Electrochemical cell device with improved lifetime including improved sealing and conduction and method of manufacture thereof

Abstract

The battery of the invention comprises a stack (I) of at least one anode (20) and at least one cathode (50) alternated, a so-called main packaging system (1020) covering four of the six faces of the stack (I), at least one anode contact member (1040) able to make an electrical contact between the stack and an external conductive element, and at least one cathode contact member (1050) able to make the electrical contact between the stack and an external conductive element. According to the invention, the battery further comprises a so-called additional packaging system (1030) comprising two front areas (1031, 1032) each covering a respective front area (1021, 1022) of the main packaging system, and two lateral areas (1033, 1035) each covering a respective lateral area (1023, 1025) of the main packaging system without any contact member, each of the two front areas (1031, 1032) of the additional packaging system (1030) further covering a front end (1041, 1042, 1051, 1052) of the anode contact member and of the cathode contact member, respectively, and each of the front areas (1031, 1032) of the additional packaging system forms a surface continuity with the lateral areas (1033, 1035) of the additional packaging system.

Description

Technical Field

[0001] This invention relates to electrochemical devices of battery type. These electrochemical devices are particularly applicable to lithium-ion batteries. The invention relates to novel battery architectures that provide improved impermeability and conductivity, as well as longer lifespan. The invention further relates to methods for manufacturing such batteries. Background Technology

[0002] Certain types of batteries, especially some types of thin-film batteries, require encapsulation to achieve a longer lifespan because oxygen and moisture can cause them to degrade. Lithium-ion batteries, in particular, are highly sensitive to moisture. The market demands product lifespans exceeding 10 years; therefore, encapsulation is essential to guarantee this lifespan.

[0003] Thin-film lithium-ion batteries are multilayered stacks, comprising electrode layers and electrolyte layers typically between one and ten μm thick. These layers can comprise a stack of multiple cell units. These batteries are highly sensitive to self-discharge. Depending on the location of the electrodes, particularly the proximity of the electrode edges and the cleanliness of the cuts in multilayer batteries, leakage current can occur at the ends, resulting in creeping short circuits that degrade battery performance. This phenomenon is exacerbated if the electrolyte membrane is very thin.

[0004] These solid-state thin-film lithium-ion batteries typically use an anode with a lithium metal layer. It was found that the volume of the anode material changes significantly during battery charge and discharge cycles. More specifically, during charge and discharge cycles, a portion of the lithium metal is converted into lithium ions, which are then inserted into the structure of the cathode material; this process is accompanied by a reduction in the anode volume. This cyclical change in volume can degrade the mechanical and electrical contact between the electrode and the electrolyte layer. This process reduces battery performance throughout its lifespan.

[0005] Cyclic changes in the volume of the anode material also induce cyclic changes in the volume of the battery cells. This generates cyclic stress in the encapsulation system, making it prone to cracking and leading to a loss of impermeability (or even integrity) of the encapsulation system. This phenomenon is another reason for the degradation of battery performance during its lifespan.

[0006] More specifically, the active materials in lithium-ion batteries are highly sensitive to air, and especially to moisture. Mobile lithium ions spontaneously react with trace amounts of water to form LiOH, leading to calendar aging of the battery. The amount of lithium reacting with water is no longer available for energy storage, which reduces battery capacity through premature aging. For this reason, extreme care must be taken during battery manufacturing to maintain completely anhydrous conditions. Similarly, to ensure calendar life, the battery is protected from external environmental influences by hermetically sealed packaging that prevents water penetration, which can further reduce battery capacity.

[0007] Water permeation through the encapsulation structure is a well-known phenomenon. The impermeability of the encapsulation is typically expressed as water vapor transmission rate (WVTR). This ratio depends on the materials used, the manufacturing process, and the thickness.

[0008] The quality of packaging is extremely important for lithium-ion batteries.

[0009] Furthermore, all lithium-ion conductive electrolytes and intercalation materials are non-reactive to moisture. For example, Li4Ti5O4 is non-reactive when exposed to air or trace amounts of water. 12 It will not deteriorate. In contrast, once Li 4+x Ti5O 12 If lithium is filled in a form where x > 0, the excess lithium (x) is atmospherically sensitive and spontaneously reacts with trace amounts of water to form LiOH. The resulting lithium is therefore unusable for storing electricity, leading to a loss of battery capacity.

[0010] To prevent the active materials of lithium-ion batteries from being exposed to air and water, and to prevent this type of aging, the batteries must be protected by encapsulation systems. Numerous encapsulation systems for thin-film batteries are described in the literature.

[0011] U.S. Patent No. 2002 / 0071989 describes a packaging system for solid-state thin-film batteries, the system comprising a stack of: a first layer of dielectric material selected from alumina (Al2O3), silicon dioxide (SiO2), silicon nitride (Si3N4), silicon carbide (SiC), tantalum oxide (Ta2O5), and amorphous carbon; a second layer of dielectric material; and an impermeable sealing layer disposed on the second layer and covering the entire battery.

[0012] U.S. Patent No. 5,561,004 describes several systems for protecting thin-film lithium-ion batteries. A first proposed system includes a parylene layer covering an aluminum film deposited on the battery's active components. However, this system, which prevents the diffusion of air and water vapor, is only effective for about a month. A second proposed system includes alternating layers of parylene (500 nm thick) and metal (approximately 50 nm thick). The document states that it is preferable to recoat these batteries with a UV-cured epoxy coating to slow down the rate at which atmospheric elements degrade the batteries.

[0013] Reference is also made to international patent document WO 2019 / 002768 filed by the applicant, which describes a typical arrangement of an electrochemical device. As disclosed in this document, such a device comprises a stack of units, each unit comprising an anode current collector substrate and a corresponding cathode current collector substrate, an anode layer and a corresponding cathode layer, and at least one layer of electrolyte material or an electrolyte-impregnated separator layer. Anode contacts and corresponding cathode contacts are provided on opposite lateral surfaces of the stack.

[0014] Finally, reference is made to U.S. Patent No. 2019 / 368141, which discloses a battery intended for integration into a road. The battery includes a package 150 and a curb 160 to hold the battery components within the road structure.

[0015] According to existing technology, most lithium-ion batteries are encapsulated in a metallized polymer foil (called a "bag") surrounding the battery cell and heat-sealed at the connector tabs. These packages are relatively flexible, allowing the positive and negative terminals of the battery to be embedded within the heat-sealed polymer used to seal the package around the battery. However, this welding between the polymer foils is not entirely impermeable to atmospheric gases, as the polymer used for heat-sealing the battery is relatively permeable to atmospheric gases. Permeability increases with temperature, which accelerates aging.

[0016] However, the surface area of ​​these welded components exposed to the atmosphere remains extremely small, and the remainder of the package is formed by aluminum foil sandwiched between these polymer foils. Generally, the two aluminum foils are combined to minimize the impact of the presence of holes, which constitute defects in each of these foils. The probability of two defects aligning on each strip is greatly reduced.

