Battery

Abstract

The present invention provides a battery. The battery includes: a first electrode current collector layer having a plate shape; a plurality of first active material layers electrically contacting the first electrode current collector layer and being substantially perpendicular to the first electrode current collector layer; a conductor layer electrically contacting the first electrode current collector layer and intercalated in the plurality of first active material layers; a second active material layer including a plurality of first portions parallel to and alternately arranged with the plurality of first active material layers and a second portion facing and parallel to the first electrode current collector layer and extending from the plurality of first portions; and an electrolyte layer disposed between the plurality of first active material layers and the plurality of first portions of the second active material layer, between the plurality of first active material layers and the second portions of the second active material layer, and between the plurality of first portions of the second active material layer and the first electrode current collector layer.

Description

[0001] The present application is a divisional application of the invention patent application No. 201610012296.8, filed on January 8, 2016 and entitled “Secondary battery with high rate performance and high energy density and method for manufacturing the same”. Technical Field

[0002] Exemplary embodiments of the present invention relate to a secondary battery and a method of manufacturing the same, and more particularly, to a secondary battery having a structure that increases both energy density and rate performance and a method of manufacturing the secondary battery. Background Art

[0003] Unlike primary batteries that cannot be charged, secondary batteries can be repeatedly charged and discharged, and thus are widely used in advanced electronic devices such as cellular phones, laptop computers, and camcorders.

[0004] In particular, because lithium batteries have a higher voltage than nickel-cadmium batteries or nickel-metal hydride batteries widely used in portable electronic devices and also have a high energy density per unit weight, the demand for lithium batteries has increased. Lithium-based oxides are mainly used as positive electrode active materials for lithium batteries, and carbon materials are mainly used as negative electrode active materials for lithium batteries. Lithium batteries are generally divided into liquid electrolyte batteries and polymer solid electrolyte batteries based on the type of electrolyte. Batteries using liquid electrolytes are called lithium-ion batteries, and batteries using polymer solid electrolytes are called lithium polymer batteries.

[0005] Research has been conducted to improve the energy density and rate performance of lithium batteries. In addition, the capacity of lithium batteries can be increased by increasing the energy density, and their charging speed can be increased by improving the rate performance. Summary of the invention

[0006] One or more exemplary embodiments include a secondary battery having high energy density and high rate capability.

[0007] According to an exemplary embodiment, a battery includes: a first electrode current collector layer and a second electrode current collector layer facing each other; a plurality of first active material layers electrically contacting the first electrode current collector layer and substantially perpendicular to the first electrode current collector layer; a plurality of second active material layers electrically contacting the second electrode current collector layer and substantially perpendicular to the second electrode current collector layer; an electrolyte layer disposed between the plurality of first active material layers and the plurality of second active material layers, between the plurality of first active material layers and the second electrode current collector layer, and between the plurality of second active material layers and the first electrode current collector layer; and a first conductor layer electrically contacting the first electrode current collector layer and inserted into the plurality of first active material layers.

[0008] In exemplary embodiments, the first electrode current collector layer and the second electrode current collector layer may have a plate shape and may be parallel to each other.

[0009] In exemplary embodiments, the first electrode current collector layer and the second electrode current collector layer may have a curved plate shape and may be parallel to each other.

[0010] In an exemplary embodiment, the plurality of first active material layers may contact a first surface of a first electrode current collector layer, the plurality of second active material layers may contact a second surface of a second electrode current collector layer, and the first electrode current collector layer and the second electrode current collector layer may be arranged so that the first surface and the second surface face each other.

[0011] In example embodiments, the plurality of first active material layers may be disposed substantially perpendicular to a first surface of the first electrode current collector layer, and the plurality of second active material layers may be disposed substantially perpendicular to a second surface of the second electrode current collector layer.

[0012] In exemplary embodiments, the plurality of first active material layers and the plurality of second active material layers may have a plate shape and be alternately arranged in parallel to each other.

[0013] In exemplary embodiments, the first conductor layer may have an extended plate shape protruding substantially perpendicularly to the first surface of the first electrode current collector layer.

[0014] In an exemplary embodiment, the first conductor layer may be inserted into at least one of the plurality of first active material layers, and both side surfaces of the first conductor layer may contact the at least one of the plurality of first active material layers.

[0015] In an exemplary embodiment, a first end of the first conductor layer may contact the first surface of the first electrode current collector layer, and a second end of the first conductor layer may contact the electrolyte layer, wherein the second end may be opposite to the first end.

[0016] In example embodiments, a first end of the first conductor layer may contact the first surface of the first electrode current collector layer, and a second end of the first conductor layer may contact at least one of the plurality of first active material layers, wherein the second end may be opposite to the first end.

[0017] In exemplary embodiments, the electrolyte layer may include a solid electrolyte.

[0018] In exemplary embodiments, the electrolyte layer may meander between the plurality of first active material layers and the plurality of second active material layers, between the plurality of first active material layers and the second electrode current collector layer, and between the plurality of second active material layers and the first electrode current collector layer.

[0019] In exemplary embodiments, the battery may further include a second conductor layer electrically contacting the second electrode current collector layer and interposed in the plurality of second active material layers.

[0020] In exemplary embodiments, the second conductor layer may have an extended plate shape protruding from the second electrode current collector layer.

[0021] In an exemplary embodiment, the second conductor layer may be inserted into at least one of the plurality of second active material layers, and both side surfaces of the second conductor layer may contact the at least one of the plurality of second active material layers.

[0022] In an exemplary embodiment, a first end of the second conductor layer may contact the second electrode current collector layer, and a second end of the second conductor layer may contact the electrolyte layer, wherein the second end may be opposite to the first end.

[0023] In exemplary embodiments, a first end of the second conductor layer may contact the second electrode current collector layer, and a second end of the second conductor layer may contact at least one of the plurality of second active material layers, wherein the second end may be opposite to the first end.

[0024] In an exemplary embodiment, the plurality of first active material layers may include a positive electrode active material for forming a positive electrode, the positive electrode active material comprising a sintered polycrystalline ceramic, and the first conductor layer comprising at least one metal material of palladium (Pd), gold (Au), platinum (Pt) and silver (Ag) or an alloy thereof.

[0025] According to another exemplary embodiment, a battery includes: a first electrode current collector layer having a plate shape; a plurality of first active material layers electrically contacting the first electrode current collector layer and substantially perpendicular to the first electrode current collector layer; a conductor layer electrically contacting the first electrode current collector layer and inserted into the plurality of first active material layers; a second active material layer including a plurality of first portions parallel to the plurality of first active material layers and arranged alternately with the plurality of first active material layers and a second portion facing and parallel to the first electrode current collector layer and extending from the plurality of first portions; and an electrolyte layer disposed between the plurality of first active material layers and the plurality of first portions of the second active material layer, between the plurality of first active material layers and the second portions of the second active material layer, and between the plurality of first portions of the second active material layer and the first electrode current collector layer.

[0026] In exemplary embodiments, the plurality of first portions and the second portion of the second active material layer may be integral.

[0027] In an exemplary embodiment, the conductor layer may be inserted into at least one of the plurality of first active material layers, and both side surfaces of the conductor layer may contact the at least one of the plurality of first active material layers.

[0028] In an exemplary embodiment, a first end of the conductor layer may contact the first electrode current collector layer, and a second end of the conductor layer may contact the electrolyte layer, wherein the second end may be opposite to the first end.

[0029] In an exemplary embodiment, a first end of the conductor layer may contact the first electrode current collector layer, and a second end of the conductor layer may contact at least one of the plurality of first active material layers, wherein the second end may be opposite to the first end.

[0030] In exemplary embodiments, the electrolyte layer may meander between the plurality of first active material layers and the plurality of first portions of the second active material layer, between the plurality of first active material layers and the second portions of the second active material layer, and between the plurality of first portions of the second active material layer and the first electrode current collector layer.

[0031] According to another exemplary embodiment, a battery includes: a first electrode current collector layer and a second electrode current collector layer facing each other; a plurality of first active material layers electrically contacting the first electrode current collector layer and being perpendicular to the first electrode current collector layer; an electrolyte layer provided in a zigzag shape along surfaces of the plurality of first active material layers and a surface of the first electrode current collector layer, and including a first surface contacting the plurality of first active material layers and the first electrode current collector layer and a second surface on a side opposite to the first surface; a second active material layer electrically contacting the second electrode current collector layer and being arranged along the second surface of the electrolyte layer; and a conductor layer electrically contacting the first electrode current collector layer and being inserted into the plurality of first active material layers.

[0032] In exemplary embodiments, the second active material layer may completely fill a valley defined by the second surface of the electrolyte layer provided in a zigzag shape.

