Lithium-ion battery and method for manufacturing same

Abstract

Battery 1000 includes at least one unit cell 100 formed by an anode 20, an electrolyte 30, and a cathode 50, defining a stacked structure. The stacked structure and the battery have six faces: two opposing end faces F1 and F2, two opposing side faces F3 and F5, and two opposing long axis faces F4 and F6. It should be understood that the first long axis face F6 of the battery includes at least one anode connection region 1002, and the second long axis face F4 of the battery includes at least one cathode connection region 1006. The anode and cathode connection regions 1002 and 1006 are opposite to each other. In the first long axis direction XX' of the battery, each anode current collecting substrate 10 protrudes from each anode layer 20, each electrolytic layer 30 or the electrolyte-impregnated separation layer 31, each cathode layer 50 and each cathode current collecting substrate layer 40, and in the second long axis direction XX'' opposite to the first long axis direction XX', each cathode current collecting substrate 40 protrudes from each anode layer 20, each electrolytic layer 30 or the electrolyte-impregnated separation layer 31, each cathode layer 50 and each anode current collecting substrate layer 10.

Description

[Technical Field]

[0001] This invention relates to the field of batteries, and more particularly to lithium-ion batteries. This invention relates to a lithium-ion battery with a novel structure and a long lifespan. This invention further relates to a novel method for manufacturing this battery. [Previous Technology]

[0002] Rechargeable all-solid-state lithium-ion batteries are known. International patent document WO 2016 / 001584 (I-TEN) describes a lithium-ion battery made of an anode foil and a cathode foil, wherein the anode foil comprises a conductor substrate sequentially shielded by an anode layer and an electrolytic layer, and the cathode foil comprises a conductor substrate sequentially shielded by a cathode layer and an electrolytic layer; before or after deposition, these foils are cut into U-shaped patterns. These foils are then staggered and stacked to form a stacked structure of multiple unit cells. The anode and cathode foil cutting patterns are placed in a "head-to-tail" configuration, causing the cathode and anode stacks to be laterally offset. After the stacking step, a thick-layer encapsulation system of approximately ten micrometers is deposited on the stacked structure and located in a usable chamber within the stacked structure. This method ensures the stiffness of the structure in the cut plane and prevents the battery cells from being affected by the atmosphere. Once the stacked structure has been manufactured and packaged, it is cut along the cutting planes to obtain cell units, exposing the cathode and anode connection areas of the cells to the respective cutting planes. During these cutting steps, the packaging system can be torn off, potentially causing the impervious seal of the cell to rupture. Terminals (i.e., electrical contacts) should also be added to these clearly visible cathode and anode connection areas.

[0003] Such known solutions should have obvious specific drawbacks. Specifically, depending on the electrode placement design, especially the proximity of multiple edges of multiple electrodes in a multi-layer battery and the cleanliness of the cut, current leakage occurs at the ends, usually in the form of creeping short-circuit. Despite the use of encapsulation systems around the battery and near the cathode-anode junction area, this creeping short-circuit still reduces battery performance. Furthermore, the encapsulation system is sometimes observed to deposit unsatisfactorily on the battery, particularly at multiple edges located in the space created by the lateral offset of the electrodes.

[0004] US Patent Document US 2018 / 212210, filed by Suzuki, also discloses a battery comprising multiple cell units. The resulting stacked structure is placed within a metal casing interposed with resin. This mechanically secures the battery, preventing it from moving during operation. The resin also avoids the risk of short circuits that could originate from contact between the cell units and the metal casing, particularly during potential impacts or vibrations.

[0005] Finally, I would like to cite Japanese Patent Document JP 2007 / 005279 filed by Matsushita. This document discloses an all-solid-state battery obtained by sintering. This battery therefore does not contain any electrolyte material nor any layer of a separator soaked in such an electrolyte. [Summary of the Invention]

[0006] The present invention aims to overcome at least some of the disadvantages of the above-mentioned prior art, and in particular to obtain a rechargeable lithium-ion battery with high energy density and high power density.

[0007] The present invention is particularly useful in increasing the production output of rechargeable lithium-ion batteries with high energy density and high power density and producing more efficient packaging at a lower cost.

[0008] The present invention is particularly useful in providing a method that reduces the risk of latent or sudden short circuits and allows batteries with low self-discharge rates to be manufactured.

[0009] The present invention is particularly about providing a method that enables long-life batteries to be manufactured in a simple, reliable and fast manner.

[0010] The present invention further provides a simple, fast and low-cost battery manufacturing method.

[0011] The present invention relates firstly to a battery comprising at least one cell, wherein each cell sequentially comprises an anode current collecting substrate, an anode layer, at least one electrolytic layer and / or at least one separation layer impregnated with an electrolyte, a cathode layer and a cathode current collecting substrate.

[0012] Wherein, when the battery comprises multiple cell units, the cell units are arranged sequentially downwards, that is, the cell units overlap according to the frontal orientation of one of the main planes of the battery, so that:

[0013] The anode current collection substrate is the anode current collection substrate of two adjacent cell units, and

[0014] The cathode current collection substrate is the cathode current collection substrate of two adjacent unit cells.

[0015] At least one cell or cell defines a stacked structure.

[0016] The stacked structure and battery have six sides, namely

[0017] The so-called two end faces are opposite to each other (especially parallel to each other), and are substantially parallel to one or more of the anode current collecting substrate, one or more of the anode layer, one or more of the electrolytic layer, or one or more of the separation layer impregnated with the electrolyte, and are substantially parallel to one or more of the cathode layer and one or more of the cathode current collecting substrate.

[0018] The so-called two sides, the two sides are opposite to each other, especially parallel to each other, and

[0019] The so-called two major axial planes are opposite to each other, and in particular, parallel to each other.

[0020] It should be understood that the first long axis surface of the battery includes at least one anode connection region, and the second long axis region of the battery includes at least one cathode connection region, the at least one anode connection region and the at least one cathode connection region being laterally opposite to each other.

[0021] is characterized by

[0022] In a first long axis direction of the battery, each anode current collecting substrate protrudes from each anode layer, each electrolytic layer or each separation layer immersed in the electrolyte, each cathode layer and each cathode current collecting substrate, and

[0023] In a second long axis direction of the battery relative to the first long axis direction, each cathode current collecting substrate protrudes from each anode layer, each electrolytic layer or impregnated with each separation layer, each cathode layer and each anode current collecting substrate.

[0024] In a particular embodiment:

[0025] Each anode current collecting substrate protrudes from a first end plane, the first end plane being defined and / or by a plurality of first long axis ends of each anode layer, each electrolytic layer or each separation layer, each cathode layer, and each cathode current collecting substrate.

[0026] Each cathode current collecting substrate protrudes from a second end plane, which is defined by a plurality of second long axis ends of each anode layer, each electrolytic layer or each separation layer, each cathode layer and each anode current collecting substrate.

[0027] According to a specific advantageous embodiment of the present invention, the battery according to the present invention includes an encapsulation system that covers at least a portion of the outer periphery of a stacked structure. The encapsulation system includes at least one water-impermeable covering layer, the moisture permeability of which is less than 10⁻⁵ g / m²·d. The encapsulation system is in direct contact with the electrolyte layer and / or the separation layer impregnated with the electrolyte on each long axis surface. Preferably, the encapsulation system is also in direct contact with the anode layer, the cathode layer, and the non-protruding current collection substrate on each long axis surface.

[0028] Advantageously, the encapsulation system is electrically insulating, and the conductivity of the encapsulation system is advantageously less than 10e-11 S·m-1, especially less than 10e-12 S·m-1.

[0029] Advantageously, the packaging system covers at least a portion of the outer periphery of the stacked structure, and the packaging system covers the end faces, side faces, and at least a portion of the long axis of the stacked structure, thereby enabling...

[0030] Only the anode edges of each anode current collecting substrate protruding from each anode layer, each electrolytic layer or each decomposition layer, each cathode layer and each cathode current collecting substrate along the first long axis direction of the battery are flush with the first long axis surface, and such that

[0031] Only the cathode edges of each cathode current collecting substrate protruding from each anode layer, each electrolytic layer or each decomposition layer, each cathode layer and each anode current collecting substrate along the second long axis direction of the battery are flush with the second long axis surface, and the second long axis surface is preferably opposite to and parallel to the first long axis surface.

[0032] It should be understood that each anode edge defines an anode connection area, and each cathode edge defines a cathode connection area.

[0033] According to another embodiment of the present invention, the packaging system includes:

[0034] A first masking layer is preferably selected from parylene, fluorinated parylene, polyimide, epoxy resin, silicone resin, polyamide, sol-gel silica, organic silica and / or mixtures thereof, and is deposited on at least a portion of the outer periphery of the stacked structure.

[0035] A second cover layer is selected, which is composed of an electrically insulating material, and is deposited on at least a portion of the outer periphery of the stacked structure or on the first cover layer by atomic layer deposition.

[0036] At least one waterproof third covering layer, preferably having a moisture permeability of less than 10⁻⁵ g / m²·d, wherein the at least one third covering layer is made of ceramic material and / or low melting point glass (preferably glass with a melting point below 600°C), and is deposited on at least a portion of the outer periphery of the stacked structure or on the first covering layer.

[0037] It should be understood that when a second covering layer is present...

[0038] The second and third covering layers are repeatedly applied z times and deposited on the outer periphery of at least one third covering layer, where z ≥ 1, and

[0039] The last layer of the encapsulation system is a waterproof cover layer with a moisture permeability of less than 10-5 g / m2·d and made of ceramic material and / or low melting point glass.

[0040] According to another aspect of the present invention, at least the anode connection region, preferably a first long axis surface including at least one anode connection region, is covered by an anode contact, and at least the cathode connection region, preferably a second long axis surface including at least one cathode connection region, is covered by a cathode contact.

[0041] It should be understood that the anode contact and the cathode contact can form an electrical contact between the stacked structure and an external conductive element.

[0042] According to another embodiment of the present invention, each anode and cathode contact comprises:

[0043] A first electrical connection layer is disposed on at least an anode connection region and at least a cathode connection region, preferably disposed on a first long axis surface including at least one anode connection region and a second long axis surface including at least one cathode connection region.

[0044] The first electrical connection layer comprises a material filled with conductive particles, preferably a polymeric resin filled with conductive particles and / or a material obtained by a sol-gel method, more preferably a polymeric resin filled with graphite.

[0045] The second electrical connection layer includes a metal foil disposed on the first electrical connection layer of the material filled with conductive particles.

[0046] According to another aspect of the present invention, the minimum distance between a first long axial surface including at least one anode connection region and a first end plane defined by the first long axial ends of each anode layer, each electrolytic layer and / or each separation layer, each cathode layer and each cathode current collecting substrate is between 0.01 mm and 0.5 mm, and / or

[0047] The minimum distance between the second long axis surface including at least one cathode connection area and the second end plane defined by the second long axis ends of each anode layer, each electrolytic layer and / or each separation layer, each cathode layer and each anode current collection substrate is between 0.01 mm and 0.5 mm.

[0048] This invention is more related to a method for manufacturing at least one battery.

[0049] Each battery contains at least one cell.

[0050] Each cell sequentially comprises an anode current collecting substrate, an anode layer, at least one electrolytic layer and / or at least one separation layer impregnated with an electrolyte, a cathode layer, and a cathode current collecting substrate.