[0017] These packaging technologies ensure that, under normal operating conditions, the 10×20cm... 2 A 10Ah battery with a surface area of ​​[missing information] has a calendar life of approximately 10 to 15 years. If the battery is exposed to high temperatures, its lifespan can be reduced to less than 5 years, which is insufficient for many applications. Similar technologies can be used in other electronic components, such as capacitors and active components.

[0018] Therefore, systems and methods are needed for encapsulating thin-film batteries and other electronic components to protect them from the effects of air, moisture, and temperature. Specifically, systems and methods are needed for encapsulating thin-film lithium-ion batteries to protect them from the effects of air and moisture and from degradation during charge and discharge cycles. The encapsulation system must be impermeable and hermetically sealed; it must completely enclose and cover the component or battery; it must be flexible enough to accommodate minute variations in battery cell size (“respirations”); and it must also allow electrical isolation between oppositely polarized electrode edges to prevent any creepage short circuits.

[0019] One object of the present invention is to overcome at least partially the aforementioned disadvantages of the prior art.

[0020] Another objective of this invention is to propose a lithium-ion battery with an extremely long lifespan and a low self-discharge rate.

[0021] Specifically, the aim is to provide a method that allows for the manufacture of electronic or electrochemical devices (e.g., batteries) with extremely long lifespans in a simple, easy-to-implement, reliable, and rapid manner. More specifically, the aim is to provide a method that reduces the risk of short circuits and, in particular, allows for the manufacture of electrochemical devices, such as batteries, with low self-discharge rates and extremely long lifespans. Summary of the Invention

[0022] At least one of the above objectives is achieved through at least one objective according to the present invention as described below. The present invention provides a battery (1000) as a first objective, the battery comprising:

[0023] - Stack (I), the stack being an alternation between at least one anode (20) and at least one cathode (50), each anode and cathode being formed by a thin-layer stack, wherein the anode (20) comprises:

[0024] At least one anode current collector substrate (21),

[0025] At least one thin layer of anodic active material (22), and

[0026] Optionally, the electrolyte material thin layer (23) or the separator thin layer (23') impregnated with electrolyte,

[0027] And the cathode (50) comprises:

[0028] At least one cathode current collector substrate (51),

[0029] At least one thin layer of cathode active material (52), and optionally, a thin layer of electrolyte material (53) or a thin layer of separator impregnated with electrolyte (53'),

[0030] Thus, the stack sequentially comprises at least one anode current collector substrate (21), at least one anode active material thin layer (22), at least one electrolyte material thin layer (23, 53) or an electrolyte-impregnated separator thin layer (23', 53'), at least one cathode active material thin layer (52), and at least one cathode current collector substrate (51).

[0031] The stack (I) defines six faces, namely

[0032] - Two so-called positive planes (F1, F2), which are opposite to each other and especially parallel to each other, are generally parallel to the anode active material thin layer (22), parallel to the electrolyte material thin layer (23, 53) or the electrolyte-impregnated separator thin layer (23', 53'), and parallel to the cathode active material thin layer (52), and

[0033] - The four so-called lateral planes (F3, F4, F5, F6) are opposite to each other in pairs, and in particular, they are parallel to each other in pairs.

[0034] - A so-called primary packaging system (1020) covering at least two of the six faces of the stack (I), the packaging system comprising two forward packaging regions (1021, 1022) covering all or part of the forward faces (F1, F2) and / or two lateral packaging regions (1023, 1025) covering all or part of two of the lateral faces (F3, F5), the lateral packaging regions preferably opposite each other, and in particular parallel to each other.

[0035] - At least one anode contact component (1040) capable of making electrical contact between the stack and external conductive elements, the anode contact component at least partially covering the first (F4) of two lateral surfaces (F4, F6) not covered by the main packaging system (1020), the first surface (F4) defining at least one anode connection area.

[0036] - At least one cathode contact component (1050) capable of making electrical contact between the stack and external conductive elements, the cathode contact component at least partially covering the second (F6) of two lateral surfaces not covered by the main packaging system (1020), the second surface (F6) defining at least one cathode connection area.

[0037] The anode contact component (1040) and the cathode contact component (1050) are preferably opposite to each other, and in particular parallel to each other.

[0038] The battery is characterized in that it further includes a so-called additional encapsulation system (1030) comprising two forward regions (1031, 1032), each forward region covering the forward surface of the stack and optionally inserted into a corresponding forward region (1021, 1022) of the main encapsulation system. The additional encapsulation system further includes two lateral regions (1033, 1035), each lateral region covering the lateral surface of the stack without any contact components and optionally inserted into a corresponding lateral region (1023, 1025) of the main encapsulation system.

[0039] - Each of the two forward regions (1031, 1032) of the additional encapsulation system (1030) further covers the forward ends (1041, 1042, 1051, 1052) of the anode contact component and the cathode contact component, respectively.

[0040] - Each of the forward regions (1031, 1032) of the additional packaging system forms a surface continuity with the lateral regions (1033, 1035) of the additional packaging system.

[0041] Other features of the battery according to the present invention can be used independently or according to any technology-compatible features:

[0042] - The main packaging system includes two forward packaging regions (1021, 1022) covering all or part of the forward surfaces (F1, F2) and two lateral packaging regions (1023, 1025) covering all or part of two of the lateral surfaces (F3, F5).

[0043] - The main packaging system includes only two forward packaging regions (1021, 1022) that cover all or part of the forward surfaces (F1, F2).

[0044] - The main packaging system includes only two lateral packaging regions (1023, 1025) covering all or part of two of the lateral surfaces (F3, F5).

[0045] - Each of the two forward regions of the additional packaging system defines two protruding edges (1031A, 1031B, 1032A, 1032B), wherein each edge protrudes from the corresponding forward region of the main packaging system along the lateral axis (X) of the stack, and each protruding edge covers the corresponding end of the anode contact or cathode contact.

[0046] Along the lateral axis (X) of the stack, the primary packaging system extends to the inner surface of the contact members, while the additional packaging system extends beyond the inner surface, and in particular beyond the outer surface of these contact members.

[0047] - Each of the two forward regions of the additional packaging system defines two protruding edges (1031C, 1031D, 1032C, 1032D), wherein each edge protrudes from the corresponding forward region of the main packaging system and from the anode and cathode contact components along another lateral axis (Y) of the stack, and the protruding edges ensure the surface continuity between the forward and lateral regions of the additional packaging system.

[0048] - The opposite ends (1041, 1042, 1051, 1052) of each corresponding anode contact (1040) and cathode contact (1050) are flush with the positive regions (1021, 1022) of the main packaging system (1020).

[0049] - The main encapsulation system (1020) includes at least one first cover layer disposed on the stack (I), preferably selected from parylene, parylene F, polyimide, epoxy resin, silicone, polyamide, sol-gel silica, organosilicon silica and / or mixtures thereof.

