaic materials to smart anti corrosion coatings - the chemical and physical challenges of the application and curing processes of coatings - the assessment of coating durability and lifetime with regards to environmental exposure e.g. corrosion and photo-degradation resistance - the implantation of a responsible and sustainable engineering philosophy throughout the manufacturing route to address materials scarcity issues and the fate of the materials at the end of their useful life. To address these challenges the CDT has been co-created with industry partners to ensure that the training and research is aligned to the needs of both manufacturers and the academic community thus providing a pathway for research translation but also a talent pipeline of people who are able to lead industry in the next generation of products and processes. These advanced coating technologies require a new scientific understanding with regards to their development, application and durability and hence the academic impact is also great enabling our REs to also lead within academia.