[0051] Wherein, when the battery comprises multiple cell units, the cell units are arranged sequentially downwards, that is, the cell units overlap according to the frontal orientation of one of the main planes of the battery, so that:

[0052] The anode current collection substrate is the anode current collection substrate of two adjacent cell units, and

[0053] The cathode current collection substrate is the cathode current collection substrate of two adjacent unit cells.

[0054] At least one cell or cell defines a stacked structure.

[0055] The stacked structure and battery have six sides, namely,

[0056] The so-called two end faces are opposite to each other (especially parallel to each other), and are substantially parallel to one or more of the anode current collecting substrate, one or more of the anode layer, one or more of the electrolytic layer, or one or more of the separation layer impregnated with the electrolyte, and are substantially parallel to one or more of the cathode layer and one or more of the cathode current collecting substrate.

[0057] The so-called two sides, the two sides are opposite to each other, especially parallel to each other, and

[0058] The so-called two major axial planes are opposite to each other, and in particular, parallel to each other.

[0059] It should be understood that the first long axis surface of the battery includes at least one anode connection region, and the second long axis region of the battery includes at least one cathode connection region, the at least one anode connection region and the at least one cathode connection region being laterally opposite to each other.

[0060] thus causing

[0061] In a first long axis direction of the battery, each anode current collecting substrate protrudes from each anode layer, each electrolytic layer or each separation layer immersed in the electrolyte, each cathode layer and each cathode current collecting substrate, and

[0062] In a second long axis direction of the battery relative to the first long axis direction, each cathode current collecting substrate protrudes from each anode layer, each electrolytic layer or is impregnated with each separation layer, each cathode layer and each anode current collecting substrate of the electrolyte.

[0063] The manufacturing method includes:

[0064] Step 1: Provide at least one anodic current collecting substrate foil, the at least one anodic current collecting substrate foil having multiple grooves, multiple uncoated areas, and multiple coated areas coated with an anodic layer and selectively coated with an electrolytic layer or a release layer, and hereinafter referred to as the anodic foil.

[0065] Step 2: Provide at least one cathode current collecting substrate foil, the at least one cathode current collecting substrate foil having a plurality of grooves, a plurality of uncoated areas, and a plurality of coated areas coated with the cathode layer and selectively coated with the electrolytic layer or the separation layer, and hereinafter referred to as the cathode foil.

[0066] Step 3: Generate a stacked structure having at least one anode foil with grooves, uncoated areas, and coated areas, and at least one cathode foil with grooves, uncoated areas, and coated areas, to obtain at least one unit cell sequentially comprising an anode current collection substrate, an anode layer, at least one electrolytic layer or at least one separation layer, a cathode layer, and a cathode current collection substrate.

[0067] makes

[0068] In the first long axis direction of the battery, each anode current collecting substrate protrudes from each anode layer, each electrolytic layer and / or each separation layer, each cathode layer and each cathode current collecting substrate, and

[0069] In the second long axis direction of the battery relative to the first long axis direction, each cathode current collecting substrate protrudes from each anode layer, each electrolytic layer and / or each separation layer, each cathode layer and each anode current collecting substrate.

[0070] Step 4: Heat-treat and / or mechanically press the stacked structure of the interlaced foils obtained in Step 3 to form a reinforced stacked structure.

[0071] Step 5 is selected to create a first pair of cutting lines to separate one column of the battery from at least one other column of the battery formed from the reinforced stacked structure.

[0072] In step 6, the reinforced stacked structure obtained in step 4 is impregnated with lithium ions, for example, a liquid electrolyte or an ionic liquid containing lithium salt, or the battery column obtained in step 5 is impregnated during step 5, such that the separation layer is impregnated with the electrolyte.

[0073] Step 7 is selected to create the second pair of cutting lines and expose them:

[0074] An anode edge protruding from each anode layer, each electrolytic layer or each separation layer, each cathode layer and each cathode current collecting substrate along the first long axis of the battery, each anode edge defining at least one anode connection region, and

[0075] A cathode edge protruding from each anode layer, each electrolytic layer or each separation layer, each cathode layer and each anode current collecting substrate along the second long axis of the battery, each cathode edge defining at least one cathode connection region.

[0076] During step 5, the second pair of cutting lines separates one battery from at least one other battery formed from the column of these batteries.

[0077] In a specific embodiment of this method, if step 6 is performed after step 6, or if step 6 is not performed and step 5 is performed after step 5, or if steps 5 and 6 are not performed after step 4 and before step 7, step 8 of encapsulating and reinforcing the stacked structure or battery column is performed, wherein preferably at least a portion of the outer periphery of the battery column or stacked structure is covered by an encapsulation system, preferably the end face of the battery column or stacked structure, the side face of the battery column or stacked structure, and at least a portion of the first long axis surface and the second long axis surface are covered by the encapsulation system, such that:

[0078] Only the anode edges of each anode current collecting substrate protruding from each anode layer, each electrolytic layer or each separation layer, each cathode layer and each cathode current collecting substrate along the first long axis direction of the battery are flush with the first long axis surface, and such that...

[0079] Only the cathode edges of each cathode current collecting substrate protruding from each anode layer, each electrolytic layer or each separation layer, each cathode layer and each anode current collecting substrate along the second long axis direction of the battery are flush with the second long axis surface, and the second long axis surface and the first long axis surface are preferably opposite to each other and parallel.

[0080] It should be understood that each anode edge defines at least one anode connection area and each cathode edge defines at least one cathode connection area;

[0081] The packaging system includes:

[0082] At least one first masking layer is preferably selected from parylene, fluorinated parylene, polyimide, epoxy resin, silicone resin, polyamide, sol-gel silicon oxide, organic silicon oxide, and / or mixtures thereof, and is deposited on at least a portion of the outer periphery of the column or stack structure of the battery.

[0083] A second covering layer is selected, which is composed of an electrically insulating material and is deposited on the substrate by atomic layer deposition.

[0084] At least a portion of the outer periphery of the battery column or stack structure,

[0085] Or on the first covering layer, and

[0086] At least one water-impermeable third covering layer, preferably having a moisture permeability of less than 10⁻⁵ g / m²·d, wherein the at least one third covering layer is made of ceramic material and / or low-melting-point glass (preferably glass with a melting point below 600°C), and is deposited on at least a portion of the outer periphery of the column or stack structure of the battery or on the first covering layer.

[0087] It should be understood that the second cover layer and at least one third cover layer are repeated z times and deposited on the outer periphery of at least one third cover layer, wherein z ≥ 1, and the last layer of the encapsulation system is preferably a water-impermeable cover layer with a moisture permeability of less than 10-5 g / m2·d and made of ceramic material and / or low melting point glass.

[0088] In another specific embodiment of the method according to the invention, which can be combined with the above, after step 7, at least the anode connection region, preferably a first long axis surface including at least one anode connection region, is covered by an anode contact, the anode contact being able to form an electrical contact between the stacked structure and an external conductive element, and

[0089] At least one cathode connection region, preferably a second long axis surface including at least one cathode connection region, is covered by a cathode contact, the cathode contact being capable of generating electrical contact between the stacked structure and external conductive elements.

[0090] The fabrication of the anode contact and the cathode contact includes:

[0091] A first electrical connection layer is deposited on at least one anode connection region and at least one cathode connection region, preferably on a first long axis surface including at least one anode connection region and a second long axis surface including at least one cathode connection region. The first electrical connection layer is preferably made of a polymeric resin filled with conductive microparticles and / or a material obtained by a sol-gel method.

[0092] Optionally, when the first electrical connection layer is made of a polymeric resin filled with conductive microparticles and / or a material obtained by a sol-gel method, a drying step is performed after the step of polymerizing the polymeric resin and / or the material obtained by the sol-gel method, and

[0093] A second electrical connection layer is deposited on the first electrical connection layer, the second electrical connection layer comprising a metal foil disposed on the first electrical connection layer.

[0094] A third electrical connection layer comprising a conductive ink is deposited on the second electrical connection layer.

Implementation Method

[0095] Generally, the following geometric designations are associated with this battery:

[0096] ZZ represents the so-called frontal orientation, which is a plane orthogonal to different stacked layers;

[0097] When viewed from above (i.e., viewed from the front), XX represents the so-called longitudinal orientation, which is contained in the plane of the stacked layers and parallel to the maximum dimension of these layers.

[0098] When viewed from above, YY represents the so-called lateral or transverse orientation, which is contained in the plane of the stacked layers and parallel to the smallest dimension of these layers.

[0099] Typically, two of the three directions are given by the plane of the foil shown with reference to FIG10.

[0100] Referring to the plane of the foil shown in Figure 10, the right and left directions are therefore related to the orientation XX, the front and back directions are related to the orientation YY, and the upper and lower directions are related to the orientation ZZ.

[0101] Generally, the first major axis direction XX' pointing from right to left and the second major axis direction XX'' (i.e., from left to right) relative to the first major axis direction XX' are defined by the plane of the foil shown in FIG10. Referring again to the plane of the foil shown in FIG10, the first lateral direction YY' pointing from the front to the back, the second lateral direction YY'' relative to the first lateral direction, the first front direction ZZ' pointing from the top to the bottom, and the second front direction ZZ'' relative to the first front direction are defined.

[0102] The method according to the invention first includes the step of manufacturing a stacked structure I of interlaced foils, which are referred to hereinafter as "anode foils" or "cathode foils" depending on the specific circumstances. As detailed below, each anode foil is used to form the anode of a plurality of batteries, and each cathode foil is used to form the cathode of a plurality of batteries. The example in FIG1 shows two cathode foils having a unit body 5e and two anode foils having a unit body 2e. In practice, this stacked structure is formed by a greater number of foils, typically between one thousand and ten thousand. In the stacked structure I of interlaced foils of opposite polarities, the number of cathode foils having a unit body 5e is equal to the number of anode foils having a unit body 2e.

[0103] In an advantageous embodiment, each foil has perforations 7 at its four ends such that when these perforations 7 overlap, all the cathodes and anodes in these foils are aligned according to the invention, as will be detailed below (see Figures 1, 2 and 3). These perforations 7 at the four ends of the foil can be formed by any suitable means, particularly after manufacturing on the anode and cathode foils, or before manufacturing the anode and cathode foils on the substrate foils (anode current collecting substrate 10, cathode current collecting substrate 40).

[0104] Each anode foil includes an anode current collecting substrate 10 having an active layer coated with at least a portion of an anode material, wherein the active layer of the anode material is hereinafter referred to as the anode layer 20. Each cathode foil includes a cathode current collecting substrate 40 having an active layer coated with at least a portion of a cathode material, wherein the active layer of the cathode material is hereinafter referred to as the cathode layer 50. Each active layer can be solid, specifically having a dense or porous nature. Furthermore, to prevent any electrical contact between two active layers of opposite polarity, an electrolytic layer 30 or a subsequently electrolyte-impregnated separation layer 31 is disposed on the active layer of at least one of these current collecting substrates previously coated with active layers, in contact with the opposing active layer. The electrolytic layer 30 or the separation layer 31 can be disposed on the anode layer 20 and / or the cathode layer 50; the electrolytic layer 30 or the separation layer 31 is integrally formed with the cathode foil and / or anode foil containing it.