[0050] Each of the anode contact component (1040) and the cathode contact component (1050) includes a first electrical connection layer made of a material filled with conductive particles, and a second electrical connection layer comprising a metal foil or a metal layer disposed on the first electrical connection layer.

[0051] - The additional encapsulation system (1030) includes an encapsulation layer selected from glass, ceramic, and glass-ceramic, wherein the encapsulation layer preferably has a density of less than 10. -5 g / m 2 Water vapor permeability (WVTR) of .d

[0052] -The glass, ceramic, and glass-ceramic of the encapsulation layer are selected from the following:

[0053] - Low melting point glass, preferably selected from SiO2-B2O3, Bi2O3-B2O3, ZnO-Bi2O3-B2O3, TeO2-V2O5, and PbO-SiO2.

[0054] -Oxides and / or nitrides and / or Ta2O5 and / or aluminum oxide (Al2O3) and / or nitrogen oxides and / or SixNy and / or SiO2 and / or SiON and / or amorphous silicon and / or SiC.

[0055] The present invention also relates to a method for manufacturing the above-mentioned battery, the manufacturing method comprising:

[0056] - Supply at least one anode current collector substrate foil, said substrate foil being coated with an anode layer and optionally coated with an electrolyte material layer or an electrolyte-impregnated separator layer, hereinafter referred to as the anode foil.

[0057] - Supply at least one cathode current collector substrate foil, said substrate foil being coated with a cathode layer and optionally coated with an electrolyte material layer or an electrolyte-impregnated separator layer, hereinafter referred to as cathode foil.

[0058] - The stack (I) is prepared by alternating at least one anode foil and at least one cathode foil to sequentially obtain at least one anode current collector substrate, at least one anode layer, at least one electrolyte material layer or an electrolyte-impregnated separator layer, at least one cathode layer, and at least one cathode current collector substrate.

[0059] - The stack of alternating foils obtained in step c) is heat-treated and / or mechanically compressed to form a reinforced stack.

[0060] - Prepare the so-called main packaging system (1020) to form a packaged and cut stack that exposes at least the anode and cathode connection regions, preferably at least the faces defining the anode and cathode connection regions.

[0061] - Optionally, the stack of cut and packaged components is impregnated with a lithium-ion-carrying phase, such as a liquid electrolyte or an ionic liquid containing a lithium salt, such that the separator is impregnated with the electrolyte.

[0062] - Place each of the anode and cathode contact components on the respective lateral face of the stack that is not covered by the main packaging system.

[0063] - An additional encapsulation assembly (1030') is fabricated on the structure obtained after step g), the assembly being designed to encapsulate a reinforced stack containing contact components, and

[0064] - At least partially expose the anode and cathode contact components to form the additional encapsulation system (1030).

[0065] Other features of the battery according to the present invention can be used independently or according to any technology-compatible features:

[0066] - The method further includes fabricating a so-called primary packaging assembly (1020') on a hardened stack (I), the primary packaging system being fabricated from the primary packaging assembly.

[0067] - The main packaging system is fabricated from the main packaging assembly by performing two so-called major cuts along the first cutting plane (II II).

[0068] - The additional packaging system is fabricated from the additional packaging assembly by performing two so-called additional cuts along a second cutting plane (VV) extending outside the first cutting plane.

[0069] - In step i) of the method, at least partial exposure of the anode and cathode contact components is achieved by polishing or cutting.

[0070] The fabrication of the so-called primary encapsulation system (1020) includes depositing at least one first capping layer on the stack (I), preferably selected from parylene, parylene F, polyimide, epoxy resin, silicone, polyamide, sol-gel silica, organosilicon silica and / or mixtures thereof.

[0071] - The fabrication of an additional encapsulation system designed to encapsulate a reinforced stack containing contact components includes the deposition of encapsulation layers selected from glass, ceramics, and glass-ceramics.

[0072] - Glass, ceramics, and glass ceramics are selected from the following:

[0073] - Low melting point glass, preferably selected from SiO2-B2O3, Bi2O3-B2O3, ZnO-Bi2O3-B2O3, TeO2-V2O5, and PbO-SiO2.

[0074] -Oxides and / or nitrides and / or Ta2O5 and / or aluminum oxide (Al2O3) and / or nitrogen oxides and / or SixNy and / or SiO2 and / or SiON and / or amorphous silicon and / or SiC,

[0075] - The fabrication of the anode and cathode contact components includes:

[0076] - A first electrical connection layer made of a material filled with conductive particles is deposited on at least the anodic connection region and at least the cathode connection region. The first layer is preferably made of a polymeric resin filled with conductive particles and / or a material obtained by a sol-gel method.

[0077] Optionally, when the first layer is made of a polymeric resin filled with conductive particles and / or a material obtained by a sol-gel method, the step of polymerizing the polymeric resin and / or the material obtained by a sol-gel method is performed after the drying step, and

[0078] - A second electrical connection layer disposed on the first electrical connection layer is deposited on the first layer. The second electrical connection layer preferably comprises metal foil or metallic ink. It should be noted that, in the latter case, the drying step may alternatively be performed after the deposition of the second electrical connection layer.

[0079] - Prepare alternating, continuous cathode and anode layers, each layer including multiple so-called blank areas, and cut such that a given stack of cells can be separated from at least one other stack of another cell.

[0080] - If the blank area has bars connected in pairs by channels, and at least a portion of the bars are filled with encapsulating material, then the cutting is performed to obtain a stack with two opposing lateral faces coated with the encapsulating material.

[0081] - If the blank area has a generally I shape, then at least one line formed by multiple stacks is prepared, the front face of which is at least partially covered by the encapsulation material, and the cutting is performed to obtain a stack having a front face coated with the encapsulation material.

[0082] According to the invention, encapsulation is provided by two separate encapsulation systems. These systems are different, particularly in their dimensions. More specifically, the additional encapsulation system has a larger dimension than the main encapsulation system, thereby allowing the additional encapsulation system to protrude from the main system in at least one direction in space. Furthermore, the two systems are advantageously different in terms of the materials used in their manufacture and their dimensions. The combination of these separate encapsulation systems produces a particularly satisfactory impermeability. Moreover, according to the invention, the additional system can be prepared after the contact components have been positioned.

[0083] It should be noted that the prior art does not disclose such combinations between individual packaging systems. Specifically, this combination is not presented as taught in the aforementioned international patent document WO 2019 / 002768. Essentially, this prior art document uses a single packaging system, as mentioned in the main claims of that document. Attached Figure Description

[0084] Referring to the accompanying drawings, certain aspects and embodiments of the invention are illustrated. The drawings are given by way of non-limiting example only, in which:

[0085] Figure 1 The front view of the cross section of the stack (I) defining the six sides is illustrated. The precursor of the battery according to the invention sequentially includes at least one anode current collector substrate (21), at least one anode active material thin layer (22), at least one electrolyte material thin layer (23, 53) or an electrolyte-impregnated separator thin layer (23', 53'), at least one cathode active material thin layer (52) and at least one cathode current collector substrate (51).

