Method for manufacturing high-power lithium-ion batteries and battery obtained using this method

Abstract

The present invention relates to a novel high power battery architecture, including unique anode and cathode conduction devices, which can extend battery life.

Description

Technical Field

[0001] This invention relates to the manufacture of lithium-ion batteries. Specifically, it relates to a novel method for manufacturing a high-power lithium-ion battery. It also relates to a battery obtained using this method, which has a novel structure that extends its lifespan.

[0002] Existing technology To increase the yield of high-energy-density and high-power-density rechargeable batteries (such as solid-state batteries or batteries impregnated with liquid electrolytes), multiple batteries can be manufactured simultaneously by alternately stacking anode foils and cathode foils pre-coated with electrolyte layers.

[0003] International patent document WO 2016 / 001584 (I-TEN) describes foils comprising a conductive substrate, which sequentially covers an electrode layer, which in turn covers an electrolyte layer; these foils are cut into various patterns, particularly U-shapes, before or after deposition. These foils are stacked alternately to form a stack of multiple cell units. The anode and cathode cut patterns are placed in a "head-to-tail" configuration so that the stack of cathode and anode layers is laterally offset. According to the document, after the stacking step, a conformal thick-layer encapsulation system, typically a polymer layer about ten micrometers thick, is deposited in available cavities on and within the stack. This ensures structural rigidity at the cut planes and protects the battery from atmospheric effects. Once the stack is fabricated and encapsulated in a rigid structure, it is cut along the cut planes to obtain cell units, exposing the cathode and anode connections of the battery on each cut plane. During these cuts, the encapsulation system may be torn, resulting in the breaching of the battery's impermeability seal. It is understood that terminals (i.e., electrical contacts) are also added where these cathode and anode connections are clearly visible.

[0004] refer to Figure 12 To explain this existing technology in more detail, Figure 12 The lithium-ion battery structure described in international patent document WO 2016 / 001584 is shown. The battery 200 includes a plurality of anodes 230 and a plurality of cathodes 210, which are arranged alternately beneath each other. Each anode and each cathode includes a corresponding anode or cathode active material layer, referred to as an anode layer or a cathode layer, respectively. In addition, a layer of electrolyte material (… Figure 12(Not shown) sandwiched between the anode and cathode, the electrolyte material separates the two facing active layers. The thickness of each of these layers typically does not exceed 15 µm, and is generally between 2 µm and 8 µm. The battery has anode connections 230' on the first lateral edge 201, one below the other. Furthermore, on the opposite lateral edge 202, cathode connections 210' are provided, one below the other. The stacking of the anodes 230 and cathodes 210 is laterally offset. The position of the cathode connections 210' causes them to protrude from the free face 230'' of the anode. Similarly, on the opposite edge 201, the free face 210'' of the cathode retraces from the free face of the anode, where the anode connections 230' are subsequently deposited.

[0005] However, this known solution has certain drawbacks. More specifically, depending on the electrode location, particularly its distance from the edges of the multilayer battery electrodes and the cleanliness of the cut, leakage current, typically in the form of creepage short circuits, may occur at the ends. Despite the use of encapsulation systems around the battery and near the cathode and anode connections, this still degrades battery performance. Furthermore, the deposition of the encapsulation system on the battery is sometimes observed to be unsatisfactory, especially at the battery edges where spaces created by the lateral offset of the electrodes at the battery edges exist.

[0006] Furthermore, large cuts are required because the anode and cathode terminals recede from adjacent anode and cathode layers. These cuts must therefore be filled with insulating material. Due to their large size, this cutting results in significant material loss for the battery itself. Additionally, thick insulating layers need to be applied to the available cavities within the battery stack. These thick insulating layers weaken the overall battery packaging system because the packaging system, deposited in thick layers, tends to delaminate during cutting. Therefore, the existing architecture has technical and economic drawbacks.

[0007] Finally, in many applications, it is necessary to reduce the battery resistance, which leads to power loss. For the very high-power batteries described in the prior art, the resistance of the connecting elements significantly affects the battery resistance: a battery architecture that increases the resistance of the connecting elements is unacceptable, even if it solves some of the other problems listed above. In this regard, the connection between the connecting element and the conductive surface of the battery intended to contact the connecting element must have the lowest possible contact resistance. This connection can be achieved solely with adhesives. To achieve the above... Figure 12 This is illustrated by the fact that after encapsulating the battery and laterally cutting to expose the edges, metal foil can be bonded to these edges of the anode and cathode. A good connection has low resistance, which must not deteriorate during the battery's lifespan.

[0008] However, conductive adhesives commonly used to bond metal foil at terminals typically have high contact resistance, especially those containing graphite. Conversely, it is understood that inks containing metal nanoparticles or carbide or nitride nanoparticles can achieve excellent conductivity. However, this low resistance can only be achieved when these inks are heat-treated at temperatures sufficient to cause sintering of the conductive nanoparticles. Typically, temperatures around 400°C result in incomplete sintering, but this temperature is too high for batteries containing liquid electrolytes.

[0009] Furthermore, the density of sintered inks is not high enough to make them impermeable to water vapor (this permeability is expressed as water vapor transmission rate (hereinafter referred to as WVTR)); for example, Novacentrix ® Métalon ® - This is the case with nano-copper ink. Therefore, it is indeed necessary to improve the quality of electrical contact between the battery's conductive surface and the connecting elements, reduce contact resistance, and improve the durability of this electrical contact.

[0010] The purpose of this invention is to at least partially overcome some of the defects of the prior art.

[0011] The object of this invention is particularly to increase the production of high energy density and high power density rechargeable batteries, and to produce more efficient packaging at a lower cost.

[0012] In particular, the object of the present invention is to provide a method for reducing the risk of short circuits and manufacturing batteries with a low self-discharge rate.

[0013] In particular, the object of this invention is to provide a method for manufacturing batteries with very long lifespans in a simple, reliable and rapid manner.

[0014] A further objective of this invention is to propose a method that uses cutting steps with higher quality than existing technologies.

[0015] A further objective of this invention is to propose a method for enhancing the packaging stage and the packaging itself during the final battery production process.

[0016] A further objective of this invention is to propose a battery manufacturing method with less material loss.

[0017] In any case, the solution to these problems must not increase the battery's resistance, and if possible, the resistance must be reduced.

[0018] Purpose of the invention At least one of the above objectives is achieved by at least one objective of the invention as described below. The various objectives of the invention relate to batteries, methods of manufacturing the same, energy-consuming devices, and batteries according to another embodiment, as set forth in the appended claims.

[0019] The first object of the present invention is to provide a battery (100) comprising at least one anode (3) and at least one cathode (1), alternating on top of the other, the battery (100) comprising lateral edges (101, 102) and longitudinal edges (103, 104), the lateral edges (101, 102) comprising at least one anode connection region and at least one cathode connection region laterally opposite the anode connection region, wherein the anode (3) comprises: -Current collector substrate, -At least one anode layer, and -Optional electrolyte material layer or electrolyte-impregnated isolation layer The cathode (1) includes: -Current collector substrate, -At least one cathode layer, and -Optional electrolyte material layer or electrolyte-impregnated isolation layer Thus, the battery comprises a stack of cells sequentially consisting of at least one anode layer, at least one electrolyte material layer or an electrolyte-impregnated separator layer, and at least one cathode layer. Its features are: - Each anode and each cathode includes a respective first body (111, 131) which are separated from the corresponding second body (112, 132) by a space (113, 133) free of any electrode material, electrolyte and current collector substrate, the free space connecting the opposite longitudinal edges (103, 104) of the battery. When viewed from a top view, each anode and each cathode includes at least one first through-hole (51, 53) formed in the first body and at least one second through-hole (52, 54) formed in the second body. It should be understood that the first through hole (51) formed in the first cathode body extends in the continuation of the second through hole (54) formed in the second anode body, so that these holes (51, 54) extend in the continuation of each other, forming a first through channel (61) through the battery from one end to the other. The first through hole (53) formed in the first anode body extends in the continuation of the second through hole (52) formed in the second cathode body, so that these holes (52, 53) extend in the continuation of each other, forming a second through channel (63) through the battery from one end to the other. The battery further includes at least one cathode conductive device (71, 71', 71'') housed in the first through channel (61) and at least one anode conductive device (73, 73', 73'') housed in the second through channel (63), wherein the anode conductive device (73, 73', 73'') is capable of collecting at least a portion of the battery current flowing to at least one anode connection region, and the cathode conductive device (71, 71', 71'') is capable of collecting at least a portion of the battery current flowing to at least one cathode connection region.