[0105] Advantageously, each of the two surfaces of the anode current collecting substrate 10 or the cathode current collecting substrate 40 is at least partially coated with an anode layer 20 or a cathode layer 50, and selectively coated with an electrolytic layer 30 or a separation layer 31 respectively disposed on the anode layer 20 or the cathode layer 50. In this way, the anode current collecting substrate 10 or the cathode current collecting substrate 40 serves as a current collector for two adjacent cell units 100, 100'. Using these substrates in batteries increases the production output of rechargeable batteries with high energy density and high power density.

[0106] The mechanical structure of one of the anode foils will be described below, and it should be understood that the other anode foils have the same structure. Furthermore, as described below, the structure of the cathode foil is similar to that of the anode foil.

[0107] As shown in Figure 2, the anode foil 2e, having unit bodies 60 and 60', has a quadrilateral shape and is essentially square. As described below, the anode foil 2e defines a so-called porous central region 4, and the unit bodies are fabricated within the porous central region 4. Referring to the positioning of these unit bodies, define the so-called lateral or transverse orientation YY and the so-called horizontal orientation XX of the foil, where the lateral or transverse orientation YY corresponds to the lateral orientation of these unit bodies, and the horizontal orientation XX is orthogonal to the orientation YY. The boundary of the central region 4 is defined by a peripheral frame 6, which is solid, i.e., free from the unit bodies. Specifically, the function of this frame is to ensure that each foil can be easily handled.

[0108] The cell bodies 60 and 60' are distributed in columns L1 to Ly arranged sequentially downwards and in rows R1 to Rx adjacent to each other. As a non-limiting example, in the manufacture of surface-mount device (SMD) type micro-batteries, the anode and cathode foils used can be 100 mm x 100 mm wafers. Typically, the number of columns and rows of these foils is between 10 and 500. The required battery capacity can be achieved by changing the size of the foils and adjusting the number of columns and rows of each anode and cathode foil accordingly. The size of the anode and cathode foils can be adjusted according to actual needs. As shown in Figure 2, two adjacent columns can be separated by a bridging material 8, wherein the height H8 of the bridging material 8 is between 0.05 mm and 5 mm. Two adjacent foils can be separated by a strip material 9, wherein the width L9 of the strip material 9 is between 0.05 mm and 5 mm. These bridging materials 8 and strip materials 9 of the anode and cathode foils give the foils sufficient mechanical rigidity to be easily installed and removed.

[0109] As detailed below, the cell bodies 60, 60', 60'' include exclusion regions (i.e., uncoated regions 72, 82), coated regions 71, 81, and grooves 70, 80. These grooves 70, 80 are preferably I-shaped and through-grooves, i.e., these grooves 70, 80 pass through opposite top and bottom surfaces of the foil, respectively. These grooves 70, 80 preferably have a quadrilateral shape and are substantially rectangular. Before any anode or cathode material is applied, these grooves 70, 80 can be directly formed on the current collection substrate in conventional methods by chemical etching, electroforming, laser cutting, microperforation, or stamping. These grooves 70, 80 can also be fabricated on the following components:

[0110] A current collection substrate at least partially coated with an anode or cathode material layer, or

[0111] A current collection substrate having at least a partial coating of an anode or cathode material layer, wherein the anode or cathode material layer itself is coated with an electrolytic layer or a separation layer, i.e., on the anode or cathode foil.

[0112] When the grooves 70 are fabricated in such at least partially coated substrates, the grooves 70 and 80 can be fabricated in conventional methods, for example by laser cutting (or laser ablation), femtosecond laser cutting, micro-drilling, or stamping. The grooves 70 fabricated in all cathode foils are stacked sequentially upwards. The grooves 80 fabricated in all anode foils are stacked sequentially upwards.

[0113] One of the unit bodies 60 shown in FIG3 will now be described. It should be understood that all unit bodies 60, 60' of the anode foil are the same, and all unit bodies 60, 60'' of the cathode foil are the same.

[0114] Figure 3 shows the anode unit bodies 60 and 60'.

[0115] Each unit body 60, 60', 60'' includes a groove 80, 70 that is preferably I-shaped and serves as a through groove, an exclusion area (i.e., an uncoated area 82, 72) and a coated area 81, 71.

[0116] The coated area 81 of the anode unit body 60' should be understood as representing the area of ​​the anode foil covered by the anode layer 20, or the area covered by the anode layer 20 and the electrolytic layer 30 or the separation layer 31. The excluded area or uncoated area 82 of the anode unit body 60' should be understood as representing the area of ​​the anode foil not covered by the anode layer 20, or the area not covered by the anode layer 20 and the electrolytic layer 30 or the separation layer 31.

[0117] The uncoated anode regions 82 are regions without any electrolytic material or release layer, and also without any anode material. When generated on the anode foil, these uncoated anode regions 82 are generated in a manner that removes or prevents the presence of any electrolytic material or release layer and anode material, leaving at least a portion of the anode current collecting substrate 10. Therefore, in the first long axis direction XX' of the battery, each anode current collecting substrate 10 protrudes from each anode layer 20 and from each electrolytic layer 30 or electrolyte-impregnated release layer 31. When the current collecting substrate is completely covered by the anode layer 20, the anode layer 20 itself is selectively covered by the electrolytic layer 30 or the release layer 31, and the uncoated anode regions 82 can be generated by laser etching to partially remove the anode layer 20 or the anode layer 20 coated with the electrolytic layer 30 or the release layer 31. The uncoated anode regions 82 can also be generated in a conventional manner by partial slot-die coating of the current collecting substrate. The localized slotted coating of the current harvesting substrate allows for the localized placement of the anode layer 20 on the substrate, which can then be selectively covered subsequently with the electrolytic layer 30 or the release layer 31 using the same method. Slotted coating on a substrate with symmetry in the direction of travel allows uncoated areas 82 to be left directly on the substrate; this reduces the number of steps in the method of fabricating the cell body on the anode foil.

[0118] In the top view, relative to the center line YH of the unit bodies 60, 60', 60'', the uncoated areas 82, 72 on one side of the same unit body 60, 60', 60'' are symmetrical to the grooves 80, 70 on the other side.

[0119] Each uncoated anode region 82 is generated in the continuation of each cathode groove 70, and each uncoated cathode region 72 is generated in the continuation of each anode groove 80.

[0120] The anode foil obtained after generating the groove 80, the coated area 81 and the uncoated area 82 will be referred to below as the anode foil having the unit body 2e.

[0121] The following labels will be used:

[0122] H80 is the height of the entire anode groove and is typically between 0.25 mm and 10 mm;

[0123] L80 is the width of the entire anode groove, and is typically between 0.25 mm and 10 mm;

[0124] H82 is the height of each anode exclusion zone, and is typically between 0.25 mm and 10 mm;

[0125] L82 is the width of each anode exclusion zone, and is typically between 0.25 mm and 10 mm.

[0126] Similarly, each cathode foil is also provided with cathode unit bodies 60, 60'' of different columns and rows, and the number of cathode unit bodies 60, 60'' is equal to the number of anode unit bodies 60, 60''.

[0127] As shown in Figure 4, the structure of each cathode unit body 60'' is substantially similar to that of each anode unit body 60', that is, this cathode unit body 60'' includes an exclusion area or uncoated area 72, a coated area 71 and a groove 70.

[0128] The exclusion area or uncoated area 72 of the cathode unit body 60'' should be understood as the area in the cathode foil 5e that is not covered by the cathode layer 50, or the area that is not covered by the cathode layer 50 and the electrolytic layer 30 or the separation layer 31.

[0129] The coating area 81 of the cathode unit body 60'' should be understood as representing the area of ​​the cathode foil 5e that is covered by the cathode layer 50, or the area covered by the cathode layer 50 and the electrolytic layer 30 or the separation layer 31.

[0130] The size of the uncoated cathode region 72 is the same as the size of the anode groove 80, and similarly, the size of the uncoated anode region 82 is similar to the size of the cathode groove 70.

[0131] In the top view, the uncoated cathode region 72 overlaps the anode groove 80, and the uncoated anode region 82 overlaps the cathode groove 70.

[0132] The difference between the anode unit body 60' and the cathode unit body 60'' lies in that, on the one hand, the uncoated cathode region 72 and the uncoated anode region 82 are inverted relative to each other. On the other hand, the cathode recess 70 and the anode recess 80 are inverted relative to each other. Thus, in the top view, each uncoated anode region 82 is generated in the extension of each cathode recess 70, and each uncoated cathode region 72 is generated in the extension of each anode recess 80.

[0133] The uncoated cathode region 72 is a region without any electrolytic material or release layer and without any cathode material. When generated on the cathode foil, these uncoated cathode regions 72 are generated in a manner that removes or prevents the presence of any electrolytic material or release layer and cathode material, leaving at least a portion of the anode current collecting substrate 10. In this way, in the second long axis direction XX'' of the battery, relative to the first long axis direction XX', each cathode current collecting substrate 40 protrudes from each cathode layer 50 and from each electrolytic layer 30 or release layer 31 immersed in electrolyte. When the current collecting substrate is completely covered by the cathode layer 50, the cathode layer 50 itself may be selectively covered by the electrolytic layer 30 or release layer 31, and the uncoated cathode region 72 can be generated by laser etching to partially remove the cathode layer 50 or the cathode layer 50 coated with the electrolytic layer 30 or release layer 31. The uncoated cathode region 72 can also be generated by partial die coating of the current collecting substrate. The localized slit coating of the current collection substrate allows for the localized placement of the cathode layer 50 on the substrate, and its selective subsequent masking by the electrolytic layer 30 or the release layer 31 in the same manner. Slit coating on a substrate that is symmetrical in the direction of substrate travel allows uncoated areas 72 to remain directly on the substrate; this reduces the number of steps in the method of fabricating the cell body on the cathode foil.

[0134] The cathode foil obtained after generating the groove 70, the coated area 71 and the uncoated area 72 is hereinafter referred to as the cathode foil having the unit body 5e.

[0135] Next, a stacked structure I with at least one anode foil having a unit body 2e and at least one cathode foil having a unit body 5e will be generated to obtain at least one unit cell, wherein each unit cell sequentially includes an anode current collecting substrate 10, an anode layer 20, an electrolytic layer 30 or a separation layer 31 impregnated or subsequently impregnated with an electrolyte, a cathode layer 50 and a cathode current collecting substrate 40.

[0136] The stacked structure I includes at least one anode foil 2e and at least one cathode foil 5e arranged alternately, wherein the at least one anode foil 2e has a groove 80, an uncoated area 82 and a coated area 81, and the at least one cathode foil 5e has a groove 70, an uncoated area 72 and a coated area 71. Thus, at least one cell 100 is obtained, which sequentially includes an anode current collecting substrate 10, an anode layer 20, an electrolytic layer 30 and / or a separation layer 31, a cathode layer 50 and a cathode current collecting substrate 40.

[0137] This stacked structure I is manufactured such that:

[0138] In the first long axis direction XX' of the battery, each anode current collecting substrate 10 protrudes from each anode layer 20, each electrolytic layer 30 and / or separation layer 31, each cathode layer 50 and each cathode current collecting substrate 40, and

[0139] In the second long axis direction XX'' of the battery relative to the first long axis direction XX', each cathode current collecting substrate 40 protrudes from each anode layer 20, each electrolytic layer 30 and / or separation layer 31, each cathode layer 50 and each anode current collecting substrate 10.

