Secondary battery and method of manufacturing the same

Patent metadata

Field	Value
Publication number	US-10243179-B2
Application number	US-201615270191-A
Country	US
Kind code	B2
Filing date	Sep 20, 2016
Priority date	Nov 25, 2015
Publication date	Mar 26, 2019
Grant date	Mar 26, 2019

Abstract

A secondary battery including: a plurality of unit cells, wherein each unit cell of the plurality of unit cells includes a cathode extending in a top to bottom direction, an electrolyte membrane surrounding at least three surfaces of the cathode, and an anode surrounding at least a portion of the electrolyte membrane, wherein unit cells of the plurality of unit cells are spaced apart from each other in a left to right direction, with cavities therebetween, and a support member configured to support the plurality of unit cells in the left to right direction and disposed between unit cells of the plurality of unit cells.

First claim

What is claimed is:

1. A secondary battery comprising:
a plurality of unit cells, wherein each unit cell of the plurality of unit cells comprises
a cathode extending in a top to bottom direction,
an electrolyte membrane surrounding at least three surfaces of the cathode, and
an anode surrounding at least a portion of the electrolyte membrane,

wherein unit cells of the plurality of unit cells are spaced apart from each other in a left to right direction, with empty cavities therebetween, and
a support member configured to support the plurality of unit cells in the left to right direction and disposed between unit cells of the plurality of unit cells.

2. The secondary battery of claim 1 , wherein a width of each of the cavities in the left to right direction is from about one time to about five times greater than a width of the cathode in the left to right direction.

3. The secondary battery of claim 1 , wherein a width of each of the cavities in the left to right direction is from about one time to about five times greater than a thickness of the anode.

4. The secondary battery of claim 1 , wherein a height of the support member is from about 5% to about 15% of a height of the cathode.

5. The secondary battery of claim 1 , wherein a height of the support member is greater than a thickness of the electrolyte membrane.

6. The secondary battery of claim 1 , wherein the support member is elastically deformable.

7. The secondary battery of claim 6 , wherein the support member has a Young's modulus from about 0.1 gigapascal to about 10 gigpascals.

8. The secondary battery of claim 1 , wherein the support member is ionically conductive.

9. The secondary battery of claim 1 , wherein the support member is disposed between electrolyte membranes of adjacent unit cells.

10. The secondary battery of claim 9 , wherein the support member is disposed below the anode.

11. The secondary battery of claim 1 , wherein a volume of the anode during charging of the secondary battery is from about 150% to about 400% of a volume of the anode during discharging of the secondary battery.

12. The secondary battery of claim 1 , wherein a volume of the cathode during charging of the secondary battery is from about 110% to about 130% of a volume of the cathode during discharging of the secondary battery.

13. The secondary battery of claim 1 , further comprising:
a cathode current collector in electrical contact with an end portion of the cathode of each unit cell of the plurality of unit cells.

14. The secondary battery of claim 13 , further comprising:
an inner current collector disposed in the cathode of each unit cell of the plurality of unit cells, and electrically connected to the cathode current collector.

15. The secondary battery of claim 1 , further comprising:
an anode current collector in electrical contact with the anode.

16. The secondary battery of claim 15 , wherein the anode current collector is in electrical contact with a surface of the anode facing the cavity.

17. The secondary battery of claim 1 , wherein the cathode of each unit cell of the plurality of unit cells further extends in a front to rear direction.

18. A method of manufacturing a secondary battery, the method comprising:
removing a plurality of sacrificial layers from a stacked structure, the stacked structure comprising a plurality of cathodes and the plurality of sacrificial layers alternately stacked in a left to right direction to space each cathode of the plurality of cathodes apart from each other in the left to right direction;
forming an electrolyte membrane on surfaces of each cathode of the plurality of cathodes spaced apart from each other;
forming a support member supporting the electrolyte membrane in the left to right direction, the support member being formed between the electrolyte membranes formed on surfaces of the plurality of cathodes spaced apart from each other; and
forming an anode on surfaces of the electrolyte membranes,
wherein the forming of the anode comprises forming the anode such that an empty cavity is formed between the anodes formed on facing surfaces of the electrolyte membranes.

19. The method of claim 18 , wherein the forming of the anodes comprises forming the anodes such that a width of each of the cavities in the left to right direction is from about one time to about five times greater than a width of each of the cathodes in the left to right direction.

20. The method of claim 18 , wherein the forming of the anodes comprises forming the anodes such that a width of each of the cavities in the left to right direction is from about one time to about five times greater than a thickness of the anode.

21. The method of claim 18 , wherein the forming of the support member comprises forming the support member such that a height of the support member is from about 5% to about 15% of a height of each of the cathode.

22. The method of claim 18 , wherein the support member is elastically deformable.

23. The method of claim 22 , wherein the support member has a Young's modulus from about 0.1 gigapascal to about 10 gigapascals.

24. The method of claim 18 , wherein the support member is ionically conductive.

25. The method of claim 18 , further comprising:
forming a cathode current collector in electrical contact with the plurality of cathodes; and
forming an anode current collector in electrical contact with the anode.

26. The method of claim 25 , wherein the forming of the anode current collector comprises forming the anode current collector on a surface of each cathode of the plurality of cathodes.

27. The method of claim 18 , wherein the forming of the support member comprises:
inserting a portion of the electrolyte membrane into a pre-support member; and
removing a portion of the pre-support member and a portion of the portion of the electrolyte membrane to expose the cathode to an outside of the secondary battery.

Assignees

• Samsung Electronics Co Ltd

Inventors

• Jeong Huisu
• Cho Kyunghoon
• Yang Hojung
• Park Hwiyeol
• Heo Jin S

Classifications

• H01M10/0436 Primary

  Small-sized flat cells or batteries for portable equipment · CPC title

• H01M50/209

  adapted for prismatic or rectangular cells (H01M50/216 takes precedence) · CPC title

• H01M10/0562

  Solid materials · CPC title

• H01M10/0585

  of accumulators having only flat construction elements, i.e. flat positive electrodes, flat negative electrodes and flat separators · CPC title

• H01M4/13 Primary

  Electrodes for accumulators with non-aqueous electrolyte, e.g. for lithium-accumulators; Processes of manufacture thereof · CPC title