There are four tasks that are being researched as part of WP4
Task 4.1
Our methodology will start by optimising and controlling the coating process in formulations with fewer components, and reduced characterisation challenges. This will allow rapid progress while the sensor development required for more challenging coatings proceeds in tandem (WP3). The models development in WP2 will inform early formulation choice, and in-line process dynamic measurements made as part of our coating optimisation process will verify the theoretical and modelling insights, whilst also providing early data input into WP1. While these early stage experiments will include lower challenge, real world systems, in some cases custom model simplified formulations will be required, to clarify the basic mechanistic understanding that is needed in order to build accurate models for more complex materials. Example simplified model systems include using solids with well-defined sizes and shapes e.g. monomodal synthetic spherical colloids, to replace polydisperse irregular materials, and casting films from solutions with fewer binders and simplified rheology.
Task 4.2
Gradually building complexity, we will work with partners to identify real formulations, which whilst not replicating final device performance (i.e. coating low value, conjugated polymers cf. high purity, conductive polymers) are suitable for developing our process control and optimisation methods at the lab/pilot scale across a full range of applications, including ceramic dielectric inks, printable electrode inks and PV materials.
Task 4.3
As complexity builds progressively, testing of in-line sensors (WP3) suitable for opaque, real world system optimisation will commence along with control algorithms testing (WP1), to prepare for the fitting to environmentally controlled manufacturing scale equipment (currently used for by DCS & IMR at the Henry Royce Institute (Partner)) and future deployment at CPI (WP5). Efficiency savings (direct/indirect) will be fed to WP6 for inclusion within the LCA and TEA analysis.
Task 4.4
Running throughout this work package, for each system under investigation, in-situ measurements of the dynamics of film formation will be augmented by extensive characterisation of the final film quality obtained both in-situ, and also by off-line analysis (SEM, AFM, XRD, ellipsometry, EIS) to confirm production quality.