[0020] Other features of the battery according to the invention, which may be adopted individually or in accordance with any technically compatible features: - Each through channel extends at a certain distance from the opposite lateral edge (101, 102). - The shortest distance (D) separating each through channel (61) from the opposite lateral edge. 59 / D 56 The thickness ranges from 0.04 mm to 1.95 mm. - Each through-channel is formed directly in the lateral edges (401, 402), with the cathode or anode conductive device flush with the lateral edges and having a particularly semi-cylindrical shape. -The anode and cathode conductive devices are selected independently from: -A rod made of conductive material - Tightly fitted metal rod - A metal rod encased in a conductive sheath material. - The two opposite ends of the rod or the metal bar define fastening heads. -The battery further includes: Electrical connection supports made at least partially of conductive material. An electrical insulation device enables the two distal regions of the connecting support to be insulated from each other, and these distal regions form their respective electrical connection paths. The cathode conductive device is in electrical contact with the first electrical connection path, while the anode conductive device is in electrical contact with the second electrical connection path. - The electrical connection support is a single-layer type, particularly a metal mesh or silicon sandwich. The electrical connection support comprises multiple layers, with one layer disposed beneath another, and the support is particularly of the printed circuit board type. - The lateral dimension or width of the free space (L) 113 The value is 0.01 mm to 0.5 mm. - The lateral dimension or width of the second body (L)112 The value is 0.05 mm to 2 mm. - The free surfaces of the second body of the cathode (112') and anode (132') opposite to the free space are respectively flush with the free surfaces of the first body of the anode (131') and cathode (111'). The battery includes an encapsulation system that covers four of the six sides of the battery and partially covers two other sides, which are opposite to and substantially perpendicular to the first and second through-channels (61, 63) of the battery. The battery includes at least one anode connection region and at least one cathode connection region. -The packaging system mentioned herein includes: - At least one first covering layer deposited on the battery, preferably selected from parylene, parylene F, polyimide, epoxy resin, silicone resin, polyamide, sol-gel silica, organosilicon silica and / or mixtures thereof. - At least one second capping layer composed of an electrically insulating material is deposited on the at least one first capping layer by atomic layer deposition or PECVD, HDPCVD, or ICPCVD. It should be understood that the sequence of at least one first covering layer and at least one second covering layer can be repeated z times, where z≥1. -The packaging system includes: - At least one first cover layer with a very low WVTR, preferably less than 10. -5 g / m 2 .d, deposited on the periphery of the anode and cathode foil stack, It should be understood that the first overlay layer can be repeated z' times, where z' ≥ 1. -The at least one first overlay layer includes: - Ceramic materials, preferably selected from oxides, nitrides, oxynitrides, and Si. x N y SiO2, SiON, amorphous silicon or SiC, and / or - Low melting point glass, preferably glass with a melting point of less than 600°C, more preferably low melting point glass selected from SiO2-B2O3; Bi2O3-B2O3, ZnO-Bi2O3-B2O3, TeO2-V2O5 and PbO-SiO2. - The battery includes a terminal system covering at least the anode connection regions (75, 75') and at least the cathode connection regions (76, 76'). -The terminal system comprises, in sequence: -A conductive polymer first layer, preferably a silver-filled resin. -A second nickel layer disposed on the first layer of the terminal system, and - A third layer of tin is set on the second layer of the terminal system.

[0021] The present invention also relates to a method for manufacturing the above-mentioned battery, the method comprising: A stack of alternating foils (I) is provided, the stack comprising a first foil or anode foil, each first foil or anode foil intended to form an anode layer of a plurality of batteries, and a second foil or cathode foil, each second foil or cathode foil intended to form a cathode layer of a plurality of batteries. Each anode foil includes at least one groove or region (34) without any anode, and each cathode foil includes at least one groove or region (14) without any cathode, each groove defining at least a portion of the space free of any electrode material, electrolyte, and current collector substrate. The previously provided alternating foil stacks are subjected to heat treatment and / or mechanical compression. For each anode and each cathode, at least one first through hole (51, 53) is formed in the first body and at least one second through hole (52, 54) is formed in the second body. The first through hole (51) formed in the first cathode body extends in the continuation of the second through hole (54) formed in the second anode body, so that these holes (51, 54) extend in continuation of each other, forming a first through channel (61) through the battery from one end to the other. The first through-hole (53) formed in the first anode body extends in continuation of the second through-hole (52) formed in the second cathode body, such that these holes (52, 53) extend in continuation of each other, forming a second through-channel (63) through the battery from one end to the other. It should be understood that step c) may be performed on the anode foil and cathode foil before step a) or after step b). The cathode conductive devices (71, 71', 71'') are inserted into the first through-channel (61) and the anode conductive devices (73, 73', 73'') are inserted into the second through-channel (63). Each of these conductive devices is capable of collecting at least a portion of the battery current. Creating an incision (D) n ,D' n ), to insulate the given battery.

[0022] Other features of the method according to the invention, which may be employed individually or in accordance with any technically compatible features: - The through channel is formed at a certain distance from the lateral edge. - At least one hole is formed along the path of each cut, and each hole defines at least a portion of each through-channel. The anode and cathode trenches each include two at least partially overlapping longitudinal portions (16, 36) for defining the longitudinal edges (103, 104) of the battery, and a transverse portion (18, 38) connecting the two longitudinal portions. The transverse portions of the anode trench (38) and the cathode trench (18) are offset from each other. A first cut extends between the transverse portion of the anode trench and the end facing the longitudinal portion, while a second cut extends between the transverse portion of the cathode trench and the end facing the longitudinal portion. - Each groove has an overall H shape, with the longitudinal portion forming the vertical main groove of the H, and the transverse portion forming the channel of the H. The anode and cathode trenches are elongated, particularly I-shaped, with the anode trenches stacked on top of each other and the cathode trenches stacked on top of each other. The anode trenches are offset relative to the cathode trenches, thereby defining a plurality of intermediate spaces in which the cutouts are formed. - The method includes, after step b) or after step e), impregnating the cut stack with a lithium-ion-carrying phase, such as a lithium-salt-containing liquid electrolyte or ionic liquid, in step f). -The method includes: after step e) or after step f), encapsulating the cut stack by depositing the following layer: - Deposit at least one first capping layer on the battery, preferably selected from parylene, parylene F, polyimide, epoxy resin, silicone resin, polyamide, sol-gel silica, organosilicon silica and / or mixtures thereof. - At least one second capping layer composed of an electrically insulating material is deposited on the at least one first capping layer by atomic layer deposition or PECVD, HDPCVD, or ICP CVD. It should be understood that the sequence of at least one first covering layer and at least one second covering layer can be repeated z times, where z≥1. -The two incisions (D) n ,D' n It passes through at least most of the anodes and cathodes, and in particular through all of the anodes and cathodes.

[0023] Another object of the present invention is an energy-consuming device, comprising a body and the battery described above, the battery being capable of providing energy to the energy-consuming device, and the electrical connection support of the battery being fixed to the body.