[0033] In exemplary embodiments, the second active material layer may be provided in a zigzag shape along the second surface of the electrolyte layer provided in a zigzag shape.

[0034] In exemplary embodiments, a blank space in which the second active material layer is not filled may be defined between the plurality of first active material layers.

[0035] According to another exemplary embodiment, a method for manufacturing a battery is provided, the method comprising: preparing a sheet-like stacking structure in which at least one first active material sheet assembly and at least one sacrificial layer sheet are alternately stacked; forming a stacking structure using the sheet-like stacking structure in which at least one first active material assembly and at least one sacrificial layer are alternately stacked; forming a first electrode current collector layer on one surface of the stacking structure; forming a first electrode structure by removing the at least one sacrificial layer; and sequentially forming an electrolyte layer, a second active material layer, and a second electrode current collector layer on the first electrode structure, wherein the at least one first active material assembly and the sacrificial layer are perpendicular to the first electrode current collector layer.

[0036] In an exemplary embodiment, the first active material sheet assembly may include a first active material sheet.

[0037] In exemplary embodiments, the first active material sheet may be provided by manufacturing a slurry including an active material into a sheet form, and the sacrificial layer sheet may be provided by manufacturing a slurry including a sacrificial layer material into a sheet form.

[0038] In exemplary embodiments, the method may further include forming a base sheet including the same material as the first active material sheet between one surface of the stacked structure and the first electrode current collector layer.

[0039] In an exemplary embodiment, the at least one first active material sheet assembly may include a conductor sheet and a first active material sheet disposed on at least one surface of the conductor sheet, wherein the conductor sheet may be provided by coating a paste including a current collector material on the first active material sheet.

[0040] In an exemplary embodiment, forming a stacking structure and a first electrode current collector layer may include: cutting a sheet-like stacking structure; forming a first electrode current collector sheet by coating a paste including a current collector material on one surface of the cut stacking structure; and forming the stacking structure and the first electrode current collector layer by sintering the cut sheet-like stacking structure and the first electrode current collector sheet.

[0041] In an exemplary embodiment, forming a stacking structure and a first electrode current collector layer may include: cutting a sheet-like stacking structure; forming the stacking structure by sintering the cut sheet-like stacking structure; forming a first electrode current collector sheet by coating a paste including a current collector material on one surface of the stacking structure; and forming the first electrode current collector layer by heat treating the first electrode current collector sheet.

[0042] In an exemplary embodiment, forming a stacking structure and a first electrode current collector layer may include: sintering a sheet-like stacking structure; forming the stacking structure by cutting the sintered sheet-like stacking structure; forming a first electrode current collector sheet by coating a paste including a current collector material on one surface of the stacking structure; and forming the first electrode current collector layer by heat treating the first electrode current collector sheet.

[0043] In exemplary embodiments, the sacrificial layer may be removed using an etchant that selectively etches only the sacrificial layer.

[0044] According to another exemplary embodiment, a battery includes: a first electrode current collector layer and a second electrode current collector layer facing each other; a plurality of first active material layers electrically contacting the first electrode current collector layer and being perpendicular to the first electrode current collector layer; an electrolyte layer provided in a zigzag shape along surfaces of the plurality of first active material layers and a surface of the first electrode current collector layer, and including a first surface contacting the plurality of first active material layers and the first electrode current collector layer and a second surface on a side opposite to the first surface; and a second active material layer electrically contacting the second electrode current collector layer and being arranged along the second surface of the electrolyte layer, wherein a blank space not filled with the second active material layer can be defined between the plurality of first active material layers, wherein the second active material layer is provided in a zigzag shape along the second surface of the zigzag-shaped electrolyte layer.

[0045] The battery may further include a base layer parallel to the first electrode current collector layer between the first electrode current collector layer and the first active material layer and between the first electrode current collector layer and the electrolyte layer, and the base layer includes the same material as the first active material layer. BRIEF DESCRIPTION OF THE DRAWINGS

[0046] These and / or other exemplary embodiments will become apparent and more readily understood from the following description of exemplary embodiments in conjunction with the accompanying drawings, in which:

[0047] Figure 1 is a perspective view of an exemplary embodiment of a structure of a unit cell of a secondary battery;

[0048] Figure 2 yes Figure 1 An exploded perspective view of a structure of a unit cell of a secondary battery;

[0049] Figure 3 is a cross-sectional view of another exemplary embodiment of a structure of a unit cell of a secondary battery;

[0050] Figure 4 is a perspective view of a structure of a unit cell of a secondary battery according to a comparative example;

[0051] Figure 5 Is used for comparison Figure 1 The unit cell and Figure 4 A graph of the relationship between the height of the unit cell and the reaction surface area;

[0052] Figure 6 Is used for comparison Figure 1 The unit cell and Figure 4 A graph of the relationship between the height of the unit cell and the active material fraction;

[0053] Figure 7 is a perspective view of another exemplary embodiment of a structure of a unit cell of a secondary battery;

[0054] Figure 8 is a perspective view of another exemplary embodiment of a structure of a unit cell of a secondary battery;

[0055] Fig.9A and 9B are a perspective view and an exploded perspective view of another exemplary embodiment of a structure of a unit cell of a secondary battery, respectively;

[0056] Fig.10 By stacking multiple Figure 1 A perspective view of an exemplary embodiment of a stacked structure provided for a unit cell;

[0057] Fig.11 is a cross-sectional view of an exemplary embodiment of a structure of a secondary battery;

[0058] Figures 12 to 33 It is used to describe manufacturing Fig.11 A view of a method for a secondary battery;

[0059] Fig.34 is a cross-sectional view of another exemplary embodiment of the structure of a secondary battery;

[0060] Fig.35 is a cross-sectional view of another exemplary embodiment of the structure of a secondary battery;

[0061] Figures 36 to 41 It is used to describe manufacturing Fig.35 A view of a method for a secondary battery;

[0062] Fig.42 is a cross-sectional view of another exemplary embodiment of the structure of a secondary battery;

[0063] Figures 43 to 47 It is used to describe manufacturing Fig.42 A view of a method for producing a secondary battery; and

[0064] Fig.48 is a cross-sectional view of another exemplary embodiment of the structure of a secondary battery. DETAILED DESCRIPTION

[0065] Hereinafter, a secondary battery with high energy density and high rate performance and a method for manufacturing the secondary battery will be described in detail with reference to the accompanying drawings, wherein the same reference numerals always refer to the same elements, and the size of the elements may be exaggerated for clarity. In this regard, one or more exemplary embodiments described herein may have different forms and should not be construed as being limited to the description given herein. When one layer in the layer structure described herein is disposed "on" another layer, the layer may be directly on the other layer while contacting the other layer, or may be on the other layer without contacting the other layer.

[0066] The present invention will now be described more fully below with reference to the accompanying drawings, in which various embodiments are shown. However, the present invention can be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be comprehensive and complete and will fully convey the scope of the invention to those skilled in the art. The same reference numerals refer to the same elements throughout.

[0067] It will be understood that when an element is referred to as being “on” another element, it can be directly on the other element or intervening elements may be present. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present.

[0068] It will be understood that although the terms "first", "second", "third", etc. can be used herein to describe various elements, components, regions, layers and / or parts, these elements, components, regions, layers and / or parts should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer or part from another element, component, region, layer or part. Therefore, the "first element", "first component", "first region", "first layer" or "first part" discussed below can be referred to as the second element, second component, second region, second layer or second part without departing from the teachings herein.

[0069] The terms used herein are intended only to describe specific embodiments and are not intended to be limiting. When used herein, the singular forms "a", "an" and "the" are intended to include plural forms, including "at least one", unless the content clearly indicates otherwise. "Or" means "and / or". When used herein, the term "and / or" includes any and all combinations of one or more of the relevant listed items. It will also be further understood that the terms "include" and / or "comprise" when used in this specification indicate the presence of the features, regions, wholes, steps, operations, elements and / or parts, but do not exclude the presence or addition of one or more other features, regions, wholes, steps, operations, elements, assemblies and / or groups thereof.

[0070] In addition, relational terms such as "below" or "bottom" and "above" or "top" may be used herein to illustrate the relationship of one element to another element as shown in the accompanying drawings. It will be understood that spatial relational terms are intended to include different orientations of the device in addition to the orientations depicted in the figures. In an exemplary embodiment, when the device in one of the figures is turned over, the elements described as being on the "lower" side of the other elements will be positioned on the "upper" side of the other elements. Therefore, depending on the specific orientation of the accompanying drawings, the exemplary term "below" may include both "lower" and "upper" orientations. Similarly, when the device in one of the accompanying drawings is turned over, the elements described as being "below" or "below" other elements will be positioned "above" the other elements. Therefore, the exemplary term "below" or "below" may include both upper and lower orientations.

