Metal-air battery having folded structure and method of manufacturing the same

Abstract

A metal-air battery including: a negative electrode metal layer; a negative electrode electrolyte layer disposed on the negative electrode metal layer; a positive electrode layer disposed on the negative electrode electrolyte layer, the positive electrode layer comprising a positive electrode material which is capable of using oxygen as an active material; and a gas diffusion layer disposed on the positive electrode layer, wherein the negative electrode electrolyte layer is between the negative electrode metal layer and the positive electrode layer; wherein the negative electrode metal layer, the negative electrode electrolyte layer, and the positive electrode layer are disposed on the gas diffusion layer so that the positive electrode layer contacts a lower surface and an opposite upper surface of the gas diffusion layer, and wherein one side surface of the gas diffusion layer is exposed to an outside.

What is claimed is: 
     
         1 . A method of manufacturing a metal-air battery, the method comprising:
 disposing a negative electrode electrolyte layer on a negative electrode metal layer;   disposing a positive electrode layer, which is capable of using oxygen as an active material, on the negative electrode electrolyte layer;   disposing a gas diffusion layer on a portion of the positive electrode layer; and   bending the negative electrode metal layer, the negative electrode electrolyte layer, and the positive electrode layer on the gas diffusion layer so that the positive electrode layer contacts a lower surface and an opposite upper surface of the gas diffusion layer,   wherein one first side surface of the gas diffusion layer is exposed to the outside.   
     
     
         2 . The method of  claim 1 , further comprising:
 bending the negative electrode metal layer, the negative electrode electrolyte layer, and the positive electrode layer by 180 degrees so that the negative electrode metal layer is folded and the positive electrode layer is exposed upward;   disposing an additional gas diffusion layer on a portion of the positive electrode layer; and   bending the negative electrode metal layer, the negative electrode electrolyte layer, and the positive electrode layer on the additional gas diffusion layer so that the positive electrode layer contacts an upper surface of the additional gas diffusion layer.   
     
     
         3 . The method of  claim 2 , wherein the negative electrode metal layer, the negative electrode electrolyte layer, and the positive electrode layer have a serpentine configuration such that the positive electrode layer contacts a lower surface and an upper surface of each of the gas diffusion layer and the additional gas diffusion layer. 
     
     
         4 . The method of  claim 3 , wherein, between the gas diffusion layer and the additional gas diffusion layer, the negative electrode metal layer, the negative electrode electrolyte layer, and the positive electrode layer are bent by 180 degrees so that the negative electrode metal layer is in a folded configuration. 
     
     
         5 . The method of  claim 2 , wherein same side surfaces of the gas diffusion layer and the additional gas diffusion layer are exposed to the outside. 
     
     
         6 . The method of  claim 1 , further comprising:
 disposing a negative electrode collector which contacts a bend portion of the negative electrode metal layer.   
     
     
         7 . The method of  claim 6 , wherein the negative electrode collector extends in a direction perpendicular to a major surface of each of the negative electrode metal layer, the negative electrode electrolyte layer, the positive electrode layer, and the gas diffusion layer. 
     
     
         8 . The method of  claim 1 , wherein an end of an exposed side surface of the gas diffusion layer protrudes from the negative electrode metal layer, the negative electrode electrolyte layer, and the positive electrode layer. 
     
     
         9 . The method of  claim 8 , further comprising:
 disposing a positive electrode collector disposed on a protruding end of the gas diffusion layer.   
     
     
         10 . The method of  claim 1 ,
 wherein the negative electrode electrolyte layer comprises a separation layer which is ionically conductive and substantially impermeable to oxygen, and an electrolyte,   wherein the separation layer comprises a porous film, and   wherein the electrolyte is disposed in pores of the porous film.