[0140] In the case where the battery comprises multiple cell units 100, 100', 100'', the cell units 100, 100', 100'' are arranged sequentially downwards (i.e., overlapping ZZ according to the frontal orientation relative to the main plane of the battery presented in FIG10) such that:

[0141] The anode current collecting substrate 10 is the anode current collecting substrate 10 of two adjacent unit cells 100, 100', 100'', and wherein

[0142] The cathode current collection substrate 40 is the cathode current collection substrate 40 of two adjacent unit cells 100, 100', 100''.

[0143] Assume that the stacked structure described above has undergone steps to ensure its overall mechanical stability. These steps, which are already known, specifically include hot-pressing different layers. As described below, this stacked structure, consolidated in this way, allows for the formation of individual cells, and the number of cells is equal to the product of the number of columns (denoted by Y in Figure 2) and the number of rows (denoted by X in Figure 2).

[0144] For this purpose, please refer to Figure 5, which presents three columns Ln-1 to Ln+1 and three rows Rn-1 to Rn+1. As shown in Figures 16 and 17, according to the invention, and when the stacked structure I includes multiple columns (i.e., at least two columns of cell bodies, and these columns are hereinafter also referred to as battery columns Ln), the first pair of cutting lines DXn, DX'n are used to separate one column Ln of the battery 1000 from at least one other column Ln-1, Ln+1 of the battery in the battery formed from the reinforced stacked structure. Each cutting line is made in a conventional manner and is made in a through manner, i.e., extending through the entire height of the stacked structure. Non-limiting examples include cutting by sawing (especially cutting into squares), guillotine cutting, or laser cutting. Furthermore, the area 90 of the stacked structure where no battery foil is formed is presented in a manner filled with solid lines, while the space of the groove is left blank, and the space of the excluded area is gray.

[0145] As shown in Figure 6, which is a partial enlarged view of one of the cell bodies 60, 60' in Figure 5, each cutting line is made indifferently along the long axis of the battery, either in the first long axis direction XX' or in the second long axis direction XX''. The cutting lines DXn, DX'n are preferably parallel to each other and preferably orthogonal to the alignment lines of the uncoated areas 72, 82 of the cell bodies 60, 60', 60'' and the alignment lines of the grooves 80, 70.

[0146] Please refer to Figure 5 again. Each final battery is defined by two cutting lines DXn and DX'n (or cutting surfaces) at the front and rear ends and by a second pair of cutting lines DYn and DY'n (or cutting surfaces) at the right and left ends, wherein the cutting lines DXn and DX'n are preferably parallel to each other and the cutting lines DYn and DY'n are preferably parallel to each other.

[0147] In this Figure 5, once the cutting lines Dn, D'n and DYn, DY'n are cut, the battery 1000 will be generated as shown in the figure (hatched).

[0148] In these cases, please refer to Figure 6, and in the form of a non-limiting example, use the following reference numerals:

[0149] Dca corresponds to the minimum distance between the first major axis surface F6 and the first end plane DYa of the battery containing at least one anode connection region 1002. This distance Dca is between 0.01 mm and 0.05 mm, and it should be understood that this distance Dca is less than or equal to L82 / L70;

[0150] Dcc corresponds to the minimum distance between the second major axis plane F4 and the second end plane DY'a of the battery containing at least one cathode connection region 1006. This distance Dcc is between 0.01 mm and 0.05 mm, and it should be understood that this distance Dcc is less than or equal to L72 / L80.

[0151] Figure 7 is a schematic cross-sectional view drawn along the sectional line VII-VII extending through the battery. Figure 7 shows an alternating arrangement of two anode foils having a cell body 2e and an alternating arrangement of two cathode foils having a cell body 5e. In the same figure, the following reference numerals are given: grooves 70, 80 of cell bodies 60, 60' also shown in Figure 6, coated areas 71, 81 and uncoated areas 72, 82, and adjacent cell bodies according to an advantageous embodiment of the invention.

[0152] The anode foil having a unit body 2e includes an anode current collecting substrate 10 coated with an anode layer 20, the anode layer 20 being selectively coated with an electrolytic layer 30 or subsequently immersed in an electrolyte separation layer 31. Each cathode foil having a unit body 5e includes a cathode current collecting substrate 40 coated with a cathode layer 50, the cathode layer 50 being selectively coated with an electrolytic layer 30 or subsequently immersed in an electrolyte separation layer 31. To prevent any electrical contact between the two active layers of opposite polarity (i.e., between the anode layer 20 and the cathode layer 50), at least one electrolytic layer 30 and / or at least one separation layer 31 immersed in or subsequently immersed in an electrolyte are provided. FIG7 shows a unit cell 100, which sequentially includes an anode current collecting substrate 10, an anode layer 20, at least one electrolytic layer 30 or a separation layer 31 immersed in or subsequently immersed in an electrolyte, a cathode layer 50, and a cathode current collecting substrate 40.

[0153] Advantageously, the anode current collecting substrate 10 of the cell 100' can be adjoined to the anode current collecting substrate 10 of the adjacent cell 100''. Similarly, the cathode current collecting substrate 40 of the cell 100 can be adjoined to the cathode current collecting substrate 40 of the adjacent cell 100'.

[0154] In an advantageous embodiment, the anode current collecting substrate 10 and the cathode current collecting substrate 40 can each serve as current collectors for two adjacent cell units, as specifically shown in FIG. 7. As explained above, each of the anode current collecting substrate 10 and the cathode current collecting substrate 40 has an anode layer 20 or a cathode layer 50 coated on two sides, and an electrolytic layer 30 or a separation layer 31 respectively disposed on the anode layer 20 or the cathode layer 50 is selectively coated. This configuration increases the production output of the cells.

[0155] As shown in FIG7, each anode foil having a unit body 2e and each cathode foil having a unit body 5e are arranged such that each anode uncoated area 72 is formed in the extension of each anode groove 80, and each anode uncoated area 82 is formed in the extension of each cathode groove 70.

[0156] In the first long axis direction XX', each anode current collecting substrate 10 protrudes from the first end plane DYa, which is defined by the first long axis end of each anode layer 20, each electrolytic layer 30 or separation layer 31, each cathode layer 50 and each cathode current collecting substrate 40.

[0157] In the second long axis direction XX'' of the battery relative to the first long axis direction XX', each cathode current collecting substrate 40 protrudes from each anode layer 20, each electrolytic layer 30 or is impregnated or subsequently impregnated in the electrolyte separation layer 31, each cathode layer 50 and each anode current collecting substrate 10.

[0158] This is a particularly advantageous feature of the present invention because it prevents short circuits at the side edges of the battery, prevents current leakage, and facilitates the fabrication of electrical contacts on the anode connection region 1002 and the cathode connection region 1006.

[0159] In the cross-sectional schematic diagram, the uncoated cathode region 72 overlaps the anode groove 80, and the uncoated anode region 82 overlaps the cathode groove 70.

[0160] Advantageously, after forming the stacked structure of the anode foil having unit body 2e and the cathode foil having unit body 5e, the stacked structure I is reinforced by thermal and / or mechanical treatment (this treatment can be a hot pressing treatment that applies pressure and high temperature simultaneously). The thermal treatment of the stacked structure that enables the battery to be assembled is advantageously carried out at a temperature between 50°C and 500°C, preferably at a temperature below 350°C. The mechanical compression of the stacked structure of the anode foil having unit body 2e and the cathode foil having unit body 5e to be assembled is carried out at a pressure of 10 MPa to 100 MPa, preferably at a pressure between 20 MPa and 50 MPa.

[0161] The generation of a reinforced stacked structure for forming a battery has been described. Next, when the stacked structure I includes multiple columns (i.e., at least two columns of cell bodies, hereinafter also referred to as battery columns Ln), a pair of cutting lines DXn, DX'n can be fabricated to separate a column Ln of the battery 1000 from at least one other column Ln-1, Ln+1 of the battery formed from the reinforced stacked structure. As described above, the individual cutting lines, fabricated in a through manner (i.e., extending through the entire height of the stacked structure), are fabricated in a conventional manner. As shown in FIG17, the battery column Ln has six faces, namely:

[0162] Two so-called end faces FF1, FF2 that are opposite to each other are specifically parallel to each other and are substantially parallel to one or more anode current collection substrates 10, one or more anode layers 20, one or more electrolytic layers 30 or one or more separation layers 30 immersed in electrolyte 31, one or more cathode layers 50 and one or more cathode current collection substrates 40.

[0163] The two so-called sides FF3 and FF5 that are opposite to each other are specifically parallel to each other and parallel to the sides F3 and F5 of battery 1000; and

[0164] The two so-called major axis surfaces FF4 and FF6 are opposite to each other. Specifically, the major axis surfaces FF4 and FF6 are parallel to each other and parallel to the major axis surfaces F4 and F6 of battery 1000.

[0165] When the separation layer is used as an electrolyte host matrix, when the initial stacked structure I contains multiple battery columns Ln and when the first pair of dicing lines DXn, DX'n have been formed to separate a column Ln of the battery 1000 from at least one other column Ln-1, Ln+1 of the battery 1000 formed from the reinforced stacked structure, the previously obtained reinforced stacked structure or column Ln of the battery 1000 can be impregnated. The impregnation of the previously obtained reinforced stacked structure or column Ln of the battery 1000 can be generated by phase-carrying lithium ions, such as liquid electrolytes or ionic liquids containing lithium salts, so that the separation layer 31 is impregnated with the electrolyte.

[0166] As shown in Figure 8, after forming a reinforced stacked structure selectively impregnated with phase carrier lithium ions, this stacked structure or the column Ln of battery 1000 is encapsulated by a deposition encapsulation system 95 to ensure that the battery cells are not affected by the external environment. The encapsulation system needs to be chemically stable, able to withstand high temperatures, and not be permeated by the external environment to fulfill its function as a barrier layer.

[0167] The stacked structure can cover a packaging system, and the packaging system includes:

[0168] The selected dense and insulating first cover layer is preferably selected from parylene, parylene F, polyimide, epoxy resins, silicone, polyamide, sol-gel silica, organic silica, and / or mixtures thereof, and is deposited on the stacked structure of the anode and cathode foils; and

[0169] The selected second cover layer is composed of an electrically insulating material and is deposited on the stacked structure of the anode and cathode foils or on the first cover layer by atomic layer deposition; and

[0170] In a particularly advantageous manner, at least one third cover layer is impermeable to water, preferably having a water vapor permeance (WVTR) of less than 10⁻⁵ g / m²·d. This third cover layer is made of ceramic material and / or low-melting-point glass (preferably glass with a melting point below 600°C) and is deposited on the periphery of the stacked structure of the anode and cathode foils or the first cover layer.

[0171] It should be understood that at least one second cover layer and at least one third cover layer can be repeatedly applied z times, where z ≥ 1, and are deposited at least on the outer periphery of the third cover layer, and the last layer of the encapsulation system is a water-impermeable cover layer, preferably having a moisture permeability of less than 10-5 g / m2·d, which is made of ceramic material and / or low melting point glass.

[0172] This sequence can be repeated z times, where z ≥ 1. It has a blocking effect, and the blocking effect increases with the value of z.

[0173] The result is a robust and waterproof package that specifically prevents moisture from passing through the package system and the interface between the contacts (see Interface A in Figure 11).

