Secondary battery having high rate capability and high energy density and method of manufacturing the same

Abstract

A secondary battery includes a first electrode collector layer and a second electrode collector layer, which face each other, a plurality of first active material layers that electrically contact the first electrode collector layer and are substantially perpendicular to the first electrode collector layer, a plurality of second active material layers that electrically contact the second electrode collector layer and are substantially perpendicular to the second electrode collector layer, and a first conductor layer that electrically contacts the first electrode collector layer and is inserted into the plurality of first active material layers.

What is claimed is: 
     
         1 . A battery comprising:
 a first electrode collector layer and a second electrode collector layer, which face each other;   a plurality of first active material layers which electrically contact the first electrode collector layer and are substantially perpendicular to the first electrode collector layer;   a plurality of second active material layers which electrically contact the second electrode collector layer and are substantially perpendicular to the second electrode 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 collector layer, and between the plurality of second active material layers and the first electrode collector layer; and   a first conductor layer which electrically contacts the first electrode collector layer and is interposed in the plurality of first active material layers.   
     
     
         2 . The battery of  claim 1 , wherein the plurality of first active material layers contact a first surface of the first electrode collector layer, the plurality of second active material layers contact a second surface of the second electrode collector layer, and the first surface of the first electrode collector layer and the second surface of the second electrode collector layer face each other. 
     
     
         3 . The battery of  claim 2 , wherein the plurality of first active material layers are substantially perpendicular to the first surface of the first electrode collector layer, and the plurality of second active material layers are substantially perpendicular to the second surface of the second electrode collector layer. 
     
     
         4 . The battery of  claim 3 , wherein the plurality of first active material layers and the plurality of second active material layers have a plate shape and are alternately arranged in parallel to each other. 
     
     
         5 . The battery of  claim 3 , wherein the first conductor layer has an extended plate shape which protrudes substantially perpendicular to the first surface of the first electrode collector layer. 
     
     
         6 . The battery of  claim 5 , wherein the first conductor layer is inserted into at least one of the plurality of first active material layers, and two side surfaces of the first conductor layer contact the at least one of the plurality of first active material layers. 
     
     
         7 . The battery of  claim 5 , wherein a first end of the first conductor layer contacts the first surface of the first electrode collector layer, and a second end of the first conductor layer contacts the electrolyte layer, wherein the second end is opposite to the first end. 
     
     
         8 . The battery of  claim 5 , wherein a first end of the first conductor layer contacts the first surface of the first electrode collector layer, and a second end of the first conductor layer contacts at least one of the plurality of first active material layers, wherein the second end is opposite to the first end. 
     
     
         9 . The battery of  claim 1 , wherein the electrolyte layer comprises a solid electrolyte. 
     
     
         10 . The battery of  claim 1 , wherein the electrolyte layer is wound 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 collector layer, and between the plurality of second active material layers and the first electrode collector layer. 
     
     
         11 . The battery of  claim 1 , further comprising a second conductor layer which electrically contacts the second electrode collector layer and is inserted into the plurality of second active material layers, wherein the second conductor layer has an extended plate shape protruding from the second electrode collector layer. 
     
     
         12 . The battery of  claim 11 , wherein the second conductor layer is inserted into at least one of the plurality of second active material layers, and two side surfaces of the second conductor layer contact the at least one of the plurality of second active material layers. 
     
     
         13 . The battery of  claim 11 , wherein a first end of the second conductor layer contacts the second electrode collector layer, and a second end of the second conductor layer contacts the electrolyte layer, wherein the second end is opposite to the first end. 
     
     
         14 . The battery of  claim 11 , wherein a first end of the second conductor layer contacts the second electrode collector layer, and a second end of the second conductor layer contacts at least one of the plurality of second active material layers, wherein the second end is opposite to the first end. 
     
     
         15 . The battery of  claim 1 , wherein the plurality of first active material layers comprises a positive electrode active material including sintered polycrystalline ceramics which provides a positive electrode, and the first conductor layer comprises at least one metal material of palladium (Pd), gold (Au), platinum (Pt), and silver (Ag) and an alloy thereof. 
     
     
         16 . A battery comprising:
 a first electrode collector layer having a plate shape;   a plurality of first active material layers which electrically contact the first electrode collector layer and are substantially perpendicular to the first electrode collector layer;   a conductor layer which electrically contacts the first electrode collector layer and is interposed in the plurality of first active material layers;   a second active material layer which comprises a plurality of first portions alternately arranged in parallel to the plurality of first active material layers and a second portion which faces and is parallel to the first electrode collector layer and extends from the plurality of first portions; and   an electrolyte layer which 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 portion of the second active material layer, and between the plurality of first portions of the second active material layer and the first electrode collector layer.   
     
     
         17 . The battery of  claim 16 , wherein the conductor layer is inserted into at least one of the plurality of first active material layers, and two side surfaces of the conductor layer contact the at least one of the plurality of first active material layers. 
     