[0086] Figure 2 This diagram illustrates a front view of a cross-section of the stack of packages within a main packaging system.

[0087] Figure 3 This diagram illustrates a front view of a cross-section of the stack within the main packaging system, where the anode and cathode connection regions have been arranged along... Figure 2 The cut plane II-II is visible in the middle.

[0088] Figure 4 The diagram illustrates a front view of the stack and the battery precursor in cross-section, showing the internal structure of the stack covered by the main packaging system and the internal structure of the contact components according to the invention.

[0089] Figure 5 The diagrammatically presented front view of the cross-section of the stack in the main packaging system and the so-called additional packaging system shows the internal structure of the battery.

[0090] Figure 6 This diagram illustrates a front view of a cross-section of the stack within the main packaging system and the so-called additional packaging system, showcasing the internal structure of the battery, where the anode and cathode connection regions are arranged along... Figure 5 The visible cutting plane VV is exposed.

[0091] Figure 7 A side view of the battery according to the invention is illustrated, showing the outer surface of the anode contact component surrounded by an additional encapsulation system on the periphery of the battery.

[0092] Figure 8 and 9The cross-sectional view is shown to illustrate an alternative embodiment of the invention, in which the main packaging system covers only two sides of the cell stack.

[0093] Figure 10 and 11 To illustrate the perspective view of the anode and cathode foils arranged in an overlay manner, the foils are present in two alternative embodiments of the method of manufacturing a battery according to the present invention.

[0094] Figure 12 According to Figure 8 An alternative embodiment is shown in the front view of the steps in the battery fabrication process.

[0095] Figure 13 and 14 According to Figure 9 An alternative embodiment is shown in the front view of the steps in the battery fabrication process. Detailed Implementation

[0096] Figure 1 An electrochemical device according to a first alternative embodiment is shown, the device being a battery generally indicated by reference numeral 1. The battery comprises a stack (I) in a manner known per se, the stack being an alternation between at least one anode (20) and at least one cathode (50).

[0097] The anode (20) includes at least one anode current collector substrate (21) and at least one anode active material thin layer (22). In the example shown, the anode further includes an electrolyte material thin layer (23) or an electrolyte-impregnated separator thin layer (23'), however, the thin layer is optional.

[0098] Furthermore, the cathode (50) includes at least one cathode current collector substrate (51) and at least one cathode active material thin layer (52). In the illustrated example, the cathode further includes an electrolyte material thin layer (53) or an electrolyte-impregnated separator thin layer (53'), however, the thin layer is optional.

[0099] Therefore, the aforementioned stack sequentially includes at least one anode current collector substrate (21), at least one anode active material thin layer (22), at least one electrolyte material thin layer (23, 53) or an electrolyte-impregnated separator thin layer (23', 53'), at least one cathode active material thin layer (52), and at least one cathode current collector substrate (51).

[0100] Advantageously, after the stack has been prepared, the battery can be assembled by heat treatment and / or mechanical compression. The heat treatment enabling battery assembly is advantageously carried out at a temperature between 50°C and 500°C, preferably below 350°C. The mechanical compression of the stack is advantageously carried out at a pressure between 10 MPa and 100 MPa, preferably between 20 MPa and 50 MPa.

[0101] The stack I, which is generally a parallelepiped, has six faces. By convention, the so-called opposite end faces or front faces, which are substantially parallel to the different layers above, are first indicated by reference numerals F1 and F2. Stack 2 also defines four lateral faces F3 to F6, which are paired parallel to each other and paired opposite each other. An orthogonal coordinate system XYZ is defined associated with the stack, where the Z direction is called the front direction because it is perpendicular to the front faces above, while the other X and Y directions are called lateral directions.

[0102] The stack can be fabricated by any suitable method. According to the invention, the battery architecture includes a main packaging system, an additional packaging system, and contact components, and the architecture is particularly suitable for stacks having laterally opposed anode and cathode connection regions. Figure 1 In the example shown, a first embodiment of stacking is illustrated, wherein the stacked layers have grooves (1070) such that each cell defines a continuous region for a cathode current collector, thereby allowing electrical contact at the cathode connection region; and a continuous region for an anode current collector, thereby allowing electrical contact at the anode connection region. This arrangement allows the anode and cathode connection regions to be laterally opposite each other.

[0103] Figure 1 The stack I is shown when used alone without the other final components, such as batteries. Figure 2 As shown, in order to fabricate the battery, the six faces of stack I must first be covered by a primary encapsulation assembly, indicated by reference numeral 1020'. The six regions forming the assembly 1020' are indicated by reference numerals 1021' to 1026', respectively covering the six faces of the stack. As will be seen below, the assembly 1020' is intended to form a primary encapsulation system 1020 for protecting the battery from atmospheric effects. The primary encapsulation system is advantageously chemically stable and capable of withstanding high temperatures. The system may be atmospherically impermeable to provide an additional barrier layer function; however, as will be seen below, the primary barrier layer function is provided by additional encapsulation. The material intended to form the primary encapsulation is of any suitable type, and the primary encapsulation system 1020 particularly includes at least one first covering layer disposed on the stack (I), preferably selected from parylene, parylene F, polyimide, epoxy resin, silicone, polyamide, sol-gel silica, organosilicon silica, and / or mixtures thereof.

[0104] Typically, the first capping layer is selected from the group consisting of: silicone (e.g., deposited by impregnation or by plasma-enhanced chemical vapor deposition from hexamethyldisiloxane (HMDSO)), epoxy resin, polyimide, polyamide, poly-para-xylylene (also known as poly(p-xylylene) or more commonly referred to as parylene), and / or mixtures thereof. The first capping layer protects the sensitive elements of the battery from the effects of its environment. The thickness of the first capping layer is preferably between 0.5 μm and 3 μm.

[0105] Different para-xylene variants can be used. Advantageously, the first capping layer can be made from para-xylene C, para-xylene D, para-xylene N (CAS 1633-22-3), para-xylene F, or mixtures of para-xylene C, D, N, and / or F. Para-xylene is a dielectric, transparent, semi-crystalline material with high thermodynamic stability, excellent solvent resistance, and extremely low permeability. Para-xylene also has barrier properties that protect the battery from its external environment. When the first capping layer is made from para-xylene F, the protection of the battery is enhanced. The first capping layer is advantageously obtained by the condensation of gaseous monomers deposited on the surface by chemical vapor deposition (CVD), which produces a conformal, thin, and uniform capping of all accessible surfaces stacked. The first capping layer is advantageously rigid; the capping layer cannot be considered a flexible surface.

