Secondary battery and method of manufacturing secondary battery

Patent metadata

Field	Value
Publication number	US-10651505-B2
Application number	US-201816003641-A
Country	US
Kind code	B2
Filing date	Jun 8, 2018
Priority date	Aug 8, 2017
Publication date	May 12, 2020
Grant date	May 12, 2020

Abstract

A secondary battery may include a plurality of cathode layers which have a porous structure including a plurality of pores, have a flat plate-shape, and are arranged to be spaced apart from each other in a direction. The secondary battery further includes an electrolyte layer including a first electrolyte film and a second electrolyte film, where the first electrolyte film surrounds external surfaces of the cathode layers, and the second electrolyte film is disposed in the pores of the cathode layers. The secondary battery further includes an anode layer surrounding the first electrolyte film.

First claim

What is claimed is:

1. A secondary battery comprising:
a plurality of cathode layers arranged spaced apart from each other in a direction, wherein each of the cathode layers has a porous structure including a plurality of pores and has a flat plate-shape;
an electrolyte layer comprising:
a first electrolyte film surrounding external surfaces of the cathode layers; and
a second electrolyte film disposed in the pores of the cathode layers; and

an anode layer surrounding the first electrolyte film.

2. The secondary battery of claim 1 , wherein a volume ratio of the pores to a total volume of the cathode layers is in a range from about 12 vol % to about 30 vol %.

3. The secondary battery of claim 2 , wherein an aspect ratio of a height direction to a thickness direction of each of the cathode layers is in a range from about 3 to about 10.

4. The secondary battery of claim 2 , wherein each of the cathode layers has a thickness in a range of about 30 μm to about 50 μm.

5. The secondary battery of claim 1 , wherein each of the cathode layers comprises:
a first surface and a second surface facing each other; and
a third surface and a fourth surface facing each other,
wherein
the third and fourth surfaces extend between the first and second surfaces and have an area smaller than an area of the first and second surfaces, and
the cathode layers are arranged in a way such that the first surface of a cathode layer of the cathode layers and the second surface of an adjacent cathode layer, which is adjacent to the cathode layer among the cathode layers, face each other.

6. The secondary battery of claim 5 , wherein the first electrolyte film and the anode layer are disposed on the first surface and the second surface of each of the cathode layers.

7. The secondary battery of claim 1 , further comprising:
a cathode current collecting layer facing and contacting an end portion of each of the cathode layers; and
an anode current collecting layer contacting a portion of the anode layer and facing the cathode current collecting layer.

8. The secondary battery of claim 7 , wherein
the cathode layers, the electrolyte layer, the anode layer, the cathode current collecting layer and the anode current collecting layer collectively define a battery cell, and
the secondary battery has a stacking structure in which battery cells are stacked one on another.

9. The secondary battery of claim 1 , wherein each of the cathode layers is a sintered body comprising a cathode active material.

10. The secondary battery of claim 9 , wherein the cathode active material is a lithium transition metal oxide.

11. The secondary battery of claim 6 , wherein a portion of the first electrolyte film extends from the cathode layer to the adjacent cathode layer in the direction.

12. The secondary battery of claim 6 , wherein a portion of the anode layer extends from the cathode layer to the adjacent cathode layer in the direction.

13. The secondary battery of claim 1 , wherein a gap between two adjacent cathode layers is greater than 50% of a thickness of each of the cathode layers.

14. The secondary battery of claim 1 , wherein the secondary battery is a lithium secondary battery.

15. A method of manufacturing a secondary battery, the method comprising:
arranging a plurality of cathode layers to be spaced apart from each other in a direction on a cathode current collecting layer, wherein each of the cathode layers has a porous structure including a plurality of pores and has a flat plate-shape; and
coating an electrolyte layer on the cathode layers.

16. The method of claim 15 , wherein a volume ratio of the pores to a total volume of the cathode layers is in a range from about 12 vol % to about 30 vol %.

17. The method of claim 16 , wherein each of the cathode layers has a thickness in a range of about 30 μm to about 50 μm.

18. The method of claim 15 , wherein the electrolyte layer comprises:
a first electrolyte film surrounding external surfaces of the cathode layers; and
a second electrolyte film disposed in the pores.

19. The method of claim 15 , wherein the coating the electrolyte layer on the cathode layers comprises using a spin coating method or a dip coating method.

20. The method of claim 15 , wherein each of the cathode layers is a sintered body comprising a cathode active material.

Assignees

• Samsung Electronics Co Ltd

Inventors

• Jeong Huisu
• Kim Kyounghwan
• Park Hwiyeol
• Lee Junhyeong
• Lim Sungjin
• Heo Jin S

Classifications

• H01M2004/028

  Positive electrodes · CPC title

• H01M10/0525

  Rocking-chair batteries, i.e. batteries with lithium insertion or intercalation in both electrodes; Lithium-ion batteries · CPC title

• H01M4/485

  of mixed oxides or hydroxides for inserting or intercalating light metals, e.g. LiTi2O4 or LiTi2OxFy (H01M4/505, H01M4/525 take precedence) · CPC title

• H01M2300/0094

  in the form of layered products, e.g. coatings · CPC title

• H01M10/0562

  Solid materials · CPC title