[0024] Finally, the object of the present invention is a method for manufacturing a battery, the battery comprising at least one anode (3) and at least one cathode (1), which are alternately disposed on top of each other, the battery (100) comprising longitudinal edges (103, 104) and transverse edges (101, 102). The anode (3) comprises: -Current collector substrate, -At least one anode layer, and -Optional electrolyte material layer or electrolyte-impregnated isolation layer The cathode (1) includes: -Current collector substrate, -At least one cathode layer, and -Optional electrolyte material layer or electrolyte-impregnated isolation layer Thus, the battery comprises a stack of units sequentially formed of at least one anode layer, at least one electrolyte material layer or an electrolyte-impregnated separator layer, and at least one cathode layer. Each anode (3) includes an anode connection region located near the first lateral edge of the battery, while each cathode (1) includes a cathode connection region located on the second lateral edge of the battery opposite to the first edge. Each anode and each cathode includes a respective first body (111, 131) which is separated from the corresponding second body (112, 132) by a space (113, 133) free of any electrode material, electrolyte and current collector substrate, the free space connecting the opposite longitudinal edges (103, 104) of the battery. The manufacturing method includes: a) Providing a stack of alternating foils (I), the stack comprising a first foil or anode foil, each first foil or anode foil intended to form an anode layer of a plurality of batteries, and a second foil or cathode foil, each second foil or cathode foil intended to form a cathode layer of a plurality of batteries. Each anode foil includes at least one groove or region (34) without any anode, and each cathode foil includes at least one groove or region (14) without any cathode. Each groove defines at least a portion of the space free of any electrode material, electrolyte, and current collector substrate. The previously provided alternating foil stacks are subjected to heat treatment and / or mechanical compression. b) Perform heat treatment and / or mechanical compression on the previously provided alternating foil stacks. c) Make two cuts (D) that extend at least partially within the groove. n ,D' n The first cut extends between the transverse portion of the anode tank and the end facing the longitudinal portion, while the second cut extends between the transverse portion of the cathode tank and the end facing the longitudinal portion. The method is characterized in that at least one hole is formed along the path of each cut so that the cuts can be easily made using a cutting tool. Attached Figure Description

[0025] The accompanying drawings, given by way of non-limiting example, illustrate different aspects and embodiments of the invention.

[0026] [ Figure 12 The image shows a battery from the prior art.

[0027] [ Figure 1 [ ] is a perspective view of a stacked anode foil and cathode foil formed according to the battery manufacturing method of the present invention.

[0028] [ Figure 2 ]yes Figure 1 A front view of one of the foils.

[0029] [ Figure 3 [This is an enlarged front view showing the H-shaped groove formed in the adjacent foils and the first and second channels formed in the adjacent foils.]

[0030] [ Figure 4 [Illustration] is an enlarged perspective view showing the H-shaped grooves formed in the adjacent foils and the first and second channels formed in the adjacent foils.

[0031] [ Figure 5 [ ] is a top view showing the cutting steps performed on the different slots formed in the stack in the aforementioned figure.

[0032] [ Figure 6 [ ] is an enlarged top view showing the cut along the H-shaped groove.

[0033] [ Figure 7 ] is along Figure 6 The cross-sectional view of line VII-VII shown.

[0034] [ Figure 8 ] is along Figure 6 The cross-sectional view of line VIII-VIII shown.

[0035] [ Figure 9 The figure shows a top view of the battery of the present invention, which can be obtained in particular according to the method shown in the foregoing figure.

[0036] [ Figure 10 The battery described in this invention is shown along... Figure 6 The cross-sectional view of line XX shown is provided, and the battery can be obtained in particular according to the method shown in the aforementioned figure.

[0037] [ Figure 11 The figure shows a perspective view of the battery of the present invention, which can be obtained in particular according to the method shown in the foregoing figure.

[0038] [ Figure 12 This shows a perspective view of a prior art battery.

[0039] [ Figure 13[Illustration 1] is a top view showing the cutting steps performed on different H-shaped grooves formed in the anode foil or cathode foil of the second alternative embodiment of the present invention, and showing the first and second channels formed in the anode foil or cathode foil of the second alternative embodiment of the present invention.

[0040] [ Figure 14 [This is an enlarged top view of the cut formed along the H-shaped groove as described in the second alternative embodiment of the present invention.]

[0041] [ Figure 15 The image shows a perspective view of the battery described in this invention, which can be obtained, in particular, according to a second alternative embodiment of the invention.

[0042] [ Figure 16 ]include Figure 16 A, 16B, and 16C. These... Figure 16 A, 16B, and 16C are the battery components of this invention. Figure 15 The cross-sectional view of the XVI-XVI line shown in the figure indicates that the battery can be obtained in particular according to the method shown in the foregoing figure, wherein the first and second channels formed in the battery are filled with conductive devices to establish electrical connections between the individual cells of the battery.

[0043] [ Figure 17 [ ] is a cross-sectional view of the battery of the present invention, which can be obtained in particular by the method shown in the foregoing figure, and the battery includes conductive means for electrically connecting the individual cells of the battery and the packaging system.

[0044] [ Figure 18 ] is with Figure 5 A similar view illustrates the battery manufacturing method described in an alternative embodiment of the present invention.

[0045] [ Figure 19 ] is used Figure 18 A perspective view of the battery formed by the method shown.

[0046] [ Figure 20 ] is with Figure 16 A similar cross-sectional view shows Figure 19 The battery in it.

[0047] [ Figure 21 ] is similar to Figure 20 The cross-sectional view shows Figure 20 The battery in the device further includes encapsulation and conductive support components, and is integrated into the energy-consuming device.

[0048] [ Figure 22 This is a perspective view similar to the first figure, showing another embodiment of the anode foil and cathode foil.

[0049] [ Figure 23 ] is with Figure 18 A similar diagram illustrates the use of Figure 22 The method for manufacturing foil.

[0050] [ Figure 24 ] is along Figure 23 The cross-sectional view of line XXIV in the figure shows Figure 23 The strip formed by the cut shown.

[0051] [ Figure 25 ] is with Figure 21 A similar cross-sectional view shows a battery including the conductive support described in an alternative embodiment of the present invention. Detailed Implementation

[0052] The method described in this invention first includes a step in which alternating foil stacks I are produced, these foils being referred to hereinafter as “anode foil” and “cathode foil” as appropriate. As will be seen in more detail below, each anode foil is intended to form the anode of a plurality of batteries, and each cathode foil is intended to form the cathode of a plurality of batteries. Figure 1 The example shown illustrates five cathode foils 1 and five anode foils 3. In practice, the stack is formed from a greater number (typically ten to one thousand) of foils. In a preferred embodiment, all these foils have holes 2 at their four ends, and when these holes 2 overlap, all the cathodes and all the anodes of these foils are specifically arranged, as will be explained in more detail below (see [link to documentation]). Figure 1 and Figure 2 These holes 2 at the four ends of the foil are positioning marks used to align the foil during foil stacking.

[0053] These holes 2 at the four ends of the foil can be formed in any suitable manner, particularly in the anode and cathode foils after manufacturing, or in the anode and / or cathode foils coated with an electrolyte layer or a separator, such that the electrolyte layer or the separator is sandwiched between two foils of opposite polarity, i.e., between the anode and cathode foils.

[0054] The physicochemical structure of each anode foil or cathode foil may be of a known type, which is not within the scope of this invention and will only be described briefly. Each anode foil 3 includes an anode current collector substrate coated with an active layer of anode material, hereinafter referred to as the anode layer. Each cathode foil 1 includes a cathode current collector substrate coated with an active layer of cathode material, hereinafter referred to as the cathode layer. Each of these active layers may be solid, and more particularly, may have dense or porous properties. Furthermore, to prevent any electrical contact between two adjacent foils, i.e., between two active layers of opposite polarity, an electrolyte layer or a liquid electrolyte-impregnated insulating layer is provided on at least one of these foils, i.e., on the active layer of at least one of these pre-coated current collector substrates. Figure 1(Not shown in the figures), in contact with the active layer of the opposing foil. An electrolyte layer or a liquid electrolyte-impregnated insulating layer (not shown in the figures describing the invention) is sandwiched between two foils of opposite polarity, i.e., between the anode foil and the cathode foil. More specifically, the electrolyte layer or insulating layer may be disposed on the anode layer and / or the cathode layer; the electrolyte layer or insulating layer constitutes an integral part of the anode foil 3 and / or the cathode foil 1 containing it.

[0055] The cell unit of the battery sequentially includes 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. The current collector substrate may be a metal strip.