[0106] Once the six faces of the stack have been covered by the six regions of the encapsulation assembly 1020', then according to any appropriate means Figure 2 Plane II-II exposes the anode and cathode connection regions, which are typically parallel to the forward planes F4 and F6. The assembly 1020' can advantageously be prepared by the continuous deposition of parylene-ALD-parylene layers. The anode and cathode connection regions are preferably exposed through so-called master cuts. Figure 3 As shown, these cuts preferably allow removal of the lateral regions 1024', 1026' of the package assembly, thereby exposing the anode and cathode connection regions. Alternatively, such exposure can be achieved through steps other than cutting. Specifically, it can be done by any suitable means, particularly by chemical etching, laser cutting (or laser ablation), femtosecond laser cutting, micro-perforation, or punching. Such exposure is preferably achieved by sawing, polishing, particularly involving the use of felt and polishing paste, grinding, and / or plasma etching.

[0107] Once these major cuts are completed, a stack covered by the main packaging system is obtained, indicated by reference numeral 1020. The areas of the packaging system forming the faces F1, F2, F3, and F5 covering the stack are indicated by reference numerals 1021, 1022, 1023, and 1025. Regarding batteries impregnated with a liquid electrolyte, after obtaining the stack covered by the main packaging system and exposing the anode and cathode connections present on opposite lateral faces F4 and F6 respectively, the battery is advantageously impregnated with a lithium-ion-carrying phase, such as a liquid electrolyte or an ionic liquid containing lithium salt; this lithium-ion-carrying phase ascends capillarily through the pores of the battery, particularly the battery separators.

[0108] At the opposing lateral surfaces F4 and F6 exposed on the anode and cathode connection areas, and optionally after immersing the battery in liquid electrolyte, the anode contact 1040 and the corresponding cathode contact 1050 are then installed, as shown below. Figure 4 As shown. The so-called forward ends of these contact parts 1040 and 1050 adjacent to the forward faces of the stack are indicated by reference numerals 1041 and 1042 and 1051 and 1052. Figures 2 to 4 The steps shown are of a standard type and therefore are not described in more detail below.

[0109] Preferably, the contact components are deposited on and around the cathode and anode connection regions, preferably on the lateral surfaces defining these anode and cathode connection regions. These contact components preferably consist of a stack of layers sequentially comprising:

[0110] - A first electrical connection layer comprising a material filled with conductive particles, preferably a polymeric resin filled with conductive particles and / or a material obtained by a sol-gel method, and more preferably a graphite-filled polymeric resin, and

[0111] - The second electrical connection layer consists of a metal foil or metal layer disposed on the first layer.

[0112] When the circuit is subjected to thermal and / or vibration stress, the first electrical connection layer allows the subsequent second electrical connection layer to be secured, while providing "flexibility" at the connection without breaking the electrical contact.

[0113] The second electrical connection layer is a metal foil or metal layer. This foil or layer can be flat or textured. This second electrical connection layer provides durable moisture protection for the battery, connecting the anode connection area on the battery's side face F4 on one side and the cathode connection area on the opposite side face F6 on the other. Generally, for a given material thickness, metals make it possible to fabricate highly impermeable membranes, more impermeable than ceramic-based membranes, and even more impermeable than polymer-based membranes, which are typically not extremely impermeable to water molecules. This extends the battery's calendar life by reducing the WVTR at the contact points.

[0114] Advantageously, a third electrical connection layer, including conductive ink, can be deposited on the second electrical connection layer; the aim is to reduce water vapor permeability (WVTR) and thus extend battery life. Water vapor permeability (WVTR) can be measured using the method described in U.S. Patent No. 7,624,621, which is also described in A. Mortier et al.'s publication, "Structural properties of ultraviolet-cured polysilazane gas barrier layers on polymer substrates," in *Thin Solid Films* 6+550(2014)85-89.

[0115] The contact components allow for alternating electrical connections between the positive and negative terminals at each end. These contact components enable parallel electrical connections between different battery elements. For this purpose, only the cathode connection protrudes at one end, and the anode connection is available at the other end.

[0116] Subsequently, as Figure 5 As shown in the image, Figure 4 The six faces of the intermediate structure are covered by an additional encapsulation assembly 1030' designed to form an additional encapsulation system 1030 as shown below. This additional encapsulation system protects the entire unit from atmospheric molecular diffusion and ultimately renders it impermeable. The additional encapsulation (or additional encapsulation layer) is preferably deposited by atomic layer deposition (ALD), PECVD, high-density plasma chemical vapor deposition (HDPCVD), or inductively coupled plasma chemical vapor deposition (ICPCVD) to achieve conformal coverage of all accessible surfaces of the intermediate structure. As with the primary encapsulation described above, the additional encapsulation can advantageously be prepared by sequentially depositing parylene-ALD-parylene layers.

[0117] The thickness of the additional encapsulation layer is advantageously selected based on the required level of gas impermeability, i.e., the desired WVTR, and depends on the deposition technology used, particularly ALD, PECVD, HDPCVD, and ICP CVD. The thickness of the additional encapsulation layer is preferably between 10 nm and 15 μm. The system or the additional encapsulation layer is impermeable and preferably has a thickness of less than 10 nm. -5 g / m 2 Water vapor permeability (WVTR). Water vapor permeability can be measured using the method described in U.S. Patent No. 7,624,621, which is also described in the publication "Structural properties of ultraviolet-cured polysilazane gas barrier layers on polymer substrates" by A. Mortier et al. in Thin Solid Films 6+550(2014)85-89.

[0118] The six regions forming the additional assembly 1030' are indicated by reference numerals 1031' to 1036', and these regions respectively cover the six faces of the stack. The material intended to form the additional encapsulation may be selected from glass, ceramics, and glass-ceramics, and is preferably selected from the following:

[0119] - Low melting point glass, preferably selected from SiO2-B2O3, Bi2O3-B2O3, ZnO-Bi2O3-B2O3, TeO2-V2O5, and PbO-SiO2.

[0120] -Oxides and / or nitrides and / or Ta2O5 and / or aluminum oxide (Al2O3) and / or nitrogen oxides and / or SixNy and / or SiO2 and / or SiON and / or amorphous silicon and / or SiC.

[0121] Figure 5 The intermediate structure shown in the diagram then undergoes a so-called additional cutting operation, which proceeds along... Figure 5 The plane VV is cut in any suitable manner. These cut planes are generally parallel to plane II-II described above, however, extending outside of plane II-II in the X direction. Preferably, these cuts allow for complete or partial removal of the lateral regions 1034', 1036' of the additional encapsulation assembly, resulting in complete or partial exposure of contact parts 1040 and 1050, as... Figure 6As shown in the diagram. When these cuts are made, edge portions of the material forming the contact components can also be removed while maintaining its functionality. Advantageously, a sufficient portion of the second electrical connection layer, consisting of metal foil, is left in place. Advantageously, exposure of the first electrical connection layer is also prevented.

[0122] In this situation, the metal foil or layer can be textured to facilitate the re-establishment of electrical connections after additional cutting has been performed. Alternatively, such exposure can be achieved through steps other than cutting. Specifically, this can be done through polishing, plasma etching, chemical etching, laser cutting (or laser ablation), femtosecond laser cutting, micro-perforation, or stamping. The use of textured metal foil is particularly advantageous when the contact parts have already been exposed by sawing or polishing, especially using felt and polishing paste; this makes it easier to re-establish electrical connections, especially at localized protrusions. Alternatively, a resist can be applied to the metal portion of the current collector prior to the fabrication of additional packaging. When the resist is removed, the electrical contact is exposed again.

