Method of making lithium secondary battery

A method of making a lithium secondary battery, the method comprising:

• preparing positive metal foams and negative metal foams each having pores;
• compressing a positive metal foam and a negative metal foam to form a compressed positive metal foam and a compressed negative metal foam each including pores having a pore size of 450 μm or less;
• tensioning a positive metal foam and a negative metal foam to form a tensioned positive metal foam and a tensioned negative metal foam each including pores having a pore size of 3000 μm or more;
• preparing a positive slurry by mixing a positive electrode active material, a binder, a conductive material, and an organic solvent;
• preparing a negative slurry by a negative electrode active material, a binder, a conductive material, and an organic solvent;
• filling the pores of the compressed positive metal foam and the compressed negative metal foam with the positive slurry and the negative slurry, respectively, to form a slurry-filled compressed positive metal foam and a slurry-filled compressed negative metal foam;
• filling the pores of the tensioned positive metal foam and the tensioned negative metal foam with the positive slurry and the negative slurry, respectively, to form a slurry-filled tensioned positive metal foam and a slurry-filled tensioned negative metal foam;
• heat-treating the slurry-filled compressed positive metal foam, the slurry-filled compressed negative metal foam, the slurry-filled tensioned positive metal foam, and the slurry-filled tensioned negative metal foam to remove the organic solvent and form the heat-treated compressed positive metal foam, the heat-treated compressed negative metal foam, the heat-treated tensioned positive metal foam, and the heat-treated tensioned negative metal foam;
• and
• permeating an electrolyte into the heat-treated compressed positive metal foam and the heat-treated tensioned positive metal form resulting in a compressed positive electrode and a tensioned positive electrode;
• preparing a first separator and a second separator, and
• laminating the heat-treated compressed negative metal foam, the first separator, the compressed positive electrode, the tensioned positive electrode, the second separator, and the heat-treated tensioned negative metal foam to have a structure laminated in the described order.