     
         18 . The battery of  claim 16 , wherein the conductor layer has an extended plate shape protruding substantially perpendicular to the first electrode collector layer. 
     
     
         19 . The battery of  claim 16 , wherein a first end of the conductor layer contacts the first electrode collector layer and a second end of the conductor layer contacts the electrolyte layer, wherein the second end is opposite to the first end. 
     
     
         20 . The battery of  claim 16 , wherein a first end of the conductor layer contacts the first electrode 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. 
     
     
         21 . The battery of  claim 16 , wherein the electrolyte layer comprises a solid electrolyte and is wound 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 portion of the second active material layer, and between the plurality of first portions of the second active material layer and the first electrode collector layer. 
     
     
         22 . A battery comprising:
 a first electrode collector layer and a second electrode collector layer which face each other;   a plurality of first active material layers electrically contacting the first electrode collector layer and perpendicular to the first electrode 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 collector layer, and including a first surface contacting the plurality of first active material layers and the first electrode collector layer and a second surface at a side opposite to the first surface;   a second active material layer electrically contacting the second electrode collector layer and disposed along the second surface of the electrolyte layer; and   a conductive layer electrically contacting the first electrode collector layer and interposed in the plurality of first active material layers.   
     
     
         23 . The battery of  claim 22 , wherein the second active material layer completely fills a valley defined by the second surface of the electrolyte layer which is provided in a zigzag shape. 
     
     
         24 . The battery of  claim 22 , 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. 
     
     
         25 . The battery of  claim 24 , wherein an empty space in which the second active material layer is not completely filled is defined between the plurality of first active material layers. 
     
     
         26 . A method of manufacturing a battery, the method comprising:
 preparing a sheet stack structure in which at least one first active material sheet assembly and at least one sacrificial layer sheet are alternately stacked;   forming a stack structure in which at least one first active material assembly and at least one sacrificial layer are alternately stacked using the sheet stack structure;   forming a first electrode collector layer on one surface of the stack 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 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 collector layer.   
     
     
         27 . The method of  claim 26 , wherein the first active material sheet assembly comprises a first active material sheet. 
     
     
         28 . The method of  claim 27 , wherein the first active material sheet is provided by manufacturing a slurry comprising an active material in a form of a sheet, and the sacrificial layer sheet is provided by manufacturing a slurry comprising a sacrificial layer material in a form of a sheet. 
     
     
         29 . The method of  claim 27 , further comprising forming a base sheet which includes a same material as that of the first active material sheet between one surface of the stack structure and the first electrode collector layer. 
     
     
         30 . The method of  claim 27 , wherein the at least one first active material sheet assembly comprises a conductor sheet and the first active material sheet disposed on at least one surface of the conductor sheet, wherein the conductor sheet is provided by coating a paste comprising a collector material on the first active material sheet. 
     
     
         31 . The method of  claim 26 , wherein the forming the stack structure and the first electrode collector layer comprises:
 cutting the sheet stack structure;   forming a first electrode collector sheet by coating a paste comprising a collector material on one surface of the cut sheet stack structure; and   forming the stack structure and the first electrode collector layer by sintering the cut sheet stack structure and the first electrode collector sheet.   
     
     
         32 . The method of  claim 26 , wherein the forming the stack structure and the first electrode collector layer comprises:
 cutting the sheet stack structure;   forming the stack structure by sintering the cut sheet stack structure;   forming a first electrode collector sheet by coating a paste comprising a collector material on one surface of the stack structure; and   forming the first electrode collector layer by heat-treating the first electrode collector sheet.   
     
     
         33 . The method of  claim 26 , wherein the forming the stack structure and the first electrode collector layer comprises:
 sintering the sheet stack structure;   forming the stack structure by cutting the sintered sheet stack structure;   forming a first electrode collector sheet by coating a paste comprising a collector material on one surface of the stack structure; and   forming the first electrode collector layer by heat-treating the first electrode collector sheet.   
     
     
         34 . The method of  claim 26 , wherein the sacrificial layer is removed using an etchant which selectively etches only the sacrificial layer. 
     
     
         35 . A battery comprising:
 a first electrode collector layer and a second electrode collector layer which face each other;   a plurality of first active material layers electrically contacting the first electrode collector layer and perpendicular to the first electrode 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 collector layer, and including a first surface contacting the plurality of first active material layers and the first electrode collector layer and a second surface at a side opposite to the first surface; and   a second active material layer electrically contacting the second electrode collector layer and disposed along the second surface of the electrolyte layer,   wherein an empty space in which the second active material layer is not completely filled is defined between the plurality of first active material layer, and   wherein the second active material layer is provided in a zigzag shape along the second surface of the electrolyte layer in a zigzag shape.   
     
     
         36 . The battery of  claim 35 , further comprising a base layer parallel to the first electrode collector layer between the first electrode collector layer and the first active material layer and between the first electrode collector layer and the electrolyte layer, and including a same material as that of the first active material layer.