[0174] For the purposes of this invention, an impermeable layer is defined as having a moisture permeability (WVTR) of less than 10⁻⁵ g / m²·d. The moisture permeability can be measured by the method described in U.S. Patent 7,624,621 and is also described in the publication "Structural properties of ultraviolet cured polysilazane gas barrier layers on polymer substrates" published in Thin Solid Films 6+550 (2014) 85-89 by A. Mortier et al.

[0175] Typically, the first capping layer is selected from the group consisting of: silicone resins (e.g., by impregnation or plasma-enhanced chemical vapor deposition from hexamethyldisiloxane (HMDSO)), epoxy resins, polyimide, polyamide, poly-para-xylylene (also known as poly(p-xylylene) and preferably paraylene), and / or mixtures thereof. When the first capping layer is deposited, it prevents the sensitive element of the battery from being affected by its environment. The thickness of the first capping layer is preferably between 0.5 micrometers (µm) and 3 µm.

[0176] The first cover layer is particularly suitable for situations where the battery's electrolysis and electrode layers have porous characteristics: the first cover layer acts as a planarization layer and also has a barrier effect. For example, this first layer can line multiple micropores open on the surface of the layer to seal their access.

[0177] In this first covering layer, different parylene variants can be used, including parylene C, parylene D, parylene N (CAS 1633-22-3), parylene F, or mixtures of parylene C, D, N, and / or F. Parylene is a dielectric, transparent, semi-crystalline material with high thermal stability, excellent solvent resistance, and very low permeability. Parylene also has barrier properties. Parylene F is preferably within the scope of this invention.

[0178] This first cover layer is advantageously obtained by the condensation of gaseous monomers by chemical vapor deposition on the surface of the battery stack, which produces a consistent, thin and uniform cover over all accessible surfaces of the stacked structure. This first cover layer is advantageously robust; the first cover layer cannot be considered a flexible surface.

[0179] The second cover layer is also formed of an electrically insulating material, preferably an inorganic material. The second cover layer is deposited by atomic layer deposition (ALD), plasma-enhanced chemical vapor deposition (PECVD), high-density plasma chemical vapor deposition (HDPCVD), or inductively coupled plasma chemical vapor deposition (ICPCVD) to achieve consistent coverage of all accessible surfaces in the stacked structure previously covered by the first cover layer. Layers deposited by atomic layer deposition are mechanically fragile and require robust bearing surfaces to achieve their protective function. Depositing fragile layers on flexible surfaces can lead to crack formation, thereby compromising the integrity of the protective layer. Furthermore, the growth of layers deposited by atomic layer deposition is affected by the nature of the substrate. Depositing layers by atomic layer deposition on substrates with different chemical properties will result in inhomogeneous growth, causing the protective layer to lose its integrity. Therefore, the selected second layer preferably supports the selected first layer to ensure a substrate with consistent chemical growth.

[0180] Atomic layer deposition (ALD) is particularly suitable for masking highly rough surfaces in a completely waterproof and consistent manner. ALD allows for the formation of a consistent layer without the drawbacks of pores (so-called "pinhole-free" layers) and presents a very good barrier effect. Its water vapor transmission rate (WVTR) is very low. WVTR is used to evaluate the degree of water permeability of the encapsulation system. The lower the WVTR, the less waterproof the encapsulation system is. The thickness of this second layer is advantageously selected as a function of the required degree of waterproofness (i.e., the required WVTR) and depends on the deposition technique used (specifically, from atomic layer deposition, plasma-enhanced chemical vapor deposition, high-density plasma chemical vapor deposition, and inductively coupled plasma chemical vapor deposition).

[0181] The second masking layer can be made of ceramic material, vitreous material, or glass-ceramic material, such as in the form of oxides, alumina (Al2O3), tantalum pentoxide (Ta2O5), nitrides, phosphates, oxynitrides, or siloxanes. The thickness of this second masking layer is preferably between 10 nanometers (nm) and 10 µm, more preferably between 10 nm and 50 nm.

[0182] This second cover layer, deposited on the first cover layer by atomic layer deposition, plasma-enhanced chemical vapor deposition, high-density plasma chemical vapor deposition, or inductively coupled plasma chemical vapor deposition, firstly renders the structure impermeable to water (i.e., prevents water from penetrating into the interior of the object), and secondly provides special protection for the first cover layer, preferably made of fluorinated poly(p-xylene F), against the effects of air, moisture, and thermal exposure to prevent its degradation. This second cover layer thus extends the life of the encapsulated battery.

[0183] The second cover layer can also be directly deposited on the stacked structure of the anode and cathode foils, that is, without the first cover layer being deposited.

[0184] The third cover layer needs to be impermeable to water and preferably has a moisture permeability (WVTR) of less than 10⁻⁵ g / m²·d. This third cover layer is formed of a ceramic material and / or a low-melting-point glass (preferably glass with a melting point below 600°C) and is deposited on the periphery of the stacked structure of the anode and cathode foils or the first cover layer. The ceramic and / or glass material used in this third layer is advantageously selected from:

[0185] Low melting point glass (typically below 600°C), preferably SiO2-B2O3, Bi2O3-B2O3, ZnO-Bi2O3-B2O3, TeO2-V2O5, PbO-SiO2,

[0186] Oxide, nitride, silicon oxynitride, SixNy, SiO2, SiON, amorphous silicon or SiC.

[0187] These glasses can be deposited by molding or dip coating.

[0188] Ceramic materials are advantageously deposited at low temperatures by plasma-enhanced chemical vapor deposition or, more preferably, by high-density plasma chemical vapor deposition or inductively coupled plasma chemical vapor deposition; these methods allow for the deposition of layers with good water impermeability.

[0189] As described above, the battery according to the invention comprises an encapsulation system, which is advantageously formed in the form of continuous layers. This achieves a highly waterproof encapsulation on all surfaces of the battery. Furthermore, this encapsulation has a very small overall size, allowing for the miniaturization required to produce microbatteries.

[0190] The above description of the encapsulation system illustrates the significant differences and technical advantages compared to the content disclosed in Suzuki's U.S. Patent Document US 2018 / 212210. In conventional batteries, the resin in contact with the battery does not achieve a water-impermeable encapsulation function. Specifically, this resin does not have the permeance feature described above.

[0191] Furthermore, this document submitted by Suzuki relates to solid-state batteries. Conversely, the battery according to the invention can be not entirely solid-state. In such cases, the long axis ends of the battery are of the "open" type. Specifically, as shown in FIG9, on the opposing long axis surfaces F4, F6, a water-impermeable encapsulation system is advantageously placed at multiple ends that directly contact the separation layer 31 or the electrolyte layer 30. Thus, this encapsulation system can "close" the pores in the electrolyte layer 30 and the separation layer 31 respectively, which specifically allows the nano-confined electrolyte inside the battery to be retained in a satisfactory manner. In an alternative embodiment, although not shown, this encapsulation system can be in contact with other layers. However, this encapsulation preferably contacts all elements in the battery except for the protruding substrate on the opposing long axis surfaces of the stacked structure.

[0192] Furthermore, the packaging system according to the invention is advantageously electrically insulating. For the purposes of the invention, the conductivity of the packaging system is preferably less than 10e-11 S·m-1, particularly less than 10e-12 S·m-1. This feature is advantageous because it avoids short circuits and allows for rework of the positive and negative connections relative to compatibility with pick-and-place type electronic component placement machines. This feature can be compared with the disclosure in the aforementioned patent document filed by Suzuki, in which water impermeability is provided by a metallic outer casing.

[0193] As shown in FIG9, the coated stacked structure is then cut along the cutting lines DYn, DY'n by any suitable means to expose the anode connection region 1002 and the cathode connection region 1006 and obtain a cell.

[0194] As shown in Figures 9 and 10, the cutting along the cutting lines DYn and DY'n in the reinforced and encapsulated stacked structure results in:

[0195] Only the anode edges 1002' of each anode current collecting substrate 10 protrude from the first end plane DYa. This first end plane is defined in the first long axis direction XX' of the battery by the first long axis ends of each anode layer 20, each electrolytic layer 30 and / or separation layer 31, each cathode layer 50 and each cathode current collecting substrate 40, and is flush with the first long axis plane F6, and makes...

[0196] Only the cathode edges 1006' of each cathode current collecting substrate 40 protrude from the second end plane DY'a. This second surface is defined in the second long axis direction XX'' of the battery by the second long axis ends of each anode layer 20, each electrolytic layer 30 and / or separation layer 31, each cathode layer 50 and each anode current collecting substrate 10, and is flush with the second long axis surface F4, which is preferably opposite to and parallel to the first long axis surface F6.

[0197] It should be understood that each anode edge 1002' defines the anode connection region 1002 and each cathode edge 1006' defines the cathode connection region 1006.

[0198] Contacts 97, 97', and 97'' (electrical contacts) are respectively added to the apparent locations of the cathode connection region 1006 and the anode connection region 1002. These contact regions are preferably located on opposite sides of the battery stack structure to collect current (lateral current collector). Contacts 97, 97', and 97'' are provided at least on the cathode connection region 1006 and at least on the anode connection region 1002, preferably on the surface of the stack structure that includes at least the cathode connection region 1006 and is coated and cut, and on the surface of the stack structure that includes at least the anode connection region 1002 and is coated and cut (as shown in FIG11).

[0199] Therefore, at least the anode connection region 1002 preferably includes at least a first long axis surface F6 of the anode connection region 1002, and more preferably includes the first long axis surface F6 of the anode connection region 1002 and the end 97'a of the surfaces F1, F2, F3, and F5 adjacent to the first long axis surface F6, which is covered by an anode contact 97' capable of generating electrical contact between the stacked structure I and the external conductive element. In addition, at least the cathode connection region 1006 preferably includes at least a second long axis surface F4 of the cathode connection region 1006, and more preferably includes the second long axis surface F4 of the cathode connection region 1006 and the end 97''a of the surfaces F1, F2, F3, and F5 adjacent to the second long axis surface F4, which is covered by a cathode contact 97'' capable of generating electrical contact between the stacked structure I and the external conductive element.

[0200] Preferably, the contacts 97, 97', 97'' are formed in the vicinity of the cathode connection region 1006 and the anode connection region 1002 by a stacked structure I of a plurality of consecutive layers. These layers include a first electrical connection layer and a second electrical connection layer. The first electrical connection layer includes a material filled with conductive particles, preferably a polymeric resin filled with conductive particles and / or a material obtained by a sol-gel method, more preferably a polymeric resin filled with graphite. The second layer is composed of a metal foil disposed on the first layer.

[0201] The first electrical connection layer enables the subsequent second electrical connection layer to be fixed and at the same time provides "flexibility" at the connection, so as not to damage the electrical contacts when the circuit is subjected to thermal and / or vibration stress.

[0202] The second electrical connection layer is a metal foil. This second electrical connection layer is used to provide the battery with lasting protection against moisture. Generally, given a material thickness, metal can produce a highly impermeable film, more impermeable than ceramic-based films and even more impermeable than polymer-based films, while typically not very impermeable to the passage of water molecules. The second electrical connection layer increases battery life by reducing the moisture permeability of the contacts.

[0203] Preferably, a third electrical connection layer containing conductive ink can be deposited on the second electrical connection layer; the purpose of which is to reduce moisture permeability and thus increase battery life.

