Research is focused on novel ways of producing electrodes used in Li ion, Na ion and solid-state batteries. We are studying how to arrange more carefully the particulate and other materials that comprise an electrode. For example, we have developed manufacturing techniques that provide extra control on how a polymeric binder distributes during the drying of a slurry cast Li ion battery electrode, or how to precisely control the through thickness distribution of conducting carbon in a novel layer-by-layer spray formed electrode. By improving microstructural control we are able to extend battery performance, or extract more of the theoretical performance of the active materials. With our manufacturing abilities, the design space for battery electrode architectures is dramatically widened, as is the range of possibilities to balance electrode properties such as energy density, power, degradation, etc. Because the options are increased, we must make use of detail and novel modelling both to understand the arising electrochemical behaviour of our smart hetero-electrodes, and ultimately to design a priori the optimum arrangement of electrode materials on a micro-scale for any particular suite of desired properties. Some of the ideas and techniques are patented.