[0123] Once these additional cuts have been made, a stack is obtained that is first covered by the primary packaging system 1020 and then by the additional packaging system 1030. The regions of the additional system 1030 that form the corresponding regions 1021, 1022, 1023, and 1025 covering the primary system 1020 are indicated by reference numerals 1031, 1032, 1033, and 1035.

[0124] From such Figure 6 As shown in the cross-sectional view, the dimensions of the positive regions 1031 and 1032 of the auxiliary system 1030 in the X direction are larger than the dimensions of the positive regions 1021 and 1022 of the main system 1020. More specifically, each of the so-called main positive regions 1021 and 1022 extends into the inner surface of the opposing contact members 1040 and 1050 in the X direction. Furthermore, each of the so-called auxiliary positive regions 1031 and 1032 is flush with the outer surface of these contact members in the X direction.

[0125] Therefore, each of these regions 1031 and 1032 defines so-called protruding edges 1031A, 1031B and 1032A, 1032B in the X direction. Each of these edges 1031A, 1031B, 1032A, 1032B covers the corresponding ends 1041, 1051, 1042, 1052 of the contact members 1040, 1050. In other words, the encapsulation materials 1020, 1030 formed by both the main system and the auxiliary system define shoulders indicated by reference numerals 1060 and 1061, with the top and bottom ends of the contact members extending abutting against said shoulders, respectively.

[0126] In addition, such as Figure 6As shown, the opposing ends of each corresponding anode contact 1040 and cathode contact 1050, 1041, 1042 and 1051, 1052 respectively, are flush with the forward regions 1021 and 1022 of the encapsulation system 1020. In other words, the opposing ends extend substantially in the X direction at the free top surface of region 1021 and the free bottom surface of region 1022, respectively.

[0127] The arrangement of the additional encapsulation system on the main encapsulation system and around the contact components results in excellent impermeability of the final battery, particularly extremely low water vapor permeability. This extends battery life. More specifically, the architecture makes it possible to prevent the diffusion of water or oxygen molecules at the ends 1042, 1041 of the contact components. More specifically, the conductive adhesive used to form the contacts is not impermeable to the diffusion of water molecules, nor is the metal foil.

[0128] In addition, such as Figure 7 As shown, the dimensions of the forward regions 1031 and 1032 in the Y direction are larger than the dimensions of the forward regions 1021 and 1022 and the contact components 1040 and 1050. Therefore, each of these regions 1031 and 1032 defines so-called protruding edges 1031C, 1031D and 1032C, 1032D in the Y direction. These distinct edges create surface continuity of the additional package between each forward region 1031 or 1032 and the two lateral regions 1033 and 1035.

[0129] according to Figures 1 to 7 The aforementioned battery of the embodiment shown includes a main packaging system with four regions, each region covering a corresponding face of the main stack. However, alternatively, the main packaging system may have a smaller number of regions. In particular, the system may contain only two regions existing on opposite faces of the stack.

[0130] First, such as Figure 8 As shown, the area of ​​the main packaging system may only cover the side surfaces of the stack, which are not occupied by contact components. Alternatively, as Figure 9 As shown, these areas of the main packaging system may only cover the end faces of the stack, which are therefore parallel to the layers forming the stack. Used for manufacturing Figure 8 and 9 The battery methods shown in the document will refer to the following Figure 12 To describe.

[0131] As mentioned in the introduction, and as is known per se, multiple cell stacks can be fabricated simultaneously, such as those described above. This improves the efficiency of the general method for manufacturing the battery according to the invention. Specifically, stacks with larger dimensions can be fabricated from alternating continuous cathode layers and corresponding anode layers or foils.

[0132] For example, the physicochemical structure of each anode or cathode foil of the type known in French patent document FR 3 091 036 filed by the applicant is not within the scope of this invention and will only be described briefly. Each anode foil or corresponding cathode foil includes an anode active layer or a corresponding cathode active layer. Each of these active layers may be solid, i.e., it may have dense or porous properties. Furthermore, to prevent electrical contact between two adjacent foils, an electrolyte layer or a spacer impregnated with a liquid electrolyte is disposed on at least one of the two foils, in contact with the opposing foil. The electrolyte layer or the spacer impregnated with a liquid electrolyte is sandwiched between two foils having opposite polarities, i.e., sandwiched between an anode foil and a cathode foil, which is not shown in the figures describing the invention.

[0133] These foils or layers are notched to define so-called blank areas, which will allow for separation between different final batteries. Within the scope of this invention, different shapes can be assigned to these blank areas. As proposed by the applicant in French patent document FR 3 091 036, these blank areas can be H-shaped. (Attached) Figure 10 The stack 1100 between the anode foil or layer 1101 and the cathode foil or layer 1102 is shown. As illustrated in the figure, these different foils are cut to create the H-shaped anode blank area 1103 and the corresponding cathode blank area 1104.

[0134] Alternatively, these free zones can also be I-shaped. (See attached document) Figure 11 This illustrates the stack 1200 between the anode foil or layer 1201 and the cathode foil or layer 1202. (Example) Figure 11 As shown, these different foils are cut to produce the I-shaped anode blank area 1203 and the corresponding cathode blank area 1204.

[0135] Preferably, once the fabrication of the different cell stacks is complete, each anode and each cathode of a given battery includes a corresponding main body, which is separated from a corresponding auxiliary body by a space free of any electrode material, electrolyte, and / or conductive substrate. According to additional alternative embodiments not shown, blanking areas may be provided such that the shape of the blanking area differs from an H or I shape, for example, a U shape. However, an H or I shape is preferred.

[0136] like Figure 12 As shown in the image, Figure 8 The battery in it can be used Figure 10 The continuous preparation of foil is shown in the image. Figure 12The diagram shows blank areas on a larger scale, which are generally H-shaped. More specifically, as known from the aforementioned French patent document FR 3091 036, these blank areas have vertical bars 1103 connected in pairs via horizontal channels 1110. According to the alternative embodiment, the bars 1103 receive material 221 intended to form all or part of the main packaging system.

[0137] Furthermore, as can be seen from the aforementioned French patent documents, the stack of different units is defined by adjacent rods. Figure 12 In the diagram, these identical cell stacks are indicated from left to right by consecutive reference numerals II, I, and III. According to the alternative embodiment, a vertical cut, indicated by reference numeral DY, is then performed. This not only allows the stacks to be separated from each other in a known manner but also allows for the simultaneous acquisition of individual cell stacks covered by the lateral regions of the main encapsulation. Figure 12 In the embodiment shown, two vertical cuts DY are made because rod 1103 is relatively wide. According to an advantageous, unshown alternative embodiment, these rods can be prepared to be much narrower. In this case, a single vertical cut can be made.