[0204] Contacts 97, 97', 97'' allow electrical connections at each end to switch between positive and negative. These contacts 97, 97', 97'' enable parallel electrical connections between different battery elements. For this purpose, only the cathode connection protrudes from one end, and the anode connection is available at the other end.

[0205] International Patent Application WO 2016 / 001584 describes a stacked structure of multiple cell units, which consists of anode and cathode foils stacked in an alternating and laterally offset manner (as shown in Figure 12), and encapsulated in a packaging system 295 to prevent the cells of battery 2000 from being affected by the external environment. To obtain cell units with exposed anode connection regions 2002 and cathode connection regions 2006, the stacked structures of these packages are cut along a cut surface passing through the alternating continuous stack of electrodes and the packaging system. Because the packaging system and electrodes of batteries in the prior art have different densities, cutting along this cut surface poses a risk of the packaging system peeling off near the cut surface, which could further cause a short circuit. In International Patent Application WO 2016 / 001584, during the packaging process, the packaging layer fills the gaps in the stacked structure of foils subjected to U-shaped cuts. This packaging layer, inserted into these gaps, is thick and not well bonded to the stacked structure, which leads to a risk of the packaging system 2095 peeling off during subsequent cutting processes.

[0206] According to the present invention, this risk is eliminated by using a foil with a unit body, in which:

[0207] In the first long axis direction XX', each anode current collecting substrate 10 protrudes from the first end plane DYa, which is defined by the first long axis ends of each anode layer 20, each electrolytic layer 30 and / or separation layer 31, each cathode layer 50, and each cathode current collecting substrate 40.

[0208] In the battery, in the second long axis direction XX'' relative to the first long axis direction XX', each cathode current collecting substrate 40 protrudes from each anode layer 20, each electrolytic layer 30 or is impregnated or subsequently impregnated in the electrolyte separation layer 31, each cathode layer 50 and each anode current collecting substrate 10.

[0209] Due to the overlapping relationship between the cathode and anode foils, the hot-pressing mechanical structure of the cell body is very robust near the cutting point. Using this robust structure and the foil supporting the cell body reduces the number of defects during the cutting process and increases the cutting speed, thereby increasing the production output of the battery.

[0210] According to the present invention, the cutting lines DYn and DY'n produce high-quality and clean cuts by passing through anode foils having unit bodies 2e and cathode foils having unit bodies 5e of similar density. Furthermore, the presence of no anode material, electrolyte, impregnated or unimpregnated separation layer, and anode current collecting substrate 10 of the cathode and cathode current collecting substrate in the first major axis direction XX', and the presence of no anode material, electrolyte, impregnated or unimpregnated separation layer, and cathode current collecting substrate 40 of the anode and cathode current collecting substrate in the second major axis direction XX'', prevents any risk of short circuits and current leakage, and promotes electrical contact in the connection regions 1002 and 1006. The anode connection region 1002 and the cathode connection region 1006 are preferably laterally opposite each other.

[0211] The special structure of the battery according to the present invention prevents short circuits in the long axial surfaces F4 and F6 of the battery, prevents current leakage, and promotes electrical contact between the anode connection region 1002 and the cathode connection region 1006. Specifically, the absence of electrode material and electrolytic material on the long axial surfaces F4 and F6 of the battery, which include the anode and cathode connection regions, prevents lateral leakage of lithium ions and promotes battery balance; the effective surface of the electrodes in contact with each other is defined by the first end plane DYa and the second end plane DY'a and is substantially the same as shown in FIG7 and FIG10.

[0212] In an alternative embodiment, as shown in Figures 5 and 16, batteries 1000' can be obtained according to the present invention. These batteries 1000' correspond to batteries 1000 rotated 180 degrees relative to axis Z1000, wherein axis Z1000 is parallel to the positive axis ZZ passing through the center C1000 of the battery. Batteries 1000 and 1000' can have the same dimensions. Batteries 1000 and 1000' can have the same or different major axis dimensions. Producing batteries 1000 and 1000' in the same stacking structure optimizes battery production output while minimizing material offcuts 90.

[0213] The battery according to the invention can be made from cell bodies according to different alternative embodiments of the invention. In a non-limiting example, as shown in FIG13, the coating regions 71, 81 of the cell body can be generated by die coating on the current collecting substrates 40, 10 in a symmetrical manner in the traveling direction of the substrate. This allows the uncoated regions 72, 82 to remain directly on the substrate and thus reduces the number of steps in the method of manufacturing the cell body on the cathode and anode foils. The exclusion regions of the individual cell bodies in the same row R can be common and form exclusion bridges 82' (as shown in FIG13 and FIG14).

[0214] As shown in FIG. 15, additional batteries 1000' can be obtained according to the present invention and this same alternative embodiment of the invention. These batteries 1000' correspond to batteries 1000 rotated 180 degrees relative to axis Z1000, wherein axis Z1000 is parallel to the positive axis ZZ passing through the center C1000 of the battery. Producing batteries 1000, 1000' in the same stacked structure optimizes the battery production output while minimizing material scrap 90.

[0215] In an alternative embodiment not illustrated, the exclusion region of each cell body in row Rn can be generated from the exclusion bridge shared by each cell body in the same row Rn, thereby optimizing the production output of the battery while preventing the generation of material scrap 90. The central portion 4 of the staggered foil stacking structure is therefore used entirely for manufacturing the battery according to the invention.

[0216] Figures 18 to 20 illustrate further embodiments of the invention. In these figures, any element similar to that of the first embodiment is labeled with the same reference numeral plus 300.

[0217] As shown in Figure 20, battery 1300 differs from battery 1000 described above, specifically in that battery 1300 includes a single cell 400 covered by packaging system 395. This single cell, from top to bottom in Figure 20, comprises:

[0218] Anode current collecting substrate 310

[0219] Anode layer 320,

[0220] A separation layer 331 impregnated with an electrolyte, and the separation layer can be replaced by the aforementioned electrolytic layer.

[0221] Cathode layer 350, and

[0222] Cathode current collection substrate 340.

[0223] Referring to Figure 18, the different components of the cell are first placed sequentially on top. This architecture is generally obtained by localized deposition on the substrate. A portion of the current collector is not covered by the deposition. The current collecting substrates 310 and 340 located at opposite end faces F1 and F2 are arranged such that their opposite ends protrude from the other layers on opposite long axis surfaces F4 and F6. Next, as shown in Figure 19, these components are covered by the packaging system 395.

[0224] Next, a cut is made along the vertical lines 392 and 393 shown in Figure 19. As shown in Figure 20, the cut exposes the edges 311 and 341 of the current collecting substrates 310 and 340, respectively. It should be noted that in two opposite directions, these edges are covered by regions 394 and 396 of the packaging system 395, which protrude along the long axis XX.

[0225] Figure 21 presents yet another embodiment of the invention. In these figures, any element similar to that of the first embodiment is labeled with the same reference numeral plus 400.

[0226] Similar to battery 1000, battery 1400 in FIG21 includes a plurality of unit cells 500 arranged sequentially downward in the front orientation ZZ. Compared to battery 1000, battery 1400 has a packaging system 495 similar to the packaging system 395 described above. Specifically, packaging system 495 has a plurality of regions 494, 496 protruding along orientation XX. Similar to battery 1300, these regions 494, 496 are formed by cutting along cutting lines 492, 493, which are shown as vertical dotted lines in FIG21. These cuts expose the edges 411, 441 of different current collection substrates 410, 440.

[0227] Figures 22 to 24 present further embodiments of the present invention, which are to be compared with the embodiments presented in Figures 18 to 20. In Figures 22 to 24, elements similar to those in the embodiments presented in Figures 18 to 20 are labeled with the same reference numerals plus 200.

[0228] Similar to battery 1300, battery 1500 shown in Figure 24 includes a single cell 600 covered by packaging system 595. This single cell comprises, from top to bottom in Figure 24, the following:

[0229] Anode current collection substrate 510

[0230] Anode layer 520,

[0231] The separation layer 531, impregnated with the electrolyte, can be replaced by the aforementioned electrolytic layer.

[0232] Cathode layer 550, and

[0233] Cathode current collection substrate 540.

[0234] However, the difference between battery 1500 and battery 1300 is primarily that the current collecting substrates 510 and 540 do not protrude from the other layers along their long axis XX. Furthermore, battery 1500 is equipped with two additional components, namely electrical connectors 560 and 570 located on opposite end faces of the cell 600. Specifically, each connector is identical to the others and typically has a thickness of less than 300 µm, preferably less than 100 µm.

[0235] The various connectors are advantageously made of conductive materials, particularly metallic materials. Specifically, metallic materials include aluminum, copper, or stainless steel. To improve their weldability, these materials can be coated with a thin layer of gold, nickel, or tin.

[0236] The bonding method between connector 560 and current collecting substrate 510 will now be described on the one hand, and the bonding method between connector 570 and current collecting substrate 540 on the other hand. These bonding methods are typically formed by conductive adhesive (especially graphite adhesive) or adhesive filled with copper or aluminum metal nanoparticles. This conductive adhesive layer is not shown in FIG24 and typically has a thickness of 0.1 micrometers to several micrometers. Alternatively, this conductive adhesive layer can be replaced by soldering.

[0237] As shown in Figure 22, each connector 560, 570 is positioned offset along its long axis on its respective current collection substrate 510, 540. More specifically, the first ends of these connectors define protrusions 562, 572, which protrude from the long axis surfaces F4, F6 of the cell in two opposite directions. Furthermore, at one end of the connector opposite to these protrusions, each connector is recessed from the cell to define its respective shoulder 564, 574. This configuration is an advantageous feature and makes the connectors more visually identifiable from the other layers.

[0238] The cell 600 with connectors is then covered by the encapsulation system. As shown in FIG23, the long axis and side faces of the cell, as well as shoulders 564, 574, are first partially covered by the encapsulation system 595'. Referring to FIG24, the end faces of the connectors are then covered to form the final encapsulation system 595. Finally, a cut is made, which is not shown but is similar to the cut made along vertical lines 392, 393 in FIG19. Such a cut exposes the edges 566, 576 of the connectors. In this example, the encapsulation system is provided in two consecutive steps, but it should be understood that a single step may also be provided.

[0239] FIG25 presents an alternative embodiment to the embodiments presented in FIGS. 22 to 24. In FIG25, elements similar to those in FIGS. 22 to 24 are labeled with the same reference numerals plus 100. As described above, electrical connectors 560 and 570 protrude from the cell in two opposite directions along their major axis. Conversely, as shown in FIG25, electrical connectors 660 and 670 of the battery 1600 both protrude in the same direction, i.e., to the right in FIG25.

[0240] The embodiments presented in Figures 18 to 25 and Figures 22 to 25 have several specific advantages. Specifically, they relate to "single-cell battery" type batteries, which are particularly suitable for specific applications requiring high energy density. Furthermore, such an architecture simplifies the packaging process.

[0241] Finally, the embodiments presented in Figures 22 to 25 relate to the use of electrical connectors, which also have several specific advantages. This thus avoids the need for localized deposition on the substrate, allowing the entire surface of the current collecting substrate to be coated with electrode material. Because lateral offset is generated in the connector, it is not necessary to perform localized deposition on the current collector as in the embodiments shown in Figures 18, 19, and 20.