[0056] Advantageously, both sides of the anode current collector substrate or the separate cathode current collector substrate can be coated with an anode layer or a cathode layer, optionally with an electrolyte layer or a separator layer disposed on the anode layer or the separate cathode layer. In this case, the anode current collector substrate or the separate cathode current collector substrate will act as current collectors for two adjacent cell units. Using these substrates in batteries increases the yield of rechargeable batteries with high energy density and high power density.

[0057] The mechanical structure of one of the cathode foils 1 will now be described. It should be understood that the other cathode foils have the same structure. Furthermore, as shown below, the anode foil 3 has a structure very similar to that of the cathode foil 1.

[0058] like Figure 2 As shown, the cathode foil 1 is quadrilateral, approximately square. It defines a so-called perforated central region 10 in which H-shaped grooves are formed, which will be described below. Referring to the positioning of these H-shaped grooves, a so-called vertical direction YY corresponding to the vertical direction of these H-shaped grooves is defined, as well as a so-called horizontal direction XX perpendicular to the YY direction. The central region 10 is defined by a solid, i.e., groove-free outer frame 12. The function of this frame is specifically to ensure ease of handling each foil.

[0059] H-shaped grooves are distributed in rows L1 to L2. y Inside, one row is below another, and columns R1 to R... x Within the structure, one column is adjacent to the other. As a non-limiting example, within the scope of manufacturing microcells of surface mount device type (hereinafter referred to as SMD), the anode and cathode foils used can be 100 mm x 100 mm wafers. Typically, these foils have 10 to 500 rows and 10 to 500 columns. Their dimensions can vary as a function of the desired cell capacity, and the number of rows and columns of each anode and cathode foil can be adjusted accordingly. The dimensions of the anode and cathode foils used can be adjusted as needed. Figure 2 As shown, adjacent rows are separated by material bridges 20, with heights of H.20 This indicates a thickness between 0.05mm and 5mm. Adjacent columns are separated by material strips 22, with a width of L... 22 This indicates a thickness between 0.05 mm and 5 mm. These material bridges and strips in the anode and cathode foils give them sufficient mechanical stiffness to facilitate handling.

[0060] The trenches 14 are through-holes, meaning they are openings on both the top and bottom surfaces of the foil. The trenches 14 can be formed directly on the substrate in a manner known per se prior to any deposition of the anode or cathode material by chemical etching, electroforming, laser cutting, micro-perforation, or stamping. These trenches can also be formed, in a manner known per se, on a substrate coated with anode or cathode material, for example, by laser cutting, femtosecond laser cutting, micro-perforation, or stamping, or on an anode or cathode foil coated with an electrolyte layer or separator. Figure 3 As specifically shown, the grooves 14 formed in all the cathodes overlap.

[0061] One of the H-shaped grooves 14 will now be described, but it should be understood that all cuts formed in the cathode foil are identical. The groove 14 is formed by two vertical, parallel main grooves 16, whose tops are connected by a horizontal channel 18, preferably perpendicular to the two main grooves 16. The meanings of the following symbols are as follows: H 14 This refers to the height of the entire groove, which is generally between 0.25-10mm. L 14 This refers to the width of the entire groove, which is generally between 0.25 and 10 mm. L 16 This refers to the width of each main groove, which is generally between 0.02-5mm; H 18 This refers to the height of each channel, which is generally between 0.01 and 0.5 mm. D 18 It is the height difference between the top of the main groove and the top of the channel, which is generally between 0.05-2mm.

[0062] In addition, especially Figure 10 As shown, at least a first through hole 51 is formed in the first body, and a second through hole 52 is formed in the second body.

[0063] Through-holes 51 / 52 / 53 / 54, also known as through-holes, are openings on the top and bottom surfaces of the foil, respectively. These through-holes can be formed directly on the anode and / or cathode foils before or after alternating foil stacking, in a manner known per se, before or after the stacking of the alternating foils, which include a first foil or anode foil, each intended to form an anode layer of multiple cells, and a second foil or cathode foil, each intended to form a cathode layer of multiple cells. Through-holes can be formed by chemical etching, electroforming, laser cutting, micro-perforation, or stamping.

[0064] like Figure 3 As specifically shown, the first through-hole 51 and the second through-hole 52 formed in all cathodes overlap. Through-holes 53 and 54 are as follows. Figure 10 As shown.

[0065] Each anode is also provided with slots 34 in different rows and columns, the same number as the number of slots 14. Specifically, for example... Figure 4 As shown, the structure of each groove 34 is basically similar to that of each groove 14, that is, groove 34 includes two vertical main grooves 36 connected by a channel 38. The dimensions of the vertical main grooves 36 are the same as those of the vertical main grooves 16, and similarly, the dimensions of the channel 38 are similar to those of the channel 18.

[0066] When viewed from above, the vertical main groove 36 overlaps with the vertical main groove 16. The only difference between grooves 14 and 34 is that channel 38 is located at the bottom. Specifically, as... Figure 3 As shown, when viewed from the top view, channels 18 and 38 are symmetrical about each other with respect to the center line of H (denoted as XH).

[0067] In addition, especially Figure 3 As shown, at least a first through hole 53 is formed in the first body, and a second through hole 54 is formed in the second body.

[0068] Advantageously, the first through-hole 51 formed in the first cathode body extends in a continuation of the second through-hole 54 formed in the second anode body, such that these holes 51 / 54 extend in continuation of each other, forming a first through-channel 61 passing through the battery from one end to the other. Preferably, the first through-hole 53 formed in the first anode body extends in a continuation of the second through-hole 52 formed in the second cathode body, such that these holes 53 / 52 extend in continuation of each other, forming a second through-channel 63 passing through the battery from one end to the other.

[0069] Advantageously, the second vias 52 / 54 are spaced from the channels 18 and 38 of the slots to prevent any short-circuit risk while maintaining the mechanical strength of the stack. This distance is preferably selected based on the properties of the anode and cathode foils, particularly the properties, thickness, and stiffness of the current collector substrate used. The presence of these vias in the stack must not weaken the mechanical strength of the stack. The size of the vias can be adjusted as needed.

[0070] Advantageously, as detailed below, first and second through-holes 53 / 52 / 51 / 54 are formed at a distance from the lateral edges 101 and 102 of the battery to define material strips 56 / 57 / 58 / 59. Advantageously, second through-holes 52 / 54 are formed in the corresponding second bodies 112 / 132 at a distance from the corresponding free spaces 113 / 133 in the battery, thereby defining second material strips not shown in the figures. It is assumed that the above stack undergoes steps to ensure its overall mechanical stability. These steps, known in themselves, particularly include hot-pressing the different layers. As shown below, such a stack can form a single battery, the number of which is equal to the product of the number of rows Y and the number of columns X.

[0071] Therefore, refer to Figure 5 It shows three lines of L n-1 To L n+1 and three columns R n-1 To R n+1 According to the present invention, each row of the groove is made with two slits D. n and D' n Each cut is made in a through-cut manner, meaning it extends across the entire height of the stack, and is made in a manner known to people in itself. Non-limiting examples include cutting by sawing (especially cutting into cubes), guillotine cutting, or laser cutting.

[0072] Especially Figure 6 As shown, this figure is Figure 5 An enlarged view of one of the grooves, each cut forming between the corresponding channel and the H-facing end. It is assumed that the thickness of the cuts is negligible. Under these conditions, refer to the non-limiting example form. Figure 6 The following points should be noted: Cut D n The distance D between the opposite face of the horizontal channel 18 20 It is between 0.05mm and 2mm, but it should be understood that this distance D 20 Less than or equal to D 18 ; Cut D' n The distance D between the opposite face of the horizontal channel 38 40 It is between 0.05mm and 2mm, but it should be understood that this distance D40 Less than or equal to D 38 .

[0073] Still referencing Figure 5 Each final cell is defined by two cutouts at the top and bottom, and by the inner surface of a vertical main groove of shape H on the right and left sides. Figure 5 In the middle, once battery 100 is along the cutting line D n and D' n The areas 40 of the foil stack that do not constitute a battery are shown as dashed lines, while the volume of the slots is left blank. Furthermore, Figure 5 First and second channels 61 / 63 are shown passing through the battery from one end to the other, and these channels will subsequently fill conductive devices protruding from the top and bottom surfaces of the battery. These first and second channels 61 / 63 are preferably substantially perpendicular to the cathode and anode foils constituting the stack.

