Self-healing solid-state battery configuration and method of manufacture thereof

1 . An electrode stack for a solid-state battery, the electrode stack comprising:

a cathode including:

a cathode current collector; and

a first layer of material applied to the cathode current collector, including:

a cathode active material;

a first shape-memory ionomer configured as a first binder; and

a conductive material;

a solid electrolyte separator layer, including a second shape-memory ionomer configured as a second binder; and

an anode including:

a layer including lithium metal, silicon, or graphite; and

an anode current collector;

wherein the electrode stack has an original cell impedance; and

wherein the first shape-memory ionomer and the second shape-memory ionomer are configured for selectively restoring the electrode stack to an original shape after heating the electrode stack above a glass transition temperature of the first shape-memory ionomer and the second shape-memory ionomer for 10 minutes for a period of time up to 10 hours and once a cell impedance of the electrode stack is increased by 20% over the original cell impedance.

2 . The electrode stack of claim 1 , wherein the solid electrolyte separator layer includes an oxide material configured for being electrochemically stable in relation to the cathode and the anode.

3 . The electrode stack of claim 1 , wherein the solid electrolyte separator layer includes:

a first sub-layer applied to the first layer of material and including lithium lanthanum zirconium oxide (LLZO), lithium lanthanum titanium oxide (LLTO), lithium germanium vanadium oxide, lithium nitrides, lithium halides, or lithium aluminum titanium phosphate (LATP); and

a second sub-layer including a sulfide-based solid electrolyte material.

4 . The electrode stack of claim 1 , wherein the solid electrolyte separator layer includes a double-layer solid electrolyte including a first sub-layer and a second sub-layer, wherein the first sub-layer and the second sub-layer exist as discrete layers.

5 . The electrode stack of claim 1 , wherein the solid electrolyte separator layer includes a gradient solid electrolyte layer including a first sub-layer and a second sub-layer and a gradually changing mixture between the first sub-layer and the second sub-layer.

6 . A solid-state battery comprising:

an electrode stack including:

a cathode including:

a cathode current collector; and

a first layer of material applied to the cathode current collector, including:

a cathode active material;

a first shape-memory ionomer configured as a first binder; and

a conductive material;

a solid electrolyte separator layer, including:

a first sub-layer applied to the first layer of material and including:

lithium lanthanum zirconium oxide (LLZO), lithium lanthanum titanium oxide (LLTO), lithium germanium vanadium oxide, lithium nitrides, lithium halides, or lithium aluminum titanium phosphate (LATP); and

a second shape-memory ionomer configured as a second binder; and

a second sub-layer including a sulfide-based solid electrolyte material; and

an anode including:

a layer of lithium metal; and

an anode current collector;

wherein the electrode stack has an original cell impedance; and

wherein the first shape-memory ionomer and the second shape-memory ionomer are configured for selectively restoring the electrode stack to an original shape after heating the electrode stack above a glass transition temperature of the one of the first shape-memory ionomer and the second shape-memory ionomer for 10 minutes for a period of time up to 10 hours and once a cell impedance of the electrode stack is increased by 20% over the original cell impedance.

7 . The solid-state battery of claim 6 , wherein the solid electrolyte separator layer includes a double-layer solid electrolyte, wherein the first sub-layer and the second sub-layer exist as discrete layers.

8 . The solid-state battery of claim 6 , wherein the solid electrolyte separator layer includes a gradient solid electrolyte layer including a gradually changing mixture between the first sub-layer and the second sub-layer.

9 . The solid-state battery of claim 6 , wherein the solid-state battery is a prismatic can battery including a plurality of electrode stacks.

10 . The solid-state battery of claim 6 , wherein the electrode stack is a jelly roll electrode.

11 . A method to manufacture an electrode stack of a solid-state battery, the method comprising:

creating a first mixture of particles including a cathode active material, a first shape-memory ionomer configured as a first binder, and a conductive material;

electrostatic spray depositing through a first spray the first mixture of particles as a first layer upon a planar substrate configured for operation as a cathode current collector;

creating a second mixture of particles including lithium lanthanum zirconium oxide (LLZO) lithium lanthanum titanium oxide (LLTO), lithium germanium vanadium oxide, lithium nitrides, lithium halides, or lithium aluminum titanium phosphate (LATP) and a second shape-memory ionomer configured as a second binder;

creating a second layer upon the first layer, including:

electrostatic spray depositing through a second spray the second mixture of particles as a first sub-layer of the second layer upon the first layer;

electrostatic spray depositing through a third spray a sulfide-based solid electrolyte powder as a second sub-layer of the second layer;

creating a layer of lithium metal upon the second layer;

creating a layer of anode current collector material upon the layer of lithium metal; and

wherein the first shape-memory ionomer and the second shape-memory ionomer are configured for selectively restoring the electrode stack to an original shape; and

subsequent to a period of using the electrode stack, waiting for a cell impedance of the electrode stack to increase by 20% over an original cell impedance, then heating the electrode stack above a glass transition temperature of the one of the first shape-memory ionomer and the second shape-memory ionomer for 10 minutes for a period of time up to 10 hours.

12 . The method of claim 11 , wherein creating the second layer includes:

electrostatic spray depositing the second mixture of particles as the first sub-layer; and

subsequently electrostatic spray depositing the sulfide-based solid electrolyte powder as the second sub-layer;

wherein the first sub-layer and the second sub-layer exist as discrete layers.

13 . The method of claim 11 , wherein creating the second layer includes creating a gradient solid electrolyte layer wherein a solid electrolyte mixture changes gradually between the first sub-layer and the second sub-layer.

14 . The method of claim 11 , further comprising utilizing a hot roller operation to control porosity of a portion of the electrode stack.

15 . The method of claim 11 , wherein the sulfide-based solid electrolyte powder includes Li 2 S—P 2 S 5 system (Li 3 PS 4 , Li 7 P 3 S 11 ), Li 2 S—P 2 S 5 —P 2 O 5 system (Li 3 PS 3.75 O 0.25 , Li 7 P 3 S 9.75 O 1.25 ), Li 2 S—P 2 S 5 —LiM; M=Cl, Br, I (Li 6 PS 5 Cl, Li 6 PS 5 Br, Li 6 PS 5 I), or Li 2 S—P 2 S 5 —XS 2 ; X=Ge, Sn, Si (Li 10 GeP 2 S 12 , Li 10 SnP 2 S 12 , Li 10 SiP 2 S 12 ).

16 . The method of claim 11 , wherein the conductive material includes solid electrolyte particles, carbon black, or graphene.