[0071] As used herein, "about" or "approximately" is inclusive of the stated value and means within an acceptable range of deviation for the particular value as determined by one of ordinary skill in the art, taking into account the measurement in question and the errors associated with the measurement of the particular quantity (i.e., the limitations of the measurement system). For example, "about" can mean within one or more standard deviations, or within ±30%, 20%, 10%, 5% of the stated value.

[0072] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by those of ordinary skill in the art to which the present invention belongs. It will be further understood that terms, such as those defined in common dictionaries, should be understood to have meanings consistent with their meanings in the context of the relevant art and invention, and will not be understood as idealized or overly formalized meanings unless explicitly defined as such herein.

[0073] Exemplary embodiments are described herein with reference to cross-sectional views, which are schematic diagrams of idealized embodiments. Thus, deviations from the illustrated shapes, for example, caused by manufacturing techniques and / or tolerances, are possible. Therefore, the embodiments described herein should not be understood as being limited to the specific shapes of the regions shown here, but will include deviations in shapes, for example, caused by manufacturing. In exemplary embodiments, regions shown or described as flat may generally have rough and / or nonlinear features. In addition, the sharp angles shown may be rounded. Therefore, the regions shown in the accompanying drawings are schematic in nature, and their shapes are not intended to illustrate the precise shapes of the regions, and are not intended to limit the scope of the claims.

[0074] Figure 1 is a perspective view of a structure of a unit cell of a secondary battery 100 according to an exemplary embodiment, Figure 2 yes Figure 11 is an exploded perspective view of the structure of a unit cell of a secondary battery 100. Figure 1 and 2 , the secondary battery 100 according to the exemplary embodiment may include: a first electrode current collector layer 101 and a second electrode current collector layer 111 facing each other; a plurality of first active material layers 102 electrically contacting the first electrode current collector layer 101; a plurality of second active material layers 112 electrically contacting the second electrode current collector layer 111; and an electrolyte layer 120 disposed between the plurality of first active material layers 102 and the plurality of second active material layers 112, between the plurality of first active material layers 102 and the second electrode current collector layer 111, and between the plurality of second active material layers 112 and the first electrode current collector layer 101. In addition, the secondary battery 100 may further include a first conductor layer 103 electrically contacting the first electrode current collector layer 101 and being inserted into the plurality of first active material layers 102, and a second conductor layer 113 electrically contacting the second electrode current collector layer 111 and being inserted into the plurality of second active material layers 112.

[0075] In an exemplary embodiment, the first and second electrode current collector layers 101 and 111 may include a conductive metal material such as copper (Cu), gold (Au), platinum (Pt), silver (Ag), zinc (Zn), aluminum (Al), magnesium (Mg), titanium (Ti), iron (Fe), cobalt (Co), nickel (Ni), germanium (Ge), indium (In), or palladium (Pd). Figure 1 and 2 As shown, the first and second electrode current collector layers 101 and 111 may have a flat plate shape and may be disposed parallel to each other.

[0076] The first active material layer 102 may electrically contact the surface of the first electrode current collector layer 101, and the second active material layer 112 may electrically contact the surface of the second electrode current collector layer 111. In an exemplary embodiment, the first and second active material layers 102 and 112 may be attached to the surfaces of the first and second electrode current collector layers 101 and 111 facing each other, for example, respectively. Here, the first active material layer 102 may include a combination of a positive electrode active material, a conductive agent, and a binder, and the first electrode current collector layer 101 may be a positive electrode current collector. In an alternative exemplary embodiment, the first active material layer 102 may include only a positive electrode active material without a conductive agent or a binder. In an exemplary embodiment, the first active material layer 102 may include a sintered polycrystalline ceramic or single crystal for forming a positive electrode, such as LiCoO 2The second active material layer 112 may include a combination of a negative electrode active material, a conductive agent, and a binder, and the second electrode current collector layer 111 may be a negative electrode current collector. In an alternative exemplary embodiment, the second active material layer 112 may include only a negative electrode active material without a conductive agent or a binder. In an exemplary embodiment, the second active material layer 112 may include a negative electrode metal such as Li metal.

[0077] In addition, the first and second conductor layers 103 and 113 may include the same conductive metal material as the first and second electrode current collector layers 101 and 111. However, the material of the first conductor layer 103 provided in the first active material layer 102 may be limited according to the method of manufacturing the secondary battery 100. In an exemplary embodiment, when the first active material layer 102 and the first conductor layer 103 are provided by inserting a metal paste between positive electrode active material sheets and sintering the metal paste and the positive electrode active material sheets together, for example, a metal material that maintains stability during sintering and does not affect the first active material layer 102 may be used as a material of the first conductor layer 103. In an exemplary embodiment, in this case, the first conductor layer 103 may include a metal material such as palladium (Pd), gold (Au), platinum (Pt), or silver (Ag), or an alloy thereof.

[0078] like Figure 1 and 2 As shown, the plurality of first active material layers 102 and the plurality of second active material layers 112 may be arranged substantially perpendicular to the first and second electrode current collector layers 101 and 111. In an exemplary embodiment, for example, the first active material layer 102 may protrude substantially perpendicularly to the surface of the first electrode current collector layer 101, and the second active material layer 112 may protrude substantially perpendicularly to the surface of the second electrode current collector layer 111. However, the first and second active material layers 102 and 112 may not be completely perpendicular to the first and second electrode current collector layers 101 and 111, but may be inclined. The plurality of first active material layers 102 and the plurality of second active material layers 112 may have a flat plate shape and may be arranged alternately. In other words, the plurality of first active material layers 102 and the plurality of second active material layers 112 may be arranged perpendicularly to the first and second electrode current collector layers 101 and 111 between the first and second electrode current collector layers 101 and 111, and may be arranged alternately along a direction parallel to the surfaces of the first and second electrode current collector layers 101 and 111.

[0079] The electrolyte layer 120 may be disposed so that the plurality of first active material layers 102 do not directly contact the plurality of second active material layers 112 and the second electrode current collector layer 111. In addition, the electrolyte layer 120 may be disposed so that the second active material layer 112 does not directly contact the plurality of first active material layers 102 and the first electrode current collector layer 101. Therefore, the electrolyte layer 120 may be disposed in a meandering manner between the plurality of first active material layers 102 and the plurality of second active material layers 112, between the plurality of first active material layers 102 and the second electrode current collector layer 111, and between the plurality of second active material layers 112 and the first electrode current collector layer 101. Therefore, the first and second active material layers 102 and 112 may exchange metal ions through the electrolyte layer 120 without directly contacting each other. In addition, the first electrode current collector layer 101 is not electrically connected to the second active material layer 112, and the second electrode current collector layer 111 is not electrically connected to the first active material layer 102. According to an exemplary embodiment, the electrolyte layer 120 may include a solid electrolyte having a fixed meandering shape. In an exemplary embodiment, the electrolyte layer 120 may include a solid electrolyte such as Li 3 PO 4 , Li 3 PO 4-x N x 、LiBO 2-x N x , Li 3 PO 4 N x 、LiBO 2 N x , Li 4 SiO 4 -Li 3 PO 4 Or Li 4 SiO 4 -Li 3 VO 4 .

[0080] Since the electrical conductivity of the first and second active material layers 102 and 112 is generally lower than that of the first and second electrode current collector layers 101 and 111, the first conductor layer 103 and the second conductor layer 113 may be respectively inserted into the first active material layer 102 and the second active material layer 112 for uniform ion exchange reaction between the first active material layer 102 and the second active material layer 112. In an exemplary embodiment, the first conductor layer 103 may be, for example, electrically connected to the first electrode current collector layer 101 and inserted into the first active material layer 102. In addition, the second conductor layer 113 may be electrically connected to the second electrode current collector layer 111 and inserted into the second active material layer 112.

[0081] The first conductor layer 103 and the first electrode current collector layer 101 may be bonded to each other after being separately manufactured using different materials, but in an alternative exemplary embodiment, the first conductor layer 103 and the first electrode current collector layer 101 may be a whole using the same conductive material. Similarly, the second conductor layer 113 and the second electrode current collector layer 111 may be bonded to each other after being separately manufactured using different materials, but in an alternative exemplary embodiment, the second conductor layer 113 and the second electrode current collector layer 111 may be a whole using the same conductive material. In an exemplary embodiment, for example, the first electrode current collector layer 101 may be provided to have a first conductor layer 103 having a plurality of extended plate shapes protruding perpendicularly to a surface of the first electrode current collector layer 101, and the second electrode current collector layer 111 may be provided to have a second conductor layer 113 having a plurality of extended plate shapes protruding perpendicularly to a surface of the second electrode current collector layer 111. Figure 1 and 2 In the embodiment, the first and second conductor layers 103 and 113 have a flat plate shape, but may not be completely flat. In an exemplary embodiment, the first and second conductor layers 103 and 113 may have any of various shapes, such as a fishbone shape, a mesh shape, or a matrix shape.

