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

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.

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.