[0138] like Figure 13 and 14 As shown in the image, Figure 9 The battery in it can be used Figure 11 The foil stacking process is shown. Following steps not shown, this stacking of foils is completely covered by encapsulation material intended to form the main encapsulation system. Once this coverage is complete, only the cell stacks located at the outer edges of the foil are covered not only on the end faces of the stack but also on some of the lateral faces of the stack. In contrast, all the “center” cell stacks are covered only on their opposite end faces.

[0139] Then, multiple horizontal cuts are performed, only... Figure 11 The diagram shows a single horizontal cut indicated by the reference DX symbol. Once these horizontal cuts have been made, multiple strips are placed... Figure 13 The image shows a strip. Each strip is formed by a single line of cells stacked adjacent to each other.

[0140] Given that each band comprises a significantly higher number of such stacks Figure 13 The image shows three adjacent stacks, I, II, and III. Only the two cell stacks located at opposite ends of each line are covered with encapsulation material on the end faces and some side faces of the stack. In contrast, the other so-called intermediate cell stacks are only covered on the end faces of the stack.

[0141] Finally, as Figure 14As shown, vertical cuts are made along each line. This allows a given stack to be separated from each of its neighboring stacks. These vertical cuts are fabricated, for example... Figure 14 The stacks are stacked in the form of I, etc., in which only the end faces are coated with encapsulation material.

[0142] Batteries according to the invention, including such an architecture, can be used as is or integrated into electronic circuits. Electrical contacts compatible with reflow soldering assembly steps can be fabricated on the surface of the battery, including exposed contact components. In this case, and as a function of the battery's end use, the contact components of the battery according to the invention, preferably including contact components, can be covered with a multilayer system consisting of, for example, a first layer of conductive polymer, preferably a conductive polymer filled with silver epoxy resin, a second layer of nickel deposited on the first layer by electrodeposition, and a third layer of tin deposited on the second layer by electrodeposition.

[0143] When the circuit is subjected to thermal and / or vibrational stresses, a first conductive polymer layer, preferably made of silver-filled epoxy resin, provides "flexibility" at the connection without breaking the electrical contact. A nickel layer protects the polymer layer during the soldering assembly step, and a tin layer ensures the solderability of the battery interface.

[0144] The battery according to the invention can be advantageously integrated and / or overmolded in a flat integrated circuit package that physically connects the integrated circuit to a printed circuit board, such as a quad flat no-lead (QFN) package.

[0145] The battery according to the invention can be a lithium-ion micro battery, a lithium-ion mini battery, or a high-power lithium-ion battery. The battery can in particular be designed and sized to have a capacity of less than or equal to about 1 mA h (commonly referred to as a "micro battery"), a power greater than about 1 mA h to about 1 Ah (commonly referred to as a "mini battery"), or a capacity greater than about 1 Ah (commonly referred to as a "high-power battery"). Typically, micro batteries are designed to be compatible with methods used to manufacture microelectronic devices.

[0146] Batteries with each of these three power ranges can be fabricated:

[0147] - A layer of "solid" type, i.e., without impregnation of liquid or paste phase (the liquid or paste phase may be a lithium-ion conductive medium capable of acting as an electrolyte).

[0148] -Or it has a mesoporous "solid" type layer impregnated with a liquid or paste phase, typically a lithium-ion conductive medium, which spontaneously penetrates the layer and does not reappear from it, so that the layer can be considered quasi-solid.

[0149] -Or have impregnated porous layers (i.e., layers with an open pore network that can be impregnated with a liquid or paste phase, which gives these layers wettable properties).

Claims

1. A battery (1000), said battery comprising: - Stack (I), the stack being an alternation between at least one anode (20) and at least one cathode (50), each anode and cathode being formed by a thin-layer stack, wherein the anode (20) comprises: At least one anode current collector substrate (21). At least one thin layer of anodic active material (22), and Optionally, a thin layer of electrolyte material (23) or a thin layer of separator impregnated with electrolyte (23'). And the cathode (50) comprises: At least one cathode current collector substrate (51). At least one cathode active material thin layer (52), and optionally, an electrolyte material thin layer (53) or an electrolyte-impregnated separator thin layer (53'). Thus, the stack sequentially includes at least one anode current collector substrate (21), at least one anode active material thin layer (22), at least one electrolyte material thin layer (23, 53) or an electrolyte-impregnated separator thin layer (23', 53'), at least one cathode active material thin layer (52) and at least one cathode current collector substrate (51). The stack (I) defines six faces, namely - Two positive surfaces (F1, F2), which are opposite to each other and parallel to each other, parallel to the anode active material thin layer (22), parallel to the electrolyte material thin layer (23, 53) or the electrolyte-impregnated separator thin layer (23', 53'), and parallel to the cathode active material thin layer (52), and - Four lateral planes (F3, F4, F5, F6), which are paired opposite each other and parallel to each other. - A main packaging system (1020) covering at least two of the six faces of the stack (I), the packaging system comprising two forward packaging regions (1021, 1022) covering all or part of the forward faces (F1, F2) and / or two lateral packaging regions (1023, 1025) covering all or part of two of the lateral faces (F3, F5), the lateral packaging regions being opposite and parallel to each other. - At least one anode contact component (1040) capable of making electrical contact between the stack and external conductive elements, the anode contact component at least partially covering the first surface (F4) of the two lateral surfaces (F4, F6) not covered by the main packaging system (1020), the first surface (F4) defining at least one anode connection area. - At least one cathode contact component (1050) capable of making electrical contact between the stack and external conductive elements, the cathode contact component at least partially covering the second surface (F6) of the two lateral surfaces not covered by the main packaging system (1020), the second surface (F6) defining at least one cathode connection area. The anode contact component (1040) and the cathode contact component (1050) are opposite to each other and parallel to each other. The battery is characterized in that it further includes an additional encapsulation system (1030), the additional encapsulation system comprising: - Two positive regions (1031, 1032), each defining two protruding edges (1031A, 1031B, 1032A, 1032B) extending from the corresponding positive region (1021, 1022) of the main packaging system (1020) along the lateral axis X of the stack, each protruding edge covering the corresponding positive end (1041, 1042, 1051, 1052) of the anode contact or the cathode contact. - Two lateral regions (1033, 1035), each of which covers the side surface of the stack without any contact components and optionally intersects with the corresponding lateral region (1023, 1025) of the main packaging system. - Each of the forward regions (1031, 1032) of the additional packaging system forms a surface continuity with the lateral regions (1033, 1035) of the additional packaging system.

2. The battery of claim 1, wherein the main packaging system comprises two forward packaging regions (1021, 1022) covering all or part of the forward surfaces (F1, F2), and two lateral packaging regions (1023, 1025) covering all or part of two of the lateral surfaces (F3, F5).

3. The battery according to claim 1, wherein the main packaging system comprises only two forward packaging regions (1021, 1022) covering all or part of the forward surfaces (F1, F2).