[0082] Since the first conductor layer 103 having a flat plate shape is inserted into each of the first active material layers 102, both side surfaces of the first conductor layer 103 may contact the first active material layer 102. Similarly, since the second conductor layer 113 is inserted into each of the second active material layers 112, both side surfaces of the second conductor layer 113 may contact the second active material layer 112. The first conductor layer 103 and the second conductor layer 113 may extend from the first electrode current collector layer 101 and the second electrode current collector layer 111, respectively, to contact the electrolyte layer 120. In other words, the first ends of the first conductor layer 103 and the second conductor layer 113 may contact the first and second electrode current collector layers 101 and 111, respectively, and the second ends of the first conductor layer 103 and the second conductor layer 113 may contact the electrolyte layer 120. Thus, the first conductor layer 103 and the second conductor layer 113 may completely divide the first active material layer 102 and the second active material layer 112, respectively. In an exemplary embodiment, for example, the first active material layer 102 may be divided into two parts 102 a and 102 b by the first conductor layer 103 , and the second active material layer 112 may be divided into two parts 112 a and 112 b by the second conductor layer 113 .

[0083] Since the first conductor layer 103 and the second conductor layer 113 are respectively inserted into the first active material layer 102 and the second active material layer 112, electrons can be easily transferred from the ends of the first active material layer 102 and the second active material layer 112 adjacent to the electrolyte layer 120 to the first electrode current collector layer 101 and the second electrode current collector layer 111, respectively. In an exemplary embodiment, for example, when the first conductor layer 103 is not used, the end region of the first active material layer 102 adjacent to the electrolyte layer 120 is far from the first electrode current collector layer 101 compared to other regions of the first active material layer 102, and therefore, it may be difficult to transfer electrons from the end of the first active material layer 102 to the first electrode current collector layer 101. In this regard, when the length of the first active material layer 102 increases, the end region of the first active material layer 102 may not be utilized. However, by using the first and second conductor layers 103 and 113, electrons can be easily transferred from the first and second electrode current collector layers 101 and 111 to the ends of the first active material layer 102 and the second active material layer 112 adjacent to the electrolyte layer 120. Therefore, in the entire area of ​​the first and second active material layers 102 and 112, metal ions are uniformly exchanged through the electrolyte layer 120 between the first and second active material layers 102 and 112, so that the lengths of the first and second active material layers 102 and 112 can be sufficiently long.

[0084] exist Figure 1 and 2 In the embodiment, the first and second conductor layers 103 and 113 are respectively inserted into all of the first and second active material layers 102 and 112, but the exemplary embodiment is not limited thereto. In other words, the first and second conductor layers 103 and 113 may be selectively inserted into some of the first and second active material layers 102 and 112. In the exemplary embodiment, for example, the first conductor layer 103 and the second conductor layer 113 may be respectively inserted into every other first active material layer 102 and the second active material layer 112.

[0085] In addition, Figure 1 and 2 In the embodiment, the first and second electrode current collector layers 101 and 111 have a complete plate shape, and the secondary battery 100 has a complete rectangular shape, but the exemplary embodiment is not limited thereto. In the exemplary embodiment, for example, Figure 3 is a cross-sectional view of a structure of a unit cell of a secondary battery 100 ′ according to another exemplary embodiment. Figure 3As shown, the secondary battery 100' may be in a curved rectangular shape. In this case, the first and second electrode current collector layers 101 and 111 may have a curved plate shape while being parallel to each other, and the curved plate shape has a curvature. The secondary battery 100' having such a curved rectangular shape may be applied to any of various electronic devices manufactured to have a curved shape.

[0086] According to the above exemplary embodiment, both the energy density and rate performance of the secondary battery 100 can be improved because the first active material layer 102 and the second active material layer 112, which are parallel and independent to each other, are alternately arranged perpendicular to the surfaces of the first and second electrode current collector layers 101 and 111 between the first and second electrode current collector layers 101 and 111, which are parallel to each other. In the exemplary embodiment, for example, when the height h of the unit cell of the secondary battery 100 is increased by increasing the height of the first and second active material layers 102 and 112, the reaction surface area increases in proportion to the height of the unit cell, so the rate performance is improved. In addition, when the height of the unit cell increases, the fraction of the first and second active material layers 102 and 112 occupying the secondary battery 100 increases, so the energy density of the secondary battery 100 can also be improved. Therefore, the duration of using the secondary battery 100 increases while the charging speed is improved. In addition, because a solid electrolyte is used, the secondary battery 100 according to the exemplary embodiment can have high battery stability. Since the unit cells of such a secondary battery 100 may have a small size, the secondary battery 100 may be used for small devices such as a mobile device or a wearable device.

[0087] Figure 4 is a perspective view of a structure of a unit cell of a secondary battery 10 according to a comparative example, Figure 5 and 6 is a graph for comparing the characteristics of the secondary battery 100 and the secondary battery 10. Specifically, Figure 5 Is used for comparison Figure 1 The secondary battery 100 and Figure 4 A graph of the secondary battery 10 regarding the relationship between the height of the unit cell and the reaction surface area, Figure 6 Is used for comparison Figure 1 The secondary battery 100 and Figure 4 FIG. 1 is a graph of the secondary battery 10 regarding the relationship between the height of a unit cell and the fraction of active material.

[0088] First, refer to Figure 4 , the secondary battery 10 according to the comparative example includes a first electrode current collector layer 11, a first active material layer 13, a separator 20, a second active material layer 14, and a second electrode current collector layer 12 sequentially stacked in the stated order. Figure 4As shown, the first electrode current collector layer 11, the first active material layer 13, the separator 20, the second active material layer 14, and the second electrode current collector layer 12 are all parallel to each other. In addition, it is assumed that the secondary battery 10 according to the comparative example uses a liquid electrolyte.

[0089] Figure 5 and 6 The graph is obtained by changing the height of the unit cells of the secondary battery 100 and the secondary battery 10, while assuming that the length and width of the unit cell do not change, that is, about 294 micrometers (μm) and about 20 μm, respectively. In addition, it is assumed that in the secondary battery 100, the thickness of the first and second active material layers 102 and 112 is about 20 μm and the thickness of the electrolyte layer 120 is about 1 μm, and in the secondary battery 10, the thickness of the first and second active material layers 13 and 14 is about 50 μm and the thickness of the separator 20 is about 20 μm. In addition, it is assumed that in the secondary batteries 100 and 10, the thickness of the first and second electrode current collector layers 101 and 111 and 11 and 12 is about 15 μm. The size of the above-mentioned secondary battery 10 is based on the specifications of commercial batteries.

[0090] like Figure 5 As shown, even when the height of the unit cell increases, the reaction surface area of ​​the secondary battery 10 is uniformly maintained. However, the reaction surface area of ​​the secondary battery 100 may increase linearly in proportion to the height. Figure 6 , when the height of the unit cell increases, the active material volume fraction increases in both the secondary batteries 10 and 100, but overall, the active material volume fraction of the secondary battery 100 is higher than that of the secondary battery 10. In an exemplary embodiment, for example, when the height of the unit cell is about 150 μm, the reaction surface area of ​​the secondary battery 10 is about 58,800 square micrometers (μm 2 ), the active material volume fraction of the secondary battery 10 is about 0.67, and the reaction surface area of ​​the secondary battery 100 is about 333,200 μm 2 The active material volume fraction of secondary battery 100 is about 0.76. Thus, the reaction surface area of ​​secondary battery 100 is at least 5 times that of secondary battery 10 and the active material volume fraction is at least 13 percent (%) higher than that of secondary battery 10.

[0091] Figure 7 is a perspective view of a structure of a unit cell of a secondary battery 200 according to another exemplary embodiment. Figure 1In the secondary battery 100, the first conductor layer 103 and the second conductor layer 113 contact the electrolyte layer 120 by extending from the first electrode current collector layer 101 and the second electrode current collector layer 111 to the electrolyte layer 120, respectively. Therefore, the first conductor layer 103 and the second conductor layer 113 can completely and respectively divide the first active material layer 102 and the second active material layer 112. However, as Figure 7 As shown, the first and second conductor layers 103 and 113 may extend close to the electrolyte layer 120, but may not contact the electrolyte layer 120. In this case, the two portions 102a and 102b of the first active material layer 102 that respectively contact the two side surfaces of the first conductor layer 103 may not be completely divided, and may be connected to each other at a region adjacent to the electrolyte layer 120. Similarly, the two portions 112a and 112b of the second active material layer 112 that respectively contact the two side surfaces of the second conductor layer 113 may not be completely divided, and may be connected to each other at a region adjacent to the electrolyte layer 120. Figure 7 In the embodiment, the first and second conductor layers 103 and 113 do not contact the electrolyte layer 120 , but in alternative exemplary embodiments, any one of the first and second conductor layers 103 and 113 may contact the electrolyte layer 120 and the other may not contact the electrolyte layer 120 .