[0242] Referring to the embodiments in Figures 22 to 25, the present invention relates more to a battery 1500 comprising a stacked structure of at least one cell, particularly formed from a single cell 600, each cell sequentially comprising an anode current collecting substrate 510, an anode layer 520, at least one electrolytic layer 530 and / or at least one separation layer 531 impregnated with an electrolyte, a cathode layer 550, and a cathode current collecting substrate 540.

[0243] The stacked structure and the battery have six sides, namely

[0244] Two so-called end faces F1 and F2, end faces F1 and F2 are opposite to each other and are substantially parallel to the layer and the current collection substrate.

[0245] Two so-called major axial surfaces F4 and F6, which are opposite to each other and respectively contain the anode and cathode connection regions, and

[0246] Two so-called sides that are opposite to each other,

[0247] The battery is characterized by further including two electrical connectors 560 and 570 located on opposite end faces of the stacked structure, wherein the first end (protrusion 562, 572) of each electrical connector protrudes beyond the long axis surface F4, F6 of the stacked structure along the long axis direction XX.

[0248] Other features of this battery according to this additional purpose of the invention:

[0249] The first end 562 of the connector 560 protrudes beyond the first long axis surface F4 in a first direction, and the first end 572 of the other connector 570 protrudes beyond the other long axis surface F6 in a direction opposite to the first direction.

[0250] The first ends 662 and 672 of the two connectors 660 and 670 protrude beyond the same long axis surface F4 in the same direction.

[0251] Each electrical connector is bonded to the corresponding current collection substrate through a conductive adhesive.

[0252] The current collection substrate, anode layer, cathode layer and separation layer do not protrude beyond the long axis of the stacked structure.

[0253] Each electrical connector defines a shoulder 564, 574 relative to a protruding end of the relatively stacked structure.

[0254] The method according to the invention is particularly suitable for manufacturing completely solid-state batteries, i.e., batteries in which the electrodes and electrolytes are solid and do not contain liquid or even immersed in solid state.

[0255] The method according to the invention is particularly suitable for manufacturing batteries considered to be in a quasi-solid-state, such batteries comprising at least one separation layer 31 impregnated with an electrolyte. The separation layer is preferably a porous inorganic layer and has:

[0256] Porosity greater than 30%, preferably mesoporous, with a porosity preferably between 35% and 50%, more preferably between 40% and 50%.

[0257] The pores have an average diameter D50 of less than 50 nm.

[0258] The thickness of the separation layer is advantageously less than 10 µm, more preferably between 2.5 µm and 4.5 µm, so as to reduce the final thickness of the battery without degrading the properties of the separation layer. The pores of the separation layer are impregnated with an electrolyte, preferably a phase carrier lithium ion, such as a liquid electrolyte or an ionic liquid containing lithium salt. The liquid "nano-entrapped" or "nano-entrapped" in the pores (especially in mesopores) can no longer be drained. The liquid is restricted by a phenomenon called "absorption in the mesoporous structure" (which is not described in the relevant content on lithium-ion batteries) and cannot be drained, even when the cell is placed in a vacuum environment. The battery can therefore be regarded as a quasi-solid-state battery.

[0259] The battery according to the present invention can be a lithium-ion microbattery, a lithium-ion mini-battery, or a high-power lithium-ion battery. Specifically, the battery according to the present invention can be designed or sized to have a charge of less than or equal to about 1 milliampere-hour (mAh) (commonly referred to as a "microbattery"), a charge of greater than about 1 mAh up to about 1 ampere-hour (Ah) (commonly referred to as a "mini-battery"), or a charge of greater than about 1 Ah (commonly referred to as a "high-power battery"). Typically, the microbattery is configured to be compatible with methods of manufacturing microelectronic components.

[0260] Batteries in each of these three power ranges can be generated as follows:

[0261] The layer has a "solid" type, that is, it is not impregnated with a liquid or viscous substance (the liquid or viscous substance may be a lithium-ion conductive medium that can serve as an electrolyte).

[0262] Or a mesoporous "solid" type layer impregnated with a liquid or adhesive substance, typically a lithium-ion conductive medium, in which the liquid or adhesive substance spontaneously passes through the layer and no longer emerges, thus allowing the layer to be considered a quasi-solid.

[0263] Or have an impregnated porous layer (i.e., a layer having a network of open pores that can be impregnated by a liquid or viscous substance, which imparts wet properties to the layer). [Simplified Explanation of the Diagram]

[0265] Related drawings, as non-limiting examples, illustrate different aspects and embodiments of the invention. FIG1 is a perspective view of anode and cathode foils for forming a stacked structure according to the battery manufacturing method of the invention, the anode and cathode foils having a cell body including uncoated areas, coated areas, and grooves. FIG2 is a front view showing a foil, particularly showing an anode foil of FIG1. ​​FIG3 is a partially enlarged front view showing a cell body manufactured in an anode foil according to the invention or an alternative embodiment of the invention, the cell body consisting of uncoated areas (hereinafter referred to as exclusion areas), coated areas, and grooves. FIG4 is a partially enlarged perspective view showing the uncoated areas (or exclusion areas), coated areas, and grooves of these cell bodies located in adjacent foils. FIG5 is a top view showing the cutting steps performed on different cell bodies provided in the stacked structure of the foregoing drawings. FIG6 is a partially enlarged top view showing the completed cutting in the cell body. Figure 7 is a cross-sectional view along section line VII-VII in Figure 6, showing a stacked structure of anode and cathode unit bodies according to the present invention or an alternative embodiment thereof, each unit body comprising an uncoated area, a coated area, and a groove. Figure 8 is a cross-sectional view along section line VII-VII in Figure 6, showing a stacked structure of multiple unit bodies encapsulated in a packaging system. Figure 9 is a cross-sectional view along section line VII-VII, showing a battery according to the present invention including a packaging system, which can be obtained particularly by the method shown in the foregoing figures. Figure 10 is a perspective view showing a battery according to the present invention including a packaging system, which can be obtained particularly by the method shown in the foregoing figures. Figure 11 is a cross-sectional view along section line VII-VII, showing a battery according to the present invention including a packaging system and contacts, which can be obtained particularly by the method shown in the foregoing figures. Figure 12 is a perspective view of a battery according to the prior art. Figure 13 is a front view showing a foil according to an alternative embodiment of the invention, particularly an anode foil in which the anode exclusion region is manufactured in the form of a single exclusion strip. Figure 14 is a top view showing the cutting steps performed on different cell bodies in a stacked structure according to an alternative embodiment of the invention. Figure 15 is a top view showing the cutting steps performed on different cell bodies in a stacked structure according to an alternative embodiment of the invention and the battery obtained according to this alternative embodiment. Figure 16 is a top view of a battery line according to the invention. Figure 17 is a perspective view showing a battery line according to the invention including a packaging system, which can be obtained particularly by the method shown in the foregoing figures.Figures 18 to 20 are front views illustrating the sequential manufacturing steps of a battery according to another embodiment of the present invention, wherein the battery comprises a single cell and each current collector forms a tab. Figure 21 is a front view similar to Figure 8, illustrating an alternative embodiment of the battery in Figure 8. Figures 22 to 24 are front views similar to Figures 18 to 21, illustrating the sequential manufacturing steps of a battery according to yet another embodiment of the present invention using a metal grid-type electrical connection support. Figure 25 is a front view similar to Figure 24, illustrating an alternative embodiment of the embodiment in Figure 24.

Claims

1. A battery comprising at least one cell, the at least one cell sequentially comprising an anode current collecting substrate, an anode layer, at least one electrolyte layer and / or at least one separator layer impregnated with an electrolyte, a cathode layer and a cathode current collecting substrate, the at least one cell defining a stacked structure, the stacked structure and the battery having six faces, the six faces comprising: two end faces, the two end faces being opposite each other and substantially parallel to one or more of the anode current collecting substrates, one or more of the anode layers, one or more of the electrolyte layers or one or more of the separator layers impregnated with the electrolyte, and the two end faces being substantially parallel to one or more of the cathode layers and one or more of the cathode current collecting substrates; two side faces, the two side faces being opposite each other; and a first long axis surface. The battery has a so-called second long axis surface, the first long axis surface and the second long axis surface are opposite to each other, the first long axis surface of the battery includes at least one anode connection region, and the second long axis surface of the battery includes at least one cathode connection region, the at least one anode connection region and the at least one cathode connection region are laterally opposite to each other, wherein in a first long axis direction of the battery, each anode current collecting substrate protrudes from each anode layer, each electrolytic layer or each separation layer, each cathode layer and each cathode current collecting substrate immersed in the electrolyte, and in a second long axis direction of the battery relative to the first long axis direction, each cathode current collecting substrate protrudes from each anode layer, each electrolytic layer or each separation layer, each cathode layer and each anode current collecting substrate immersed in the electrolyte.

2. The battery as claimed in claim 1, wherein the battery comprises a plurality of cell units arranged sequentially downwards, the cell units overlapping according to a frontal orientation relative to one of the main planes of the battery, the cell units defining the stacked structure.

3. The battery as claimed in claim 2, wherein each of the anode current collecting substrates is the anode current collecting substrate of two adjacent cell units, and each of the cathode current collecting substrates is the cathode current collecting substrate of two adjacent cell units.

4. The battery as claimed in claim 1 or 3, wherein the two end faces opposite each other are parallel to each other, the two side faces opposite each other are parallel to each other, and the first long axis face and the second long axis face opposite each other are parallel to each other.

5. The battery as claimed in claim 1, wherein each of the anode current collecting substrates protrudes from a first end plane, the first end plane being defined by a plurality of first long axis ends of each of the anode layers, each of the electrolytic layers or each of the separation layers, each of the cathode layers, and each of the cathode current collecting substrates.

6. The battery as claimed in claim 1, wherein each of the cathode current collecting substrates protrudes from a second end plane, the second end plane being defined by a plurality of second long axis ends of each of the anode layers, each of the electrolytic layers or each of the separation layers, each of the cathode layers, and each of the anode current collecting substrates.

7. The battery as claimed in claim 1 further includes an encapsulation system that covers at least a portion of the outer periphery of the stacked structure, the encapsulation system including at least one waterproof cover layer having a moisture permeability of less than 10⁻⁵ g / m²·d, the encapsulation system being in direct contact at least on each of the first long axis surfaces and the second long axis surfaces with each of the electrolyte layers and / or the separation layers impregnated with the electrolyte.

8. The battery as claimed in claim 7, wherein the packaging system also directly contacts the non-protruding portions of the anode layer, the cathode layer, the anode current collecting substrate, and the cathode current collecting substrate on each of the first longitudinal surface and the second longitudinal surface.

9. The battery as claimed in claim 7, wherein the encapsulation system is electrically insulating and the conductivity of the encapsulation system is advantageously less than 10e-11 S·m-1.

10. The battery as claimed in claim 7, wherein the packaging system covers the two end faces, the two side faces, and at least a portion of the first long axis face and the second long axis face of the stacked structure such that: only the anode edges of each anode current collecting substrate protruding from each of the anode layers, each of the electrolytic layers or each of the separation layers, each of the cathode layers, and each of the cathode current collecting substrates along the first long axis direction of the battery are flush with the first long axis face, and only the cathode edges of each cathode current collecting substrate protruding from each of the anode layers, each of the electrolytic layers or each of the separation layers, each of the cathode layers, and each of the anode current collecting substrates along the second long axis direction of the battery are flush with the second long axis face, each anode edge defining the at least one anode connection region, and each cathode edge defining the at least one cathode connection region.