4. The battery of claim 1, wherein the main packaging system comprises only two lateral packaging regions (1023, 1025) covering all or part of two of the lateral surfaces (F3, F5).

5. The battery of claim 4, wherein along the lateral axis X of the stack, the primary packaging system extends to the inner surface of the contact members, while the additional packaging system extends beyond the inner surface to the outer surface of these contact members.

6. The battery of claim 5, wherein each of the two forward regions of the additional encapsulation system defines two protruding edges, wherein each protruding edge protrudes from the corresponding forward region of the main encapsulation system and from the anode and cathode contact members along another lateral axis Y of the stack, the protruding edges ensuring the surface continuity between the forward region and the lateral region of the additional encapsulation system.

7. The battery according to any one of claims 1 to 6, wherein the opposite ends (1041, 1042, 1051, 1052) of each respective anode contact (1040) and cathode contact (1050) are flush with the positive region (1021, 1022) of the main packaging system (1020).

8. The battery according to any one of claims 1 to 6, wherein the main encapsulation system (1020) includes at least one first cover layer disposed on the stack (I), selected from parylene, parylene F, polyimide, epoxy resin, silicone, polyamide, sol-gel silica, organosilicon silica and / or mixtures thereof.

9. The battery according to any one of claims 1 to 6, wherein each of the anode contact member (1040) and the cathode contact member (1050) comprises a first electrical connection layer made of a material filled with conductive particles, and a second electrical connection layer comprising a metal foil or a metal layer disposed on the first electrical connection layer.

10. The battery according to any one of claims 1 to 6, wherein the additional encapsulation system (1030) comprises an encapsulation layer selected from glass, ceramic, and glass-ceramic, said encapsulation layer having a density of less than 10. -5 Water vapor permeability (WVTR) g / m2·d.

11. The battery of claim 10, wherein the glass, ceramic, and glass-ceramic of the encapsulation layer are selected from the following: -Low melting point glass, selected from SiO2-B2O3, Bi2O3-B2O3, ZnO-Bi2O3-B2O3, TeO2-V2O5, and PbO-SiO2. -Oxides and / or nitrides and / or Ta2O5 and / or aluminum oxide (Al2O3) and / or nitrogen oxides and / or SixNy and / or SiO2 and / or SiON and / or amorphous silicon and / or SiC.

12. A method for manufacturing a battery according to any one of claims 1 to 11, the manufacturing method comprising: (a) Supply at least one anode current collector substrate foil, said substrate foil being coated with an anode layer and optionally coated with an electrolyte material layer or an electrolyte-impregnated separator layer, hereinafter referred to as the anode foil. (b) Supply at least one cathode current collector substrate foil, said substrate foil being coated with a cathode layer and optionally coated with an electrolyte material layer or an electrolyte-impregnated separator layer, hereinafter referred to as cathode foil. (c) Preparing the stack (I) in which at least one anode foil and at least one cathode foil alternate to sequentially obtain at least one anode current collector substrate, at least one anode layer, at least one layer of electrolyte material or an electrolyte-impregnated separator layer, at least one cathode layer, and at least one cathode current collector substrate. (d) The stack of alternating foils obtained in step c) is heat-treated and / or mechanically compressed to form a reinforced stack. (e) Fabricating the primary packaging system (1020) to form a packaged and diced stack exposing at least the anode and cathode connection regions. (f) Optionally, the cut and packaged stack is impregnated with a lithium-ion-carrying phase, such as a liquid electrolyte or an ionic liquid containing a lithium salt, such that the separator is impregnated with the electrolyte. (g) Place each of the anode and cathode contact components on a respective lateral face of the stack that is not covered by the main packaging system. (h) An additional encapsulation assembly (1030') is fabricated on the structure obtained after step g), the assembly being designed to encapsulate the reinforced stack containing the contact components, and (i) At least partially expose the anode and cathode contact components to form the additional encapsulation system (1030).

13. The method of claim 12, further comprising fabricating a primary packaging assembly (1020') on the hardened stack (I), the primary packaging system being fabricated from the primary packaging assembly.

14. The method of claim 13, wherein the main packaging system is fabricated from the main packaging assembly by performing two main cuts along the first cutting plane (II II).

15. The method of claim 14, wherein the additional packaging system is fabricated from the additional packaging assembly by performing two additional cuts along a second cutting plane (VV) extending outside the first cutting plane.

16. The method according to any one of claims 12 to 15, wherein at least partial exposure of the anode and cathode contact components according to step i) of the method is achieved by polishing or by cutting.

17. The method according to any one of claims 12 to 15, characterized in that... The fabrication of the main encapsulation system (1020) includes depositing at least one first capping layer on the stack (I), selected from parylene, parylene F, polyimide, epoxy resin, silicone, polyamide, sol-gel silica, organosilicon silica and / or mixtures thereof.

18. The method according to any one of claims 12 to 15, characterized in that... The fabrication of an additional encapsulation system designed to encapsulate the reinforced stack containing contact components includes the deposition of an encapsulation layer selected from glass, ceramics, and glass-ceramics.

19. The method of claim 18, wherein the glass, ceramic, and glass-ceramic are selected from the following: -Low melting point glass, selected from SiO2-B2O3, Bi2O3-B2O3, ZnO-Bi2O3-B2O3, TeO2-V2O5, and PbO-SiO2. -Oxides and / or nitrides and / or Ta2O5 and / or aluminum oxide (Al2O3) and / or nitrogen oxides and / or SixNy and / or SiO2 and / or SiON and / or amorphous silicon and / or SiC.

20. The method according to any one of claims 12 to 15, characterized in that... The fabrication of the anode and cathode contact components includes: - A first electrical connection layer made of a material filled with conductive particles is deposited on at least the anode connection region and at least the cathode connection region, the first electrical connection layer being made of a polymeric resin filled with conductive particles and / or a material obtained by a sol-gel method. Optionally, 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, the step of polymerizing the polymeric resin and / or the material obtained by a sol-gel method is performed after the drying step, and - Deposit a second electrical connection layer disposed on the first electrical connection layer, the second electrical connection layer comprising a metal foil or a metallic ink, in the latter case, the drying step may alternatively be performed after the deposition of the second electrical connection layer.

21. The method according to any one of claims 12 to 15, the method further comprising preparing alternating, continuous cathode and anode layers, each layer including a plurality of blank areas, and cutting such that a given stack of batteries can be separated from at least one other stack of another battery.

22. The method of claim 21, wherein the blank area has bars connected in pairs by channels, wherein at least a portion of the bars is filled with encapsulation material, and then the cutting is performed to obtain a stack having two opposing lateral faces coated with the encapsulation material.

23. The method of claim 21, wherein the blank area has an I shape, at least one line formed by a plurality of stacks is prepared in the method, the front face of the line being at least partially covered by an encapsulation material, and the cutting is performed to obtain a stack having a front face coated with the encapsulation material.

Images