[0074] Figure 7 and Figure 8 This is a cross-sectional view taken along parallel cutting lines. Cutting plane VII-VII extends through the vertical main groove of H, while cutting plane VIII-VIII penetrates the material. Figure 7 Area 40 is shown, and this area is also... Figure 5 As shown, this corresponds to material scraps, particularly scraps of anode material 43 and cathode material 41. Figure 8 The cutting is shown to occur through the anode and cathode, i.e., at a distance D from the channel of the H-shaped groove. 20 The first body 111, corresponding to 131, and the second body 112, corresponding to 132, are separated from each cathode 1 and corresponding anode 3 of the battery 100 by spaces 113, 133, respectively free of any electrode material, electrolyte, and / or current collector substrate. This is a particularly advantageous feature of the invention because it improves the cutting quality and prevents short circuits at the battery side edges compared to the prior art.

[0075] International patent application WO 2016 / 001584 describes a stack of multiple cell units consisting of anode and cathode foils stacked alternately and laterally offset (see [link to patent application]). Figure 12 The battery is encapsulated within a packaging system to protect it from environmental influences. Cutting these encapsulated stacks to obtain cell units with exposed anode and cathode connections is performed along a cutting plane that passes through alternating, continuous electrodes and the packaging system. Due to the density differences between the electrodes and the packaging system in prior art batteries, cutting along this cutting plane can result in the packaging system being torn apart near the cutting plane, creating a risk of short circuits. In the prior art, during the encapsulation process, the encapsulation layer fills the gaps in the foil stack with U-shaped cuts. The encapsulation layer inserted into these gaps is thick and does not adhere well to the stack, leading to a risk of the packaging system being torn apart during subsequent cutting.

[0076] According to the present invention, by using a foil with an H-shaped cut, this risk is eliminated because the hot-pressed H-shaped mechanical structure is very rigid near the cut due to the alternating stacking of cathode and anode foils. Using this rigid structure, and using a foil with an H-shaped cut, the number of defects during the cutting process can be reduced, the cutting speed can be increased, and thus the battery yield can be improved.

[0077] According to the present invention, D' is performed using an anode and a cathode of similar density. n and D n This allows for a cleaner, higher-quality cut. Furthermore, the absence of any electrode material, electrolyte, and / or current collector substrate eliminates the risk of short circuits.

[0078] Now for reference Figures 9 to 11 These figures illustrate a battery 100 of the battery described in this invention. The longitudinal and transverse centerlines of the battery are indicated by reference numerals X100 and Y100, respectively. The transverse edges of the battery are indicated by reference numerals 101 and 102, and the longitudinal edges of the battery are indicated by reference numerals 103 and 104. Furthermore, each cathode is indicated by reference numeral 110, and each anode is indicated by reference numeral 130. The number of these cathodes is the same as the number of these anodes, corresponding to the number of cathode foils and anode foils in the aforementioned stack.

[0079] like Figure 9 As shown, when viewed from the top view, the free spaces in the cathode overlap. Furthermore, according to the same top view, the free spaces in the anode overlap. Finally, according to the same top view, the free spaces in the cathode and anode are not aligned; that is, they do not overlap. For example, this is evident in… Figure 10 It is specifically shown in the text.

[0080] Free space 113 connects the relative longitudinal edges of the battery, these edges in Figure 9 The top and bottom edges are shown in the diagram. This free space extends between the opposing longitudinal edges of the battery, separating the first body from the second body for each anode and each cathode.

[0081] Each cathode 110 includes a first body 111, a second body 112 located on a first lateral edge 101, and a space 113 free of any electrode material, electrolyte, and / or current collector substrate. The latter extends between longitudinal edges 103 and 104, with a width corresponding to the width of the channel 18 of the aforementioned groove 14. Similarly, each anode 130 includes a first body 131 and a second body 132 located on a lateral edge 102 opposite edge 101. The first body 131 and the second body 132 are separated by a space 133 free of any electrode material, electrolyte, and / or current collector substrate, connecting edges 103 and 104, i.e., extending between longitudinal edges 103 and 104. The two free spaces 113 and 133 are symmetrical about the centerline Y100.

[0082] The width L of each free space is 113. 113 This corresponds to the width of the channel 18 belonging to the groove described in the aforementioned figure. Furthermore, the width L of each second body 112... 112 Corresponding to distance D 20 For reference Figure 6 or Figure 8 As stated above.

[0083] Figure 13 Another alternative embodiment of the invention is shown. Figure 13 In the middle, with the first embodiment shown Figures 1 to 11 Any similar mechanical components are indicated by the same reference numerals, which are increased by 1000.

[0084] The main difference between the second alternative embodiment and the first alternative embodiment is that: the H-shaped grooves 1014 are distributed in rows L1 to L... y Inside, one row is below another, and columns R1 to R... x Within, one column is next to the other. In this way, located in column R... n At least one vertical main groove 1016 in the groove is located in column R n-1 and / or R n+1 At least one vertical main groove 1016 of adjacent grooves is aligned. In this case, two adjacent columns are not separated by material strips. Figure 13 As shown, adjacent rows are separated by material bridge 1020, with a height of H. 1020 The thickness is indicated to be between 0.05 mm and 5 mm. These material bridges provide the anode and cathode foils with sufficient mechanical stiffness to facilitate handling.

[0085] In this second alternative embodiment of the invention, the H-shaped groove 1014 may preferably be the same as in the first alternative embodiment. The groove 1014 is preferably formed by two vertical parallel main grooves 1016, which are connected at their tops by a horizontal channel 1018, preferably perpendicular to the two vertical main grooves 1016.

[0086] Each cathode has slots 1014 with different rows and columns. Each anode also has slots 1034 with different rows and columns, the number of which is the same as the number of slots 1014.

[0087] The structure of each groove 1034 is substantially similar to that of each groove 1014, i.e., groove 1034 includes two vertical main grooves 1036 connected by a channel 1038. The dimensions of the vertical main grooves 1036 are the same as those of the vertical main grooves 1016, and similarly, the dimensions of the channel 1038 are similar to those of the channel 1018.

[0088] When viewed from above, the vertical main groove 1036 overlaps with the vertical main groove 1016. The only difference between grooves 1014 and 1034 is that the channel 1038 is located at the bottom. Specifically, as... Figure 14 As shown, when viewed from the top view, channels 1018 and 1038 are symmetrical about each other with respect to the center line of H (denoted as XH').

[0089] Assume the aforementioned anode and cathode foil stack undergoes steps to ensure its overall mechanical stability. These steps, known in themselves, particularly include hot-pressing the different layers. As shown below, such a stack can form a single cell, the number of which is equal to the product of the number of rows Y and the number of columns X.

[0090] Therefore, refer to Figure 14 It shows three lines of L n-1 To L n+1 and three columns R n-1 To R n+1 According to the present invention, each row of the groove is made with two slits D. n and D' n Each cut is made in a through-cut manner, meaning it extends across the entire height of the stack, in a manner known to all. Non-limiting examples include cutting by sawing (particularly cutting into cubes), guillotine cutting, or laser cutting.

[0091] Each cut is formed between the corresponding channel and the H-facing end. The thickness of the cut is ignored. Figure 15 As shown, the cutting is performed through the anode and cathode, that is, at a distance D from the channel of the H-shaped groove. 1020The first body 1111, corresponding to 1131, and the second body 1112, corresponding to 1132, are separated from each cathode 1110 and corresponding anode 1130 of the battery 1100 by spaces 1113, corresponding to 1133, respectively, which are free of any electrode material, electrolyte, and / or current collector substrate. This is a particularly advantageous feature of the invention because it improves the cutting quality and prevents short circuits at the battery side edges compared to the prior art. Each final battery 1100 is defined by two cuts at the top and bottom, and by the inner surface of a vertical main groove of shape H on the right and left sides. Figure 13 In the middle, once battery 1100 is along the cutting line D n and D' n The area 1040 of the foil that does not constitute the battery in the stack is shown as a dashed line, while the volume of the slot is blank.