[0092] Figure 8 is a perspective view of a structure of a unit cell of a secondary battery 300 according to another exemplary embodiment. Figure 1 The secondary battery 100, Figure 8 The secondary battery 300 does not include the second conductor layer 113. The other configurations of the secondary battery 300 may be the same as those of the secondary battery 100. When the second active material layer 112 includes an active material having a sufficiently high electrical conductivity, electrons can be smoothly transferred from the end of the second active material layer 112 adjacent to the electrolyte layer 120 to the second electrode current collector 111, and thus the second conductor layer 113 may be omitted. Figure 8 Although not shown in the figure, when the first active material layer 102 includes an active material having a sufficiently high electrical conductivity, the first conductor layer 103 may be omitted. Figure 8 In the embodiment, the first conductor layer 103 contacts the electrolyte layer 120 , but according to another exemplary embodiment, the first conductor layer 103 may not contact the electrolyte layer 120 .

[0093] Fig.9A and 9B 1 and 2 are perspective views and exploded perspective views of the structure of a unit cell of a secondary battery 400 according to another exemplary embodiment, respectively. Figure 1The secondary battery 400 may not use the second electrode current collector layer, and the second active material layer 114 may operate as the second electrode current collector layer. Other configurations of the second battery 400 may be the same as those of the secondary battery 100.

[0094] When the second active material layer 114 includes an active material having excellent electrical conductivity such as Li metal, the second active material layer 114 may operate as an electrode current collector layer, such as Fig.9A and 9B Therefore, the second active material layer 114 may include a plurality of first portions 114a arranged alternately and parallel to the plurality of first active material layers 102 and a second portion 114b facing and parallel to the first electrode current collector layer 101. The second portion 114b of the second active material layer 114 may be used as Figure 1 The second electrode current collector layer 111 operates and has a plate shape. In addition, the plurality of first portions 114a may be an extended plate shape protruding vertically from the second portion 114b. The plurality of first portions 114a and the second portion 114b may be integral and include the same material. The electrolyte layer 120 may be disposed in a meandering manner between the plurality of first active material layers 102 and the plurality of first portions 114a of the second active material layer 114, between the plurality of first active material layers 102 and the second portion 114b of the second active material layer 114, and between the plurality of first portions 114a of the second active material layer 114 and the first electrode current collector layer 101.

[0095] Fig.10 According to an exemplary embodiment, by stacking a plurality of Figure 1 A perspective view of a stacked structure 500 provided by a unit cell of a secondary battery 100. Fig.10 , when the unit cells of the secondary battery 100 are stacked, the unit cells may be arranged so that the first electrode current collector layer 101 and the second electrode current collector layer 111 of the same type contact each other. In an exemplary embodiment, for example, the first electrode current collector layer 101 of the unit cell of the secondary battery 100 may contact the first electrode current collector layer 101 of the unit cell of another secondary battery 100, and the second electrode current collector layer 111 of the unit cell of the secondary battery 100 may contact the second electrode current collector layer 111 of the unit cell of another secondary battery 100. In addition, the first wire 501 may be connected to the first electrode current collector layer 101, and the second wire 502 may be connected to the second electrode current collector layer 111, so that the unit cells of the secondary battery 100 stacked one on top of another are electrically connected in parallel.

[0096] Fig.11 is a cross-sectional view of a structure of a secondary battery 600 according to an exemplary embodiment.

[0097] Fig.11 The secondary battery 600 and Figure 1 The secondary battery 100 is different in that the electrolyte layer 120 does not directly contact the second electrode current collector layer 111. Figure 1 In the secondary battery 100, since the second active material layers 112 are completely spaced apart from each other, the second electrode current collector layer 111 is exposed between the second active material layers 112. Therefore, the electrolyte layer 120 contacts the second electrode current collector layer 111 between the second active material layers 112 adjacent to each other. Fig.11 In the secondary battery 600, the end portions of the second active material layer 112 are connected to each other and extend along the surface of the second electrode current collector layer 111 to cover the second electrode current collector layer 111. Therefore, the electrolyte layer 120 does not contact the second electrode current collector layer 111 between the second active material layers 112 adjacent to each other. Instead, the electrolyte layer 120 contacts a surface that is provided along the surface of the second electrode current collector layer 111 as the end portions of the second active material layer 112 connected to each other.

[0098] In other words, Fig.11 In the exemplary embodiment of the present invention, the electrolyte layer 120 may be provided in a zigzag shape between the first active material layer 102 and the second active material layer 112 and between the second active material layer 112 and the first electrode current collector layer 101. Therefore, the first surface of the electrolyte layer 120 may be provided in a zigzag shape to contact the surface of the first active material layer 102 and the surface of the first electrode current collector layer 101. The second active material layer 112 may be provided to contact the second surface of the electrolyte layer 120 on the opposite side to the first electrode current collector layer 101.

[0099] Figures 12 to 33 It is used to describe manufacturing Fig.11 A method of manufacturing a secondary battery 600 is shown. Hereinafter, it is assumed that the first electrode current collector layer 101 is a positive electrode current collector, the first active material layer 102 is a positive electrode active material, the second electrode current collector layer 111 is a negative electrode current collector, and the second active material layer 112 is a negative electrode active material.

[0100] Reference Fig.12 , prepare a first active material sheet 102'. In an exemplary embodiment, the first active material sheet 102' may have a thickness of, for example, about 1 μm to about 30 μm, but the embodiment is not limited thereto. The first active material sheet 102' may be a positive electrode sheet. In this case, the first active material sheet 102' may include a positive electrode material such as lithium cobalt oxide (LCO). However, the embodiment is not limited thereto. The first active material sheet 102' may be formed by mixing a slurry 52 (refer to Fig.13 ) is manufactured and provided in the form of sheets.

[0101] Fig.13 1 is a diagram showing a process of forming the first active material sheet 102' using tape casting. Fig.13 First, a slurry 52 including, for example, a positive electrode material, a dispersant, a solvent, a binder, and a plasticizer is prepared. Subsequently, the slurry 52 is applied to the carrier film 50 on the conveyor belt. Here, the slurry 52 may be applied to the carrier film 50 to have a uniform thickness using, for example, a doctor blade. Next, the slurry 52 applied to the carrier film 50 is dried, so that the first active material sheet 102' may be manufactured.

[0102] Here, in order to effectively dry the slurry 52, the slurry 52 may be heated at a predetermined temperature. The first active material sheet 102' manufactured in this manner may include a positive electrode material, a dispersant, a binder, and a plasticizer. As described above, the first active material sheet 102' is manufactured, for example, using tape casting. However, the embodiment is not limited thereto, and the first active material sheet 102' may be manufactured in various ways.

[0103] Reference Fig.14 , preparing the sacrificial layer sheet 131'. Although the sacrificial layer sheet 131' may have a thickness of about 1 μm to about 50 μm, the embodiment is not limited thereto. The sacrificial layer sheet 131' may be provided by manufacturing a slurry including, for example, a sacrificial layer material, a dispersant, a solvent, a binder, and a plasticizer into a sheet form. Here, for example, Li 2 CoSiO 4 It can be used as a sacrificial layer material. However, the embodiment is not limited thereto, and various other materials may be used.

[0104] Reference Fig.15 , preparing a first active material sheet assembly 105'. The first active material sheet assembly 105' may be manufactured by forming a first conductor sheet 103' on a first active material sheet 102b' and by laminating a first active material sheet 102a' on the first conductor sheet 103'. The first conductor sheet 103' may be provided by coating the first active material sheet 102b' with a paste including a current collector material. In an exemplary embodiment, the first conductor sheet 103' may be provided to have a thickness equal to or less than about 1 μm, for example, but the embodiment is not limited thereto. Fig.15 In the embodiment, the first active material sheets 102a' and 102b' are respectively disposed on both sides of the first conductor sheet 103', so that the first active material sheet assembly 105' can be manufactured. However, the first active material sheet 102' may be disposed only on one side of the first conductor sheet 103'.

