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Battery Electrode Manufacturing
We develop and use computational tools to promote digital twinning of battery electrode manufacturing, from very upstream stages, and study their influences on downstream performance.
Coating
The aim here is to use CFD with appropriate rheological behaviour to simulate battery ink coating during slot-die coating and/or R2R process.
We are also keen on developing alternative advanced manufacturing techniques such "3D printing", which offers a promising avenue for advancing battery technology, unlocking new possibilities for design, performance, and sustainability.
Slot-die coating of battery electrodes.
angled_side.mp4Material extrusion (MEX) on a ramped surface.
Dry manufacturing - twin screw extruder
Optimising Solvent-Free Battery Electrode Manufacturing through DEM Modelling
Optimising Solvent-Free Battery Electrode Manufacturing through DEM Modelling
We use Discrete Element Method (DEM) simulations to investigate twin-screw extrusion for solvent-free lithium-ion battery electrode manufacturing. Our research explores how processing parameters, including screw speed, feeding conditions and particle cohesion, influence electrode microstructure, porosity, filament expansion and quality consistency. The findings provide new insights into optimising dry electrode manufacturing, supporting more sustainable, cost-effective and high-performance battery production.
Drying
The evaporation process is normally characterised by the drying rate curve, and depending on the water content, it typically has three different stages: (1) first a relatively constant and high evaporation rate, (2) a falling evaporation rate, and (3) a constant and low evaporation rate. These three stages influence the final property of the ceramic layer, in the sense that they can cause severe drying stresses as well as elongated drying time.
Investigation of influencing parameters
Drying of layered/graded ceramics
Multi nozzle drying of battery electrodes.
Calendering
We use Discrete Element Method (DEM) modelling to simulate the calendering process of battery electrodes. This is then coupled with CFD to predict porous electrode characteristics, i.e. porosity, permeability, and tortuosity, to be simulated in electrochemical- thermal models for performance modelling [ref].
Pore-scale prediction of transport properties in lithium-ion batteries.
Modelling approaches for battery callendering.
Particle breakage during battery electrode calendering.
Fuel Cell/Electrolyser Manufacturing
The gas diffusion layer (GDL) plays a critical role in the performance and durability of proton exchange membrane (PEM) fuel cells/electrolysers by facilitating the transport of reactant gases (hydrogen and oxygen) to the catalyst layer and removing the products of the electrochemical reactions (water and heat). GDL impacts water management, gas transport, electrical conductivity, durability, and the resultant PEMFC performance. Achieving consistent GDL properties and performance across large-scale production is challenging. Variations in material properties, thickness, porosity, and surface characteristics can impact fuel cell performance and durability. The aim is to digitise the GDL medium, extract its porous characteristics, and use the to conduct channel/stack level performance simulations.
Tape Casting
We aim to use flow analysis of ceramic tape casting in order to design tapes with desired properties, mainly tape thickness, uniformity of tapes, and controlling heterogeneity. The tapes are normally used for electric substrates, multilayer ceramics (MLCs) for solid oxide fuel cells (SOFCs), and functionally graded ceramics (FGCs).
Functionally graded ceramics
Particle migration
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