[0092] According to the present invention, D' is performed using an anode and a cathode of similar density. n and D n This allows for a cleaner, higher-quality cut. Furthermore, the absence of any electrode material, electrolyte, and / or current collector substrate eliminates the risk of short circuits.

[0093] like Figure 15 As shown, each cathode 1110 includes a first body 1111, a second body 1112 located on a first lateral edge 1101, and a space 1113 free of any electrode material, electrolyte, and / or current collector substrate. The latter extends between the longitudinal edges, and its width corresponds to the width of the channel 1018 of the aforementioned groove 1014. Similarly, each anode 1130 includes a first body 1131 and a second body 1132 located on a lateral edge 1102 opposite to edge 1101. The first body 1131 and the second body 1132 are separated by a space 1133 free of any electrode material, electrolyte, and / or current collector substrate, connecting the longitudinal edges, i.e., extending between longitudinal edges 1103 and 1104. The two free spaces 1113 and 1133 are symmetrical about the centerline Y100.

[0094] The width L of each free space 1113 1113 This corresponds to the width of the channel 1018 belonging to the groove described in the aforementioned figure. Furthermore, as described above, the width L of each second body 1112... 1112 Corresponding to distance D 1020 .

[0095] Even though the arrangement of the slots 1014 is different, the battery 1100 obtained according to the second alternative embodiment of the present invention is the same in all respects as the battery obtained according to the first alternative embodiment of the present invention.

[0096] In a third alternative embodiment of the invention (not shown in the accompanying drawings), the H-shaped grooves 14 / 1014 are distributed in rows L1 to L2. y Inside, one row is below another, and columns R1 to R... x Inside, one column is next to another. Thus, on the same anode foil and / or cathode foil, the H-shaped grooves 14 / 1014 according to the first and second alternative embodiments of the invention are arranged on the anode foil and / or cathode foil in such a way that they maintain sufficient mechanical rigidity to make these foils easy to handle and advantageously enable the stack to define a maximum number of cell cells.

[0097] Even though the arrangement of the tanks 14 / 1014 on the anode foil and / or cathode foil is different, the battery 1100 obtained according to the third alternative embodiment of the present invention is identical in all respects to the battery obtained according to the first and / or second alternative embodiments of the present invention.

[0098] Figure 11 and 12 The comparison highlights the advantages of the present invention. More specifically, the battery's essentially entire volume is occupied by useful material, i.e., material that contributes to the electrochemical function of battery 100. More specifically, only two very small free spaces 133 / 1133 cannot be considered as useful material. In this regard, refer to Figure 10 It can be seen that the free surface of the second cathode body is flush with the free surface of the first anode body, while the free surface of the second anode body is flush with the free surface of the first cathode body. In other words, the opposite side edges of the battery described in this invention, including the electrode material, are substantially continuous, in contrast... Figure 12 The prior art shown is discontinuous due to the presence of a backlash region.

[0099] "The free aspect of the second subject" corresponds to the aspect belonging to the second subject that is opposite to the first subject. "The free aspect of the first subject" corresponds to the aspect belonging to the first subject that is opposite to the second subject.

[0100] refer to Figure 10 The following points should be noted: - A first through hole 51 formed in the first cathode body extends in the continuation of a second through hole 54 formed in the second anode body, such that these holes 51 / 54 extend in continuation of each other, forming a first through channel 61 through the battery from one end to the other.

[0101] - The first through hole 53 formed in the first anode body extends in the continuation of the second through hole 52 formed in the second cathode body, so that these holes 53 / 52 extend in the continuation of each other, forming a second through channel 63 through the battery from one end to the other.

[0102] Advantageously, the second through-hole 52 is formed in the second body of the cathode, and is at a certain distance D from the free space 113 (corresponding to the channel 18 of the groove 14). 57 This is to prevent any short-circuit risk. Similarly, a second through-hole 54 is formed in the second anode body, at a distance D from the free space 133 (corresponding to the channel 38 of the groove 34). 59 To prevent any short circuit risk.

[0103] Advantageously, the first and second through holes 53 / 52 / 51 / 54 are formed at a certain distance from the lateral edges 101 and 102 of the battery, defining the material bands 56 / 57 / 58 / 59.

[0104] The meanings of the following symbols are as follows: D 56 The width of the material strip 56 corresponds to the distance between the free surface of the battery 100 of the present invention and the surface opposite to the first through hole 51 formed in the cathode first body; this distance D 56 It is between 0.04mm and 1.95mm, but it should be understood that this distance D 56 Basically equal to distance D 59 And it is smaller than the width of the second anode body; D 57 The width of the material strip 57 corresponds to the distance between the free surface of the battery 100 of the present invention and the surface opposite to the second through hole 52 formed in the second cathode body; this distance D 57 It is between 0.04mm and 1.95mm, but it should be understood that this distance D 57 Basically equal to distance D 58 And it is smaller than the width of the second cathode body; D 58 The width of the material strip 58 corresponds to the distance between the free surface of the battery 100 of the present invention and the surface opposite to the first through hole 53 formed in the anode first body; this distance D 58 It is between 0.04mm and 1.95mm, but it should be understood that this distance D 58 Basically equal to distance D 57 ; D 59 The width of the material strip 59 corresponds to the distance between the free surface of the battery 100 of the present invention and the surface opposite to the second through hole 52 formed in the second anode body; this distance D 59 It is between 0.04mm and 1.95mm, but it should be understood that this distance D 59 Basically equal to distance D 56.

[0105] like Figure 16 A, 16B, and 16C As shown, the first and second channels 61 / 63 formed in the battery of the present invention are filled with conductive devices for making electrical connections between the individual cells of the battery. These conductive devices protrude from the top and bottom surfaces of the battery.

[0106] The conductive devices can be made of conductive materials. Advantageously, these conductive devices have extremely low WVTR; these conductive devices are impermeable. They are in close contact with the stacked electrical connection areas.

[0107] For example, a conductive device can be: - A rod made of a conductive material, such as conductive glass or metal inserted into a channel in a molten state or by any suitable means. Upon solidification, the material forms the aforementioned rod, with its two opposite ends preferably defining fastening heads, such as... Figure 16 As shown in A, - A tightly fitted metal rod, wherein fastening heads are preferably defined at its two opposite ends, such as Figure 16 As shown in B, - A metal rod encased in a conductive sheath material, the sheath being obtained from glass or metal in a molten state or inserted into a channel by any suitable means. Upon solidification, the material forms a conductive sheath-encased metal rod, the two opposite ends of which preferably define fastening heads, such as... Figure 16 As shown in C.

[0108] Each of these fastening heads, at its top or at each end of the opposite conductive device, may define an electrical connection region, namely, the anode connection region 75 / 75' or the cathode connection region 76 / 76' of the battery of the present invention, thereby making the battery include at least one anode connection region 75 / 75' and at least one cathode connection region 76 / 76'.

[0109] The conductivity of conductive glass can be achieved by adding particles of gold, nickel, chromium, nickel-chromium alloys, tungsten, molybdenum, graphite, carbides, or nitrides to the glass.

[0110] These electrical connections are impermeable and have a low water vapor transmission rate (WVTR, also known as water vapor permeability). Water vapor transmission rate is particularly dependent on the materials used and their manufacturing process. Water vapor transmission rate, or permeability, can be determined using the methods described in US Patent Document US 7,624,621 and in the published document "Structural properties of ultraviolet cured polysilazane gas barrier layers on polymer substrates" by A. Mortier et al., published in Thin Solid Films 6+550 (2014) 85-89. A lower WVTR indicates a more impermeable encapsulation system.

[0111] "The free aspect of the second subject" corresponds to the aspect belonging to the second subject that is opposite to the first subject.

[0112] "The free aspect of the first subject" corresponds to the aspect belonging to the first subject that is opposite to the second subject.