[0105] Reference Fig.16, at least one first active material sheet assembly 105' and at least one sacrificial layer sheet 131' are alternately and repeatedly stacked, thereby providing a sheet-like stacked structure 630'. Here, the number of stacking the first active material sheet assembly 105' and the sacrificial layer sheet 131' may be about 1 to about 2000 times. However, the embodiment is not limited thereto. Subsequently, referring to Fig.17 , using a cutter such as a blade 60 to cut the sheet-like stacked structure 630' into Fig.18 Each of the plurality of sheet-like stacked structures 640' has a desired size. One of the plurality of sheet-like stacked structures 640' after being divided is Fig.18 Shown in.

[0106] Reference Fig.19 The first electrode current collector sheet 101' is disposed on the divided sheet-like stacked structure 640'. The first electrode current collector sheet 101' is disposed on one surface of the sheet-like stacked structure 640' ( Fig.19 Here, the first electrode current collector sheet 101' may be a positive electrode current collector paste. The first electrode current collector sheet 101' may be provided by coating one surface of the sheet-like stacked structure 640' with a paste including a current collector material such as Al, Ni, Ag, Au, Pt, or Pd. In an exemplary embodiment, the first electrode current collector sheet 101' may be provided to have a thickness of, for example, about 1 μm to about 10 μm, but embodiments are not limited thereto.

[0107] Reference Fig. 20 , sintering the sheet-like stacked structure 640' and the first electrode current collector sheet 101' at a predetermined temperature. Here, the sintering temperature may be, for example, about 1000 degrees Celsius (°C) to about 1050°C. However, the embodiment is not limited thereto. Through the sintering process, the sintered stacked structure 640 (refer to Fig.21 ) and the first electrode current collector layer 101 (refer to Fig.21 ). Here, the sintered stacked structure 640 includes at least one first active material assembly 105 and at least one sacrificial layer 131. The first active material assembly 105 includes a first conductor layer 103 and two portions 102a and 102b of the first active material layer 102, which are respectively arranged on two surfaces of the first conductor layer 103. The first conductor layer 103 can be provided by a sintering process of a first conductor sheet 103' including a paste, and the two portions 102a and 102b of the first active material layer 102 can be provided by a sintering process of first active material sheets 102a' and 102b'. In addition, the sacrificial layer 131 can be provided by a sintering process of a sacrificial layer sheet 131'. In addition, the first electrode current collector layer 101 can be provided by a sintering process of a first electrode current collector sheet 101'.

[0108] Reference Fig.21 , the sacrificial layer 131 is removed from the sintered stack structure 640. The sacrificial layer 131 may be removed using an etchant for selectively dry-etching or wet-etching only the sacrificial layer 131. In an exemplary embodiment, hydrofluoric acid (HF) may be used as the etchant. However, for example, the embodiment is not limited thereto.

[0109] As described above, by removing the sacrificial layer 131, the first electrode structure 650 having a three-dimensional (3D) structure is completed. Fig. 22 As shown. The first electrode structure 650 includes a first electrode current collector layer 101 and the at least one first active material assembly 105 disposed on the first electrode current collector layer 101. Here, the at least one first active material assembly 105 may be disposed perpendicular to the first electrode current collector layer 101. The first active material assembly 105 may include a first conductor layer 103 and two portions 102a and 102b of the first active material layer 102 disposed on two surfaces of the first conductor layer 103, respectively. The first active material assembly 105 may also include a first conductor layer 103 and a first active material layer 102 disposed on one side of the first conductor layer 103.

[0110] The first electrode structure 650 may be manufactured using a process different from the above process. Figures 23 to 25 is a view illustrating another exemplary process of manufacturing the first electrode structure 650 .

[0111] Reference Fig.23 , in manufacturing Fig.18 After the sheet-like stacked structure 640' shown in FIG. 1 is formed, the sheet-like stacked structure 640' is sintered at a predetermined temperature. Through the sintering process, a sintered stacked structure 640 (see FIG. 1 ) is provided. Fig.24 ). Here, the sintered stacked structure 640 includes at least one first active material assembly 105 and at least one sacrificial layer 131. The first active material assembly 105 includes a first conductor layer 103 and two portions 102a and 102b of the first active material layer 102, respectively disposed on both sides of the first conductor layer 103. The first conductor layer 103 may be provided by a sintering process of a first conductor sheet 103' including a paste, and the two portions 102a and 102b of the first active material layer 102 may be provided by a sintering process of first active material sheets 102a' and 102b'. In addition, the sacrificial layer 131 may be provided by a sintering process of a sacrificial layer sheet 131'.

[0112] Reference Fig.24, a first electrode current collector sheet 101' is disposed on one surface of the sintered stacked structure 640. The first electrode current collector sheet 101' may be provided by coating one surface of the sintered stacked structure 640 with a paste including a current collector material such as Al, Ni, Ag, Au, Pt, or Pd. In an exemplary embodiment, the first electrode current collector sheet 101' may be disposed to have a thickness of, for example, about 1 μm to about 10 μm, but the embodiment is not limited thereto. Fig.25 , heat-treating the first electrode current collector sheet 101' including the paste at a predetermined temperature to form a first electrode current collector layer 101 (refer to Fig.21 ). Subsequently, a process of manufacturing the first electrode structure 650 by etching and removing the sacrificial layer 131 is performed, which is the same as the process described in the above embodiment.

[0113] Figures 26 to 30 is a view illustrating another exemplary process of manufacturing the first electrode structure 650 .

[0114] Reference Fig.26 , in manufacturing Fig.16 After the sheet-like stacked structure 630' is formed, the sheet-like stacked structure 630' is sintered at a predetermined temperature. The sintered stacked structure 630 (see Fig. 27 ). Here, the sintered stacked structure 630 includes at least one first active material assembly 105 and at least one sacrificial layer 131. The first active material assembly 105 includes a first conductor layer 103 and two portions 102a and 102b of the first active material layer 102, respectively disposed on both sides of the first conductor layer 103. The first conductor layer 103 may be provided by a sintering process of a first conductor sheet 103' including a paste, and the two portions 102a and 102b of the first active material layer 102 may be provided by a sintering process of first active material sheets 102a' and 102b'. In addition, the sacrificial layer 131 may be provided by a sintering process of a sacrificial layer sheet 131'.

[0115] Reference Fig. 27 The sintered laminated structure 630 is cut by the blade 60, so that the sintered laminated structure 630 is divided into a plurality of sintered laminated structures 640 each having a desired size. One of the plurality of divided sintered laminated structures 640 is Fig.28 See Fig.29, a first electrode current collector sheet 101' is disposed on one surface of the sintered stacked structure 640. In an exemplary embodiment, the first electrode current collector sheet 101' may be provided by coating one surface of the sheet-like stacked structure 640 with a paste including a current collector material such as Al, Ni, Ag, Au, Pt, or Pd. Although the first electrode current collector sheet 101' may be disposed to have a thickness of, for example, about 1 μm to about 10 μm, the embodiment is not limited thereto. Fig.30 The first electrode current collector sheet 101' including the paste is heat-treated at a predetermined temperature to form the first electrode current collector layer 101. Subsequently, a process of manufacturing the first electrode structure 650 by etching and removing the sacrificial layer 131 is performed, which is the same as that described in the above embodiment.

[0116] A method of manufacturing the secondary battery 600 including the first electrode structure 650 manufactured as described above will now be described.

[0117] Reference Fig.31 , an electrolyte layer 120 is disposed on the first electrode structure 650. The electrolyte layer 120 may be deposited on the surface of the first active material assembly 105 and the surface of the first electrode current collector layer 101 by, for example, performing chemical vapor deposition (CVD), atomic layer deposition (ALD), or sputtering. The electrolyte layer 120 is a solid electrolyte and may include an amorphous ceramic such as lithium phosphorus oxynitride (LiPON). However, the embodiment is not limited thereto. Therefore, the first surface of the electrolyte layer 120 may be in a zigzag shape to contact the surface of the first active material layer 102 and the surface of the first electrode current collector layer 101.

[0118] Reference Fig.32 , a second active material layer 112 is provided on the electrolyte layer 120. Here, the second active material layer 112 may be provided to fill the valley defined by the second surface of the zigzag-shaped electrolyte layer 120 between the first active material assemblies 105. The second active material layer 112 may be a negative electrode. In this case, the second active material layer 112 may include lithium, but the embodiment is not limited thereto. The second active material layer 112 may be provided, for example, by depositing lithium on the electrolyte layer 120 by evaporation or by filling the valley between the first active material assemblies 105 with molten lithium by means of osmotic pressure. However, the embodiment is not limited thereto, and the second active material layer 112 may be provided by other methods.

[0119] Reference Fig.33 , a second electrode current collector layer 111 is disposed on the second active material layer 112 to complete the manufacture of the secondary battery 600. Here, the second electrode current collector layer 111 as a negative electrode current collector may include, for example, copper (Cu), but the embodiment is not limited thereto.

