Zinc-ion batteries could replace lithium-ion in large-scale energy storage, but they fail too quickly to be commercially viable. Lithium-ion batteries dominate electric vehicles and electronics, but they rely on scarce, expensive materials like cobalt and nickel, use flammable electrolytes, and are hard to recycle. Zinc-ion batteries avoid all these problems—they use abundant zinc, non-flammable water-based electrolytes, and are easy to recycle. However, two flaws stop them from reaching the market: zinc grows into needle-like dendrites that short-circuit the battery, and hydrogen gas forms inside it, wasting energy and damaging components. This project designs asymmetric separators—membranes with different properties on each side—to manage the different chemical reactions at the anode and cathode. One side controls zinc-ion flow to suppress dendrites; the other is paired with a protective coating that stops hydrogen evolution. The team will also manufacture these separators using continuous roll-to-roll coating, the same process used for printing newspapers, to prove the technology can scale. If successful, this work could make grid-scale renewable energy storage safer, cheaper, and more sustainable—helping the UK meet its net-zero targets without relying on scarce materials or flammable components.
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Because of their high energy density, Lithium-ion batteries are currently the dominating technology for powering electric vehicles and portable consumer electronics. However, their high costs, flammability, and the scarcity of elements such as Li, Co and Ni used in these batteries, have motivated the search for alternative energy storage solutions. This is particularly true for applications such as renewable energy storage where cost-efficiency, safety and sustainability are more important than energy density. This work focuses on aqueous Zinc-Ion Batteries (ZIBs), which are an exciting new battery technology where a Zn metal anode is cycled against a cathode typically made out of a transition metal oxide such as MnO2. These batteries do not rely on any rare or toxic materials, they use non-flammable aqueous electrolytes and are easy to recycle. However, ZIBs suffer from two major challenges that prevent their commercial adoption, the first is the growth of Zn dendrites and the second is hydrogen evolution reactions. Our project aims to address these issues by using new asymmetric separators that are rationally designed to cater for the different chemical processes taking place on the anode (plating and stripping) and the cathode (intercallation). These separators allow for a better distribution of the Zn-Ion flux, which addresses dendrite issues, and they will be paired with artificial solid-electrolyte interphase coatings to suppress hydrogen evolution reactions. Finally, a key goal of this project is to ensure that the proposed membranes can be manufactured at scale using a continuous Roll-to-Roll (R2R) process. Along with addressing the two challenges discussed above, this is critical for ensuring that the technology proposed in this project can have a tangible real-world impact. The two institutes working on this project (UCL and Cambridge) are equipped with state of the art scale-up manufacturing tools, including Roll-to-Roll coating, automated large area spray coating and pouch cell assembly lines. We will use these facilities to fabricate 5 Ah pouch cells with a lean anode design to demonstrate the capabilities of the proposed technology to industrial stakeholders and help the UK advancing towards it net-zero goals.
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