[0113] Furthermore, the free spaces present in each anode and cathode layer of the battery eliminate the need for any encapsulation system (i.e., any insulating material within the battery, such as parylene), as these free spaces act as electrical insulators. This is beneficial for final steps in battery manufacturing, such as encapsulation. Neutralization, as in existing technologies, is no longer required. Figure 12 As shown, the recessed area within the battery is insulated by filling the gaps in the existing structure with an encapsulation system, and by filling the space present in the U-shaped cutouts that are connected end to end and offset, preventing any short circuits. Compared to the prior art, the use of a rigid structure and a foil with H-shaped cutouts in this invention facilitates encapsulation and reduces encapsulation thickness. Multilayer encapsulation systems with thinner and stiffer layers than those in the prior art are conceivable.

[0114] Advantageously, after the step of stacking the anode foil and the cathode foil, the resulting stack is assembled by heat treatment and / or mechanical compression.

[0115] Advantageously, after the stacking of the anode and cathode foils, the battery is assembled by stacking heat treatment at a temperature between 50°C and 500°C, preferably below 350°C, and / or the anode and cathode foils to be assembled are stacked under mechanical compression at a pressure between 10 and 100 MPa, preferably between 20 and 50 MPa. In one specific embodiment, after the stacking and heat treatment steps, a first through-channel 61 and a second through-channel 63 are advantageously created as described above, and then cathode conductive devices 71, 71', 71'' are inserted into the first through-channel 61, and anode conductive devices 73, 73', 73'' are inserted into the second through-channel 63, each of these conductive devices being capable of collecting at least a portion of the battery current.

[0116] In any case, these anode and cathode conductive devices protrude from the opposing surfaces of the stacked anode and cathode foil structures; such as Figure 16 As shown in A, 16B, and 16C, these conductive devices thus protrude from the overall volume of the stack.

[0117] Then along the cutting line D' in any suitable manner n and D n The stack of anode and cathode foils, which include anode and cathode conductive devices, is cut to obtain a cell.

[0118] In the case of using a liquid electrolyte-impregnated battery, it is advantageous to proceed with the preparation of the ionicly conductive device via a lithium-ion-carrying phase (e.g., an ionic liquid and / or a mixture of ionic liquids, with or without a solvent, and containing a lithium salt); this lithium-ion-carrying phase permeates into the battery through capillary action. Impregnation can be performed using techniques known per se.

[0119] After the conductive device has been formed, or in the case of a battery impregnated with a liquid electrolyte, after the battery has been impregnated with a lithium-ion carrier phase, the stack is advantageously encapsulated by a deposition encapsulation system to protect the battery cells from environmental influences. The encapsulation system must be chemically stable, heat-resistant, and impermeable to function as a barrier layer. Advantageously, the stack of anode and cathode foils according to the invention can cover a sequence of encapsulation systems (preferably z sequences), the encapsulation system comprising: - A first capping layer deposited on the stack of anode and cathode foils, preferably selected from parylene, parylene F, polyimide, epoxy resin, silicone resin, polyamide and / or mixtures thereof. A second capping layer, formed of an electrically insulating material, is deposited on the first capping layer 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).

[0120] This sequence can be repeated z times, where z ≥ 1. This multilayer sequence exhibits a barrier effect. The more times the encapsulation system sequence is repeated, the greater this barrier effect becomes. It increases with the number of deposited thin layers.

[0121] Typically, the first capping layer is made of a polymer, such as silicone, epoxy, polyimide, polyamide, or parylene (more commonly known as poly(p-xylene)). This first capping layer protects the battery's sensitive components from environmental influences. It further seals pores in the stacked surfaces and establishes a uniform adhesion layer for subsequent layers of the encapsulation system. This layer preferably covers all six sides of the battery and completely encapsulates it. The thickness of the first capping layer is preferably between 0.5 μm and 50 μm.

[0122] Advantageously, the first capping layer can be manufactured using parylene C, parylene D, parylene N (CAS1633-22-3), parylene F, or a mixture of parylene C, D, N, and / or F. Parylene (also known as poly(p-xylene)) is a dielectric, transparent, semi-crystalline material with high thermodynamic stability, excellent solvent resistance, and extremely low permeability. Parylene also provides barrier properties that protect the battery from external environmental influences. When the first capping layer is made of parylene F, the protection of the battery is enhanced. The first capping layer is preferably obtained by condensing gaseous monomers deposited on the surface via chemical vapor deposition (CVD), resulting in a conformal, thin, and uniform coverage of all accessible surfaces of the stack. The first capping layer is preferably rigid; it cannot be considered a flexible surface. Since the first capping layer is not sufficiently impermeable (in terms of water vapor permeability), at least one second capping layer, preferably made of an electrically insulating material with low water vapor permeability, should be deposited on the first capping layer.

[0123] The second capping layer is formed of an electrically insulating material, preferably an inorganic material. It is preferably deposited using atomic layer deposition (ALD), thereby achieving conformal coverage of all accessible surfaces of the stack that previously covered the first capping layer. ALD-deposited layers are mechanically very fragile and require a hard surface to function properly. Depositing a fragile layer on a flexible surface can lead to crack formation, resulting in a loss of integrity in the protective layer. Furthermore, the growth of the ALD-deposited layer is affected by the substrate properties. Layers deposited by ALD on substrates with different chemical properties will grow unevenly, which can also lead to a loss of integrity in the protective layer.

[0124] Alternating current deposition (ALD) techniques are particularly suitable for covering highly rough surfaces in a completely impermeable and conformal manner. They produce conformal layers free of defects such as pores (so-called "pinhole-free" layers) and act as excellent barriers. Their wVTR (wastewater translucency) is extremely low. The second capping layer can preferably be deposited by plasma-enhanced chemical vapor deposition (PECVD) or by chemical vapor deposition of the HDPCVD or ICPCVD type. The thickness of the second capping layer is preferably 10 nm to 10 μm. The thickness of the second layer is preferably selected according to the desired level of impermeability (i.e., the desired wVTR) and depends on the deposition technique used, particularly those selected from ALD, PECVD, HDPCVD, and ICPCVD. The second capping layer can be made of ceramic, vitreous, or glass-ceramic materials, such as oxides, nitrides, phosphates, oxynitrides, or siloxanes of the Al2O3 or Ta2O5 type.

[0125] This second capping layer, deposited on top of the first capping layer via ALD, PECVD, HDPCVD, or ICP CVD, firstly makes the structure impermeable, preventing water from migrating into the interior of the object. Secondly, it protects the first capping layer, preferably made of parylene F, from the atmosphere, especially air and water, and from the effects of heat exposure to prevent its degradation. The second capping layer improves the lifespan of the encapsulated battery.

[0126] Using this sequence of the encapsulation system, preferably encapsulating the stack of anode and cathode foils in z sequences, can minimize the WVTR of the encapsulation system, thereby improving the impermeability of the stack and the final cell.

[0127] A final capping layer can then be applied to the encapsulation system sequence, preferably a stack of anode and cathode foils encapsulated in z-sequences, thereby mechanically protecting the stack and optionally giving it an attractive appearance. The final capping layer protects and improves the lifespan of the encapsulated battery. Advantageously, the final capping layer is also selected to be heat-resistant and have sufficient mechanical strength to protect the battery during its subsequent use. Advantageously, the thickness of the final capping layer is from 1 μm to 50 μm. Ideally, the thickness of the final capping layer is approximately 10-15 µm, as such a thickness range protects the battery from mechanical damage.

[0128] The final capping layer preferably has a base layer of epoxy resin, polyethylene naphthalate (PEN), polyimide, polyamide, polyurethane, silicone resin, sol-gel silica, or organosilicon. Advantageously, the final capping layer is deposited by dip coating.

[0129] Alternatively, the packaging system protecting the battery cell or anode and cathode foil stack of the present invention from atmospheric effects can be comprised of a very low WVTR, preferably less than 10. -5 g / m 2 The first alternative capping layer sequence, preferably z' sequences, is formed. This sequence can be repeated z' times, where z ≥ 1. It has a barrier effect, which increases with the value of z'. Encapsulating the stack of anode and cathode foils with this sequence, preferably z' sequences, in the encapsulation system can minimize the WVTR of the encapsulation system, thereby improving the impermeability of the encapsulation, the impermeability of the stack, and ultimately the impermeability of the battery.