[0120] As described above, due to the use of the first active material sheet 102' and the sacrificial layer sheet 131', the time required to manufacture the first electrode structure 650 having a 3D structure can be reduced. In addition, because the ratio of the length of the first active material assembly 105 to the width of the first active material assembly 105 in the first electrode structure 650, that is, the aspect ratio of the first active material assembly 105 can be greatly improved, the energy density of the secondary battery 600 can be improved. As described above, the case where the first and second active material layers 102 and 112 are respectively the positive electrode active material and the negative electrode active material has been described. However, the embodiment is not limited thereto, and the first and second active material layers 102 and 112 may also be respectively the negative electrode active material and the positive electrode active material.

[0121] Fig.34 is a cross-sectional view of a structure of a secondary battery 600' according to another exemplary embodiment. Fig.11 , the second active material layer 112 completely fills the concave portion defined by the second surface of the electrolyte layer 120 provided in a zigzag shape. Fig.34 As shown, similar to the electrolyte layer 120, the second active material layer 112 may be provided in a zigzag shape along the second surface of the electrolyte layer 120. Therefore, a blank space in which the second active material layer 112 is not filled may be defined between the first active material assemblies 105. In an exemplary embodiment, the blank space may be provided, for example, by adjusting the amount of the second active material deposited when forming the second active material layer 112. Such a blank space may operate as a buffer space for mitigating a total volume change of the secondary battery 600' according to the volume change of the first and second active material layers 102 and 112 during the charge and discharge operation of the secondary battery 600'.

[0122] Fig.35 is a cross-sectional view of a structure of a secondary battery 700 according to another exemplary embodiment.

[0123] Reference Fig.35 , the secondary battery 700 may include a first electrode structure 750 having a 3D structure and an electrolyte layer 120, a second active material layer 112, and a second electrode current collector layer 111 sequentially disposed on the first electrode structure 750. The first electrode structure 750 includes a first electrode current collector layer 101 and at least one first active material layer 102 disposed on the first electrode current collector layer 101. The first active material layer 102 may be disposed perpendicular to the first electrode current collector layer 101. The first electrode structure 750 may be, for example, a positive electrode structure. However, the embodiment is not limited thereto, and the first electrode structure 750 may also be a negative electrode structure.

[0124] The electrolyte layer 120 is disposed on the surface of the first electrode structure 750. The electrolyte layer 120 may be deposited in a zigzag shape on the surface of the first active material layer 102 and the surface of the first electrode current collector layer 101. The second active material layer 112 is disposed on the electrolyte layer 120. Here, the second active material layer 112 may be provided to fill the space between the first active material layers 102. The second electrode current collector layer 111 is disposed on the second active material layer 112. When the first electrode structure 750 is a positive electrode structure, the second active material layer 112 and the second electrode current collector layer 111 may be a negative electrode and a negative electrode current collector, respectively. In addition, when the first electrode structure 750 is a negative electrode structure, the second active material layer 112 and the second electrode current collector layer 111 may be a positive electrode and a positive electrode current collector, respectively.

[0125] Figures 36 to 41 It is used to describe manufacturing Fig.35 FIG. 7 is a view of a method of manufacturing a secondary battery 700 .

[0126] Reference Fig.36 , alternately stacking at least one first active material sheet 102' and at least one sacrificial layer sheet 131', thereby providing a sheet-like stacked structure 730'. Here, for example, the first active material sheet 102' may have a thickness of about 1 μm to about 30 μm, and the sacrificial layer sheet 131' may have a thickness of about 1 μm to about 30 μm. However, the embodiment is not limited thereto. The manufacture of the first active material sheet 102' and the sacrificial layer sheet 131' has been described above, so the description thereof will be omitted. Subsequently, the sheet-like stacked structure 730' is cut using a blade 60 (refer to Fig.17 ) is cut and divided into a plurality of sheet-like stacked structures 740' each having a desired size. One of the plurality of sheet-like stacked structures 740' after being divided is Fig.37 Shown in.

[0127] Reference Fig.38 , a first electrode current collector sheet 101' is provided on one surface of the divided sheet-like stacked structure 740'. In an exemplary embodiment, the first electrode current collector sheet 101' may be provided by coating one surface of the sheet-like stacked structure 740' with a paste including a current collector material such as Al, Ni, Ag, Au, Pt or Pd. In an exemplary embodiment, the first electrode current collector sheet 101' may be provided to have a thickness of, for example, about 1 μm to about 10 μm, but the embodiment is not limited thereto. Next, the sheet-like stacked structure 740' and the first electrode current collector sheet 101' are sintered at a predetermined temperature. Here, the sintering temperature may be, for example, about 1000°C to about 1050°C, but the embodiment is not limited thereto. Through the sintering process, a sintered stacked structure 740 (refer to Fig.39 ) and the first electrode current collector layer 101 (refer to Fig.39 ). Here, the sintered stacked structure 740 includes at least one first active material layer 102 and at least one sacrificial layer 131. The first active material layer 102 may be provided by a sintering process of a first active material sheet 102', and the sacrificial layer 131 may be provided by a sintering process of a sacrificial layer sheet 131'. In addition, the first electrode current collector layer 101 may be provided by a sintering process of a first electrode current collector sheet 101' including a paste.

[0128] Reference Fig.39 , the sacrificial layer 131 is removed from the sintered stacked structure 740 by etching. Thus, when the sacrificial layer 131 is removed, Fig.40 As shown, a first electrode structure 750 having a 3D structure is completed. The first electrode structure 750 includes a first electrode current collector layer 101 and at least one first active material layer 102 disposed on the first electrode current collector layer 101. Here, the at least one first active material layer 102 may be disposed perpendicular to the first electrode current collector layer 101.

[0129] As described above, it is described that the first electrode structure 750 is manufactured through the sintering process and the sacrificial layer removal process after the first electrode current collector sheet 101' is disposed on one surface of the divided sheet-like stacked structure 740'. However, it is also possible to manufacture the first electrode structure 750 by performing the same Figures 23 to 25 The first electrode structure 750 is manufactured by a process similar to the process shown in FIG. That is, after the divided sheet-like stacked structure 740' is sintered and thus the sintered stacked structure 740 is provided, the first electrode current collector layer 101 is provided on one surface of the sintered stacked structure 740. Subsequently, the first electrode structure 750 may be manufactured by performing a process of removing the sacrificial layer 131. In addition, the first electrode structure 750 may also be manufactured by performing the same process as FIG. Figures 26 to 30 That is, after sintering the sheet-like stacked structure and thus providing the sintered stacked structure, the sintered stacked structure is cut and thus divided into the plurality of sintered stacked structures 740. Then, the first electrode current collector layer 101 is provided on one surface of the divided sintered stacked structures 740 and the sacrificial layer 131 is removed, so that the first electrode structure 750 can be manufactured.

[0130] Reference Fig.41 , the electrolyte layer 120 , the second active material layer 112 , and the second electrode current collector layer 111 are sequentially disposed on the first electrode structure 750 manufactured through the above process, so that the secondary battery 700 may be completed.

[0131] Fig.42 is a cross-sectional view of a structure of a secondary battery 800 according to another exemplary embodiment.

[0132] Reference Fig.42 , the secondary battery 800 may include a first electrode structure 850 having a 3D structure and an electrolyte layer 120, a second active material layer 112, and a second electrode current collector layer 111 sequentially disposed on the first electrode structure 850. The first electrode structure 850 includes a first electrode current collector layer 101, a base layer 115 disposed on the first electrode current collector layer 101, and at least one first active material layer 102 disposed on the base layer 115. The base layer 115 and the first active material layer 102 may include the same active material. The first active material layer 102 may be disposed perpendicular to the first electrode current collector layer 101 and the base layer 115. The first electrode structure 850 may be, for example, a positive electrode structure. However, the embodiment is not limited thereto, and the first electrode structure 850 may be a negative electrode structure.

[0133] The electrolyte layer 120 is disposed on the first electrode structure 850. The electrolyte layer 120 may be deposited on the surface of each first active material layer 102 and the surface of the base layer 115 in a zigzag shape. The second active material layer 112 is disposed on the electrolyte layer 120. Here, the second active material layer 112 may be provided to fill the space between the first active material layers 102. The second electrode current collector layer 111 is disposed on the second active material layer 112. When the first electrode structure 850 is a positive electrode structure, the second active material layer 112 and the second electrode current collector layer 111 may be a negative electrode and a negative electrode current collector, respectively. In addition, when the first electrode structure 850 is a negative electrode structure, the second active material layer 112 and the second electrode current collector layer 111 may be a positive electrode and a positive electrode current collector, respectively.