11. The battery as claimed in claim 7, wherein the encapsulation system comprises: a first cover layer deposited on at least a portion of the outer periphery of the stacked structure; a second cover layer composed of an electrically insulating material and deposited on at least a portion of the outer periphery of the stacked structure or on the first cover layer by atomic layer deposition; and at least one waterproof third cover layer made of a ceramic material and / or a low-melting-point glass and deposited on at least a portion of the outer periphery of the stacked structure or on the first cover layer, wherein when the second cover layer is present, the second cover layer and the at least one third cover layer are repeatedly deposited z times on the outer periphery of the at least one third cover layer, wherein z ≥ 1, and the last layer of the encapsulation system is a waterproof cover layer made of a ceramic material and / or a low-melting-point glass.

12. The battery as claimed in claim 11, wherein the first covering layer is selected from parylene, fluorinated parylene, polyimide, epoxy resin, silicone resin, polyamide, sol-gel silicon oxide, organic silicon oxide and / or mixtures thereof.

13. The battery as claimed in claim 1, wherein the at least one anode connection region is covered by an anode contact and the at least one cathode connection region is covered by a cathode contact, wherein the anode contact and the cathode contact form an electrical contact between the stacked structure and an external conductive element.

14. The battery as claimed in claim 13, wherein the first long axis surface containing the at least one anode connection region is covered by the anode contact, and the second long axis surface containing the at least one cathode connection region is covered by the cathode contact.

15. The battery as claimed in claim 13, wherein each of the anode contact and the cathode contact comprises: a first electrical connection layer disposed in the at least one anode connection region and the at least one cathode connection region, the first electrical connection layer comprising a material filled with conductive particles, and a second electrical connection layer comprising a metal foil disposed on the first electrical connection layer filled with conductive particles.

16. The battery as claimed in claim 5, wherein the minimum distance between the first long axis surface of the at least one anode connection region and the first end plane defined by the first long axis ends of each of the anode layers, each of the electrolytic layers and / or each of the separation layers, each of the cathode layers and each of the cathode current collection substrates is between 0.01 mm and 0.5 mm, and / or the minimum distance between the second long axis surface of the at least one cathode connection region and one of the second end planes defined by the second long axis ends of each of the anode layers, each of the electrolytic layers and / or each of the separation layers, each of the cathode layers and each of the anode current collection substrates is between 0.01 mm and 0.5 mm.

17. A method of manufacturing at least one battery, the at least one battery comprising at least one cell, the at least one cell sequentially comprising an anode current collecting substrate, an anode layer, at least one electrolyte layer and / or at least one separator layer impregnated with an electrolyte, a cathode layer and a cathode current collecting substrate, the at least one cell defining a stacked structure, the stacked structure and the at least one battery having six faces, the six faces including: so-called two end faces, the two end faces being opposite each other, the two end faces being substantially parallel to one or more of the anode current collecting substrates, one or more of the anode layers, one or more of the electrolyte layers or one or more of the separator layers impregnated with the electrolyte, and the two end faces being substantially parallel to the... One or more cathode layers and one or more cathode current collecting substrates, two sides facing each other, a first long axis surface and a second long axis surface facing each other, the first long axis surface of the battery including at least one anode connection region, and the second long axis surface of the battery including at least one cathode connection region, the at least one anode connection region and the at least one cathode connection region laterally facing each other, wherein in the first long axis direction of the battery, each anode current collecting substrate protrudes from each anode layer, each electrolyte layer or each separation layer impregnated with the electrolyte, each cathode layer and each cathode current collecting substrate The battery has a plate, and in a second long axis direction relative to the first long axis direction, each of the cathode current collecting substrates protrudes from each of the anode layer, each of the electrolytic layer or each of the separation layer impregnated with the electrolyte, each of the cathode layer, and each of the anode current collecting substrates. The manufacturing method includes: step 1, providing at least one anode foil, the at least one anode foil having a plurality of grooves, a plurality of uncoated areas, and a plurality of coated areas coated with the anode layer and selectively coated with the electrolytic layer or the separation layer; step 2, providing at least one cathode foil, the at least one cathode foil having a plurality of grooves, a plurality of uncoated areas, and a plurality of coated areas coated with the cathode layer and selectively coated with the electrolytic layer or the separation layer; step 3, ... A stacked structure is generated, comprising at least one anode foil having interlaced grooves, uncoated areas, and coated areas, and at least one cathode foil having grooves, uncoated areas, and coated areas, to obtain at least one cell sequentially comprising an anode current collecting substrate, an anode layer, at least one electrolytic layer or at least one separation layer, a cathode layer, and a cathode current collecting substrate. In the first long axis direction of the cell, each anode current collecting substrate protrudes from each anode layer, each electrolytic layer and / or each separation layer, each cathode layer, and each cathode current collecting substrate. And in the second long axis direction of the cell relative to the first long axis direction...Each of the cathode current collecting substrates protrudes from each of the anode layer, each of the electrolyte layer and / or each of the separation layer, each of the cathode layer and each of the anode current collecting substrates. Step 4: Heat-treat and / or mechanically press the stacked structure of the interlaced foils obtained in Step 3 to form a reinforced stacked structure. Step 5: Create a first pair of dicing lines to separate one column of the batteries from at least one other column of the batteries formed from the reinforced stacked structure. Step 6: Impregnate the reinforced stacked structure obtained in Step 4 with phase carrier lithium ions or impregnate the column of the batteries obtained in Step 5 during Step 5, such that the separation layer is impregnated with the electrolyte. Step 7: Create a second pair of dicing lines to expose the separation layer. An anode edge of each anode current collecting substrate protrudes from each of the anode layer, each of the electrolytic layer or each of the separation layer, each of the cathode layer and each of the cathode current collecting substrates along the first long axis direction of the battery, each anode edge defining the at least one anode connection region; and a cathode edge of each cathode current collecting substrate protrudes from each of the anode layer, each of the electrolytic layer or each of the separation layer, each of the cathode layer and each of the anode current collecting substrates along the second long axis direction of the battery, each cathode edge defining the at least one cathode connection region. During step 5, the second pair of cutting lines separates one battery from at least one other battery formed from the row of batteries.

18. The method of claim 17, wherein step 8, which encapsulates and reinforces the stacked structure or the column of batteries, is performed after step 6 if step 6 is performed, or after step 5 if step 6 is not performed and step 5 is performed, or after step 4 if steps 5 and 6 are not performed and before step 7, wherein at least a portion of the outer periphery of the column of batteries or the stacked structure is covered by an encapsulation system, and the end faces, sides, and at least a portion of the first long axis and the second long axis of the column of batteries or the stacked structure are covered by the encapsulation system, such that: only the anode edges of the anode current collecting substrates protruding from each anode layer, each electrolytic layer or each separation layer, each cathode layer and each cathode current collecting substrate along the first long axis of the battery are flush with the first long axis, and only the anode edges of each anode current collecting substrate protruding from each anode layer, each electrolytic layer or each separation layer, each cathode layer and each cathode current collecting substrate along the second long axis of the battery are flush with the first long axis, and only the anode edges of each anode layer, each electrolytic layer or each separation layer, each cathode layer and each cathode current collecting substrate protruding from each anode layer, each electrolytic layer or each separation layer, each cathode layer and each cathode current collecting substrate protruding from each cathode current collecting substrate along the second long axis of the battery are flush with the first long axis, and only the anode edges of each anode layer, each electrolytic layer or each separation layer, ... The cathode edges of the respective cathode current collecting substrates protruding from the respective separation layers, cathode layers, and anode current collecting substrates are flush with the second long axis surface. Each anode edge defines the at least one anode connection region, and each cathode edge defines the at least one cathode connection region. The packaging system includes: at least one first cover layer deposited on at least a portion of the outer periphery of the column or stack of the batteries; a second cover layer composed of an electrically insulating material and deposited by atomic layer deposition on at least a portion of the outer periphery of the column or stack of the batteries, or on the first cover layer; and at least one waterproof third cover layer made of ceramic material and / or low-melting-point glass and deposited on at least a portion of the outer periphery of the column or stack of the batteries, or on the first cover layer. The second cover layer and the at least one third cover layer are repeatedly deposited z times on the outer periphery of the at least one third cover layer, wherein z... ≥ 1, and the last layer of the encapsulation system is a waterproof cover layer made of ceramic material and / or low melting point glass.

19. The method as described in claim 17 or 18, wherein after step 7, the at least one anode connection region is covered by an anode contact that creates an electrical contact between the stacked structure and an external conductive element, and the at least one cathode connection region is covered by a cathode contact that creates an electrical contact between the stacked structure and the external conductive element, wherein the generation of the anode contact and the cathode contact comprises: depositing a first electrical connection layer on the at least one anode connection region and the at least one cathode connection region, the first electrical connection layer being made of a material filled with conductive particles; when the first electrical connection layer is made of a polymeric resin filled with conductive particles and / or a material obtained by a sol-gel method, performing a drying step after the step of polymerizing the polymeric resin and / or the material obtained by the sol-gel method; depositing a second electrical connection layer on the first electrical connection layer, the second electrical connection layer comprising a metal foil disposed on the first electrical connection layer; and depositing a third electrical connection layer comprising a conductive ink on the second electrical connection layer.

20. The method as described in claim 17, wherein the cutting lines in step 5 and / or step 7 are generated by laser ablation when step 5 is performed.

21. A battery comprising a stacked structure formed of at least one cell, the at least one cell sequentially comprising an anode current collecting substrate, an anode layer, at least one electrolytic layer and / or at least one separation layer impregnated with an electrolyte, a cathode layer and a cathode current collecting substrate, the stacked structure and the battery having six sides, the six sides comprising: two end faces, the two end faces being opposite to each other and parallel to each other, the two end faces being substantially parallel to the anode current collecting substrates, the anode layers, the electrolytic layers or the separation layers impregnated with the electrolyte, and the two end faces being substantially parallel to the cathode layers and the cathode current collecting substrates; two long axis faces, the two long axis faces being opposite to each other and respectively comprising an anode connection region and a cathode connection region; and two side faces, the two side faces being opposite to each other, the battery further comprising two electrical connectors located on the opposite end faces of the stacked structure, a first end of each of the electrical connectors protruding beyond each of the long axis faces of the stacked structure in a long axis orientation.

22. The battery as claimed in claim 21, wherein the first end of one of the electrical connectors protrudes beyond one of the longitudinal surfaces in a first direction, and the first end of the other electrical connector protrudes beyond the other longitudinal surface in a direction opposite to the first direction.

23. The battery as claimed in claim 21, wherein the two first ends of the two electrical connectors protrude beyond the same longitudinal surface in the same direction.

24. The battery as claimed in claim 21, wherein each of the electrical connectors is respectively coupled to the anode current collecting substrate and the cathode current collecting substrate.

25. The battery as claimed in claim 21, wherein the anode current collecting substrate, the cathode current collecting substrate, the anode layer, the cathode layer, and the separation layer do not protrude beyond the long axis surfaces of the stacked structure.

26. The battery as claimed in claim 21, wherein each of the electrical connectors defines a shoulder relative to a protruding end of the opposing stacked structure.

Images