[0130] The thickness of the first alternative cover layer is preferably 0.5 μm to 50 μm.

[0131] This alternative capping layer can be formed by depositing ceramic materials and / or low-melting-point glasses, preferably glasses with a melting point below 600°C, around the anode and cathode foil stack. The ceramic and / or glass materials used in this layer are preferably selected from: - Low melting point glass (typically <600℃), preferably SiO2-B2O3; Bi2O3-B2O3, ZnO-Bi2O3-B2O3, TeO2-V2O5, PbO-SiO2, - Oxides, nitrides, oxynitrides, Si x N y SiO2, SiON, amorphous silicon or SiC.

[0132] These glasses can be deposited through molding or dip coating.

[0133] Ceramic materials are preferably deposited at low temperatures via PECVD or, more preferably, HDPCVD or ICP CVD; these methods can deposit layers with good impermeability.

[0134] Advantageously, the alternative packaging system may include z' alternative cover layers with different properties to reduce the WVTR of the package, i.e., to improve the impermeability of the stack. For example, the packaging system may include a first layer made of ceramic material and a second layer made of low-melting-point glass disposed on the first layer, or vice versa.

[0135] Glass film encapsulation can be obtained by depositing an ink containing oxides, phosphates, borates, and / or precursors of low-melting-point glass, followed by sintering.

[0136] The result is a robust and impermeable encapsulation, which in particular prevents water vapor from passing through the interface between the encapsulation system and the contact components.

[0137] After ensuring the battery cell is impermeable through its encapsulation, electrical connections are exposed at the ends of the battery's conductive parts by any means, including polishing.

[0138] Terminals (electrical contacts) are added at the obvious cathode or anode connection (where the insulating electrolyte is not coated). These contact areas are preferably located on opposite sides of the battery stack for collecting current. The connection is preferably electroplated using techniques known to those skilled in the art, preferably by immersion in a conductive epoxy resin and / or a molten tin bath.

[0139] The terminals can be fabricated as a single metal (e.g., tin) layer or as multiple layers. Preferably, the terminals are formed by a first stacked layer near the cathode and anode connection, the first stacked layer comprising, in sequence, a first conductive polymer layer (e.g., silver-filled resin), a second nickel layer deposited on the first layer, and a third tin layer deposited on the second layer. The nickel and tin layers can be deposited using electroplating techniques.

[0140] In this three-layer composite, the nickel layer protects the polymer layer during the soldering assembly step, while the tin layer ensures the solderability of the battery interface.

[0141] Terminals allow for positive and negative electrical connections on the top and bottom surfaces of the battery. These terminals also allow for parallel electrical connections between different battery elements. The cathode connection preferably protrudes on one lateral side of the battery, and the anode connection is preferably provided on the other lateral side.

[0142] Figures 18 to 20 An alternative embodiment of the battery 100 relative to the first embodiment described above is shown. Figures 18 to 20 In this drawing, any mechanical element similar to that in the first embodiment is indicated by the same reference numerals increased by 300.

[0143] according to Figures 18 to 20 The final battery of this alternative embodiment, indicated by reference numeral 400, differs from battery 100, particularly in the position of the conductive components. Figure 5 similar, Figure 18 The arrangement of H-shaped grooves 334 is shown, which are not connected to through channels such as 61 and 63. More specifically, holes 361 and 363 are formed in the anode and cathode foils. For each H-shaped groove, holes 361 form a first row 362 between the grooves 316 and 336 of the H-shaped groove. In addition, other holes 363 form a second row 364 between the same grooves 316 and 336.

[0144] In the example shown, each row of 362 and 364 is formed by three holes. Alternatively, different numbers of these holes can be provided, depending in particular on the width of the part. A single hole can be provided, or conversely, multiple holes, far more than three, can be provided.

[0145] Each row of holes is arranged along its respective cutting lines D361 and D363, which pass through the hole. Advantageously, each cutting line passes through a different hole, through the center of these holes. In the example shown, each hole is circular, with a diameter typically between 50 µm and 5 mm. As a result, each cutting line forms the diameter of the different hole it passes through. Finally, those skilled in the art will select the distance between the edge of each hole and the opposite wall (the groove or channel of the slot) to prevent the foil from being accidentally torn.

[0146] During manufacturing, the internal volumes of the different pores are filled with a suitable conductive material. Examples include resin, polymer, or even conductive glass. Cutouts D361 and D363 thus create conductive components 371 and 373, as shown in the final battery diagram. Figure 19 and 20 As shown. The conductive member 371 is formed of conductive material initially inserted into the hole 361, while the conductive member 373 is formed of conductive material of the hole 363.

[0147] Because different foils are cut through the centers of holes 361 and 363, each conductive member 371 and 373 has a generally semi-cylindrical shape, the diameter of which corresponds to the diameter of the hole. Referring to the first embodiment, the conductive member is housed in a through-channel. In contrast to the first embodiment, the through-channel is not cylindrical but semi-cylindrical, as it corresponds to the shape of the conductive member described above.

[0148] As in particular Figure 19 As shown, each lateral edge 401, 402 is formed by alternating conductive regions, each conductive region being formed by its respective conductive members 371, 373 and a so-called open stacked region. The latter, indicated by reference numerals 375 and 377, are readily impregnated with an electrolyte. It should be noted that in Figures 18 to 20In the illustrated embodiment, each conductive member is flush with the corresponding lateral edges 401 and 402, which is the opposite of the first embodiment in which the conductive members are located at a distance from the opposite lateral edges.

[0149] Figures 18 to 20 The illustrated embodiment has specific advantages. More specifically, each conductive component is formed simultaneously with the cutting of the foil. With this in mind, the holes allow for the production of these conductive components, facilitating the cutting operation. Furthermore, the material constituting the conductive components is cured before being filled with the ionic liquid. This ensures satisfactory electrical contact.

[0150] It should also be noted that each conductive component extends horizontally to the lateral edges 401, 402 of the battery on one hand, and vertically to the top surface 405 and bottom surface 406 of the battery on the other. This provides great convenience in recovering the generated current. More specifically, the current can be collected only at the lateral edges, only at the top and bottom surfaces, or at these lateral edges and these opposite surfaces.

[0151] In particular, such as Figure 21 As shown, current can be recovered through a support beneath the battery. This support 500 is typically flat and generally less than 300 μm thick, preferably less than 100 μm. The support is preferably made of a conductive material (typically a metallic material). In particular, aluminum, copper, or stainless steel are chosen because these materials can be coated with thin layers of gold, nickel, and tin to improve their solderability. The front side of the support is indicated by reference numeral 510 and faces the anode and cathode layers respectively, while the opposite back side is indicated by reference numeral 520.

[0152] The support member has holes, specifically spaces 530 and 540, defining a central substrate 550 and two opposing transverse strips 560 and 570. The different regions 550, 560, and 570 of the support member are therefore electrically insulated from each other. For this purpose, spaces 530 and 540 can be filled with any suitable non-conductive material.

[0153] Furthermore, the transverse strips 560 and 570 form areas that are electrically insulated from each other and connected to the aforementioned conductive members 371 and 373. For this purpose, each conductive member is preferably secured to the corresponding transverse strip by inserting a buffer 562, 572 made of conductive adhesive.

[0154] This embodiment provides an encapsulation system 380 made of any suitable material similar to the encapsulation system 380 described above. To ensure a standard of substantial impermeability, it must be ensured that components that could be detrimental to the proper functioning of the battery cannot enter the cell stack of the anode and cathode. In other words, according to the invention, this involves preventing any possible "gateways" for its harmful components.

[0155] For this purpose, the encapsulation material first covers the lateral edges of the battery, namely the conductive members 371 and 373, and the open stacking regions 375 and 377. It also preferably occupies the free spaces 530 and 540 in the support 500. It also fills the intermediate space between the lower surface of the anode and cathode unit stack on one side and the opposite surface of the support on the other side. Given that this encapsulation is typically carried out in a thin layer with a thickness generally not exceeding 10 µm, the encapsulation material is particularly present on various surