Gas diffusion layer for metal-air battery, metal-air battery including the gas diffusion layer, and method of manufacturing the metal-air battery

A metal-air battery comprising:

• at least one positive electrode layer, which is configured for using oxygen as an active material and comprises a first surface and a second surface opposite the first surface;
• a gas diffusion layer on the first surface of the positive electrode layer and comprising a plurality of carbon fibers;
• an electrolyte layer on the second surface of the positive electrode layer;
• and
• a negative electrode metal layer on the electrolyte layer,
• wherein the positive electrode layer comprises a plurality of grooves formed in the first surface,
• wherein portions of the plurality of carbon fibers are in the grooves, and
• wherein the gas diffusion layer comprises:
• a first carbon fiber layer comprising a plurality of carbon fibers arranged on the positive electrode layer, and
• a second carbon fiber layer on the first carbon fiber layer and comprising a plurality of carbon fibers extending in a direction intersecting a direction in which each of the plurality of carbon fibers of the first carbon fiber layer extends.

A metal-air battery comprising:

• at least one positive electrode layer, which is configured for using oxygen as an active material and comprises a first surface and a second surface opposite the first surface;
• a gas diffusion layer on the first surface of the positive electrode layer and comprising a plurality of carbon fibers;
• an electrolyte layer on the second surface of the positive electrode layer;
• and
• a negative electrode metal layer on the electrolyte layer,
• wherein the positive electrode layer comprises a plurality of grooves formed in the first surface,
• wherein portions of the plurality of carbon fibers are in the grooves, and
• wherein the gas diffusion layer is a single layer and comprises a fold.

A metal-air battery comprising:

• at least one positive electrode layer, which is configured for using oxygen as an active material and comprises a first surface and a second surface opposite the first surface;
• a gas diffusion layer on the first surface of the positive electrode layer and comprising a plurality of carbon fibers;
• an electrolyte layer on the second surface of the positive electrode layer;
• and
• a negative electrode metal layer on the electrolyte layer,
• wherein the positive electrode layer comprises a plurality of grooves formed in the first surface,
• wherein portions of the plurality of carbon fibers are in the grooves,
• wherein the gas diffusion layer is partially on the positive electrode layer, and
• wherein the negative electrode metal layer, the electrolyte layer, and the positive electrode layer are bent over the gas diffusion layer such that the positive electrode layer contacts at least three surfaces of the gas diffusion layer, and a first surface of the gas diffusion layer is exposed.