[0134] Figures 43 to 47 It is used to describe manufacturing Fig.42 FIG. 8 is a view of a method of manufacturing a secondary battery 800 .

[0135] Reference Fig.43 , alternately stacking at least one first active material sheet 102' and at least one sacrificial layer sheet 131', thereby providing a sheet-like stacked structure. The manufacture of the first active material sheet 102' and the sacrificial layer sheet 131' has been described above, so the description thereof will be omitted. Subsequently, the sheet-like stacked structure is cut using a blade, thereby being divided into a plurality of sheet-like stacked structures 840' each having a desired size. One of the divided plurality of sheet-like stacked structures 840' is Fig.43 Shown in.

[0136] Reference Fig.44, a substrate 115' and a first electrode current collector sheet 101' are sequentially arranged on one surface of the sheet-like stacked structure 840'. The substrate 115' can be manufactured in the same manner as the first active material sheet 102' using the same material as the first active material sheet 102'. The first electrode current collector sheet 101' can be provided by coating the substrate 115' with a paste including a current collector material such as Al, Ni, Ag, Au, Pt or Pd. Next, the sheet-like stacked structure 840', the substrate 115' and the first electrode current collector sheet 101' are sintered at a predetermined temperature. Through this sintering process, a stacked structure 840 (see Fig.45 ), base 115 (reference Fig.45 ) and the first electrode current collector layer 101 (refer to Fig.45 ). Here, the stacked structure 840 includes at least one first active material layer 102 and at least one sacrificial layer 131. The at least one first active material layer 102 may be provided by a sintering process of a first active material sheet 102', and the at least one sacrificial layer 131 may be provided by a sintering process of a sacrificial layer sheet 131'. In addition, the base layer 115 may be provided by a sintering process of a substrate 115', and the first electrode current collector layer 101 may be provided by a sintering process of a first electrode current collector sheet 101' including a paste.

[0137] Reference Fig.45 , the sacrificial layer 131 is removed from the sintered stacked structure 840 by etching. Thus, the first electrode structure 850 having a 3D structure is completed. Fig.46 The first electrode structure 850 includes a first electrode current collector layer 101, a base layer 115 disposed on the first electrode current collector layer 101, and the at least one first active material layer 102 disposed on the base layer 115. Here, the at least one first active material layer 102 may be disposed perpendicular to the first electrode current collector layer 101 and the base layer 115.

[0138] As described above, the method of manufacturing the first electrode structure 850 by performing the sintering process and the process of removing the sacrificial layer 131 after forming the base sheet 115' and the first electrode current collector sheet 101' on one surface of the divided sheet-like stacked structure 840' has been described. Figures 23 to 25 That is, after providing the stacked structure 840 by sintering the divided sheet-like stacked structure 840', the base layer 115 and the first electrode current collector layer 101 are provided on one surface of the stacked structure 840. Subsequently, the first electrode structure 850 may be manufactured by performing a process of removing the sacrificial layer 131. In addition, the first electrode structure 850 may also be manufactured by performing the same process as Figures 26 to 30That is, after providing a stacked structure by sintering a sheet-like stacked structure, the stacked structure is cut and thus divided into a plurality of stacked structures 840. Then, the base layer 115 and the first electrode current collector layer 101 are disposed on one surface of the divided stacked structure 840 and the sacrificial layer 131 is removed, so that the first electrode structure 850 can be manufactured.

[0139] Reference Fig.47 , the electrolyte layer 120 , the second active material layer 112 , and the second electrode current collector layer 111 are sequentially disposed on the first electrode structure 850 , so that the secondary battery 800 may be completed.

[0140] Fig.48 is a cross-sectional view of a structure of a secondary battery 800' according to another exemplary embodiment. Fig.42 In the secondary battery 800, the second active material layer 112 completely fills the concave portion defined by the zigzag-shaped electrolyte layer 120 between the first active material layers 102. Fig.48 As shown, the second active material layer 112 may be provided in a zigzag shape along the surface of the electrolyte layer 120, like the electrolyte layer 120. Therefore, a blank space in which the second active material layer 112 is not filled may be defined between the first active material layers 102. In an exemplary embodiment, the blank space may be provided, for example, by adjusting the amount of the second active material deposited when forming the second active material layer 112. Such a blank space may operate as a buffer space for mitigating a total volume change of the secondary battery 800' according to the volume change of the first and second active material layers 102 and 112 during the charge and discharge operation of the secondary battery 800'.

[0141] Although one or more example exemplary embodiments have been described with reference to the accompanying drawings, persons skilled in the art will understand that various changes in form and details may be made therein without departing from the spirit and scope defined by the claims.

Claims

1. A battery comprising: a first electrode current collector layer having a plate shape; a plurality of first active material layers electrically contacting the first electrode current collector layer and substantially perpendicular to the first electrode current collector layer; a conductor layer electrically contacting the first electrode current collector layer and interposed between the plurality of first active material layers; a second active material layer including a plurality of first portions parallel to and arranged alternately with the plurality of first active material layers, and a second portion facing and parallel to the first electrode current collector layer and extending from the plurality of first portions, the second portion connecting the first portions adjacent to each other and separated by the first active material layer to each other; and An electrolyte layer is disposed between the plurality of first active material layers and the plurality of first portions of the second active material layer, between the plurality of first active material layers and the second portions of the second active material layer, and between the plurality of first portions of the second active material layer and the first electrode current collector layer. 2 . The battery according to claim 1 , wherein the conductor layer is inserted into at least one of the plurality of first active material layers, and both side surfaces of the conductor layer contact the at least one of the plurality of first active material layers. 3 . The battery as claimed in claim 1 , wherein the conductor layer has an extended plate shape protruding substantially perpendicularly to the first electrode current collector layer. 4 . The battery of claim 1 , wherein a first end of the conductor layer contacts the first electrode current collector layer, and a second end of the conductor layer contacts the electrolyte layer, wherein the second end is opposite to the first end. 5 . The battery of claim 1 , wherein a first end of the conductor layer contacts the first electrode current collector layer, and a second end of the conductor layer contacts at least one of the plurality of first active material layers, wherein the second end is opposite to the first end.

6. A battery as described in claim 1, wherein the electrolyte layer includes a solid electrolyte and winds between the plurality of first active material layers and the plurality of first portions of the second active material layer, between the plurality of first active material layers and the second portions of the second active material layer, and between the plurality of first portions of the second active material layer and the first electrode current collector layer.

7. The battery of claim 1, wherein the plurality of first portions and the second portion comprise the same material.

8. A battery comprising: a first electrode current collector layer and a second electrode current collector layer facing each other; a plurality of first active material layers electrically contacting the first electrode current collector layer and substantially perpendicular to the first electrode current collector layer; an electrolyte layer provided in a zigzag shape along surfaces of the plurality of first active material layers and a surface of the first electrode current collector layer, and including a first surface contacting the plurality of first active material layers and the first electrode current collector layer and a second surface on a side opposite to the first surface; a second active material layer electrically contacting the second electrode current collector layer and disposed along the second surface of the electrolyte layer to continuously cover the plurality of first active material layers, the electrolyte layer and the second electrode current collector layer being completely separated by the second active material layer; and A conductor layer electrically contacts the first electrode current collector layer and is interposed between the plurality of first active material layers. 9 . The battery according to claim 8 , wherein the second active material layer completely fills a recess defined by the second surface of the electrolyte layer provided in a zigzag shape. 10 . The battery according to claim 8 , wherein the second active material layer is provided in a zigzag shape along the second surface of the electrolyte layer provided in a zigzag shape.

11. The battery according to claim 10, wherein Empty spaces in which the second active material layer is not filled are defined between the plurality of first active material layers.

12. A battery comprising: a first electrode current collector layer and a second electrode current collector layer facing each other; a plurality of first active material layers electrically contacting the first electrode current collector layer and perpendicular to the first electrode current collector layer; an electrolyte layer provided in a zigzag shape along surfaces of the plurality of first active material layers and a surface of the first electrode current collector layer, and including a first surface contacting the plurality of first active material layers and the first electrode current collector layer and a second surface on a side opposite to the first surface; and a second active material layer electrically contacting the second electrode current collector layer and disposed along the second surface of the electrolyte layer to continuously cover the plurality of first active material layers, the electrolyte layer and the second electrode current collector layer being completely separated by the second active material layer, wherein empty spaces in which the second active material layer is not filled are defined between the plurality of first active material layers, and The second active material layer is provided in a zigzag shape along the second surface of the electrolyte layer in a zigzag shape.

13. The battery of claim 12, further comprising a base layer parallel to the first electrode current collector layer between the first electrode current collector layer and the first active material layer and between the first electrode current collector layer and the electrolyte layer, and the base layer comprises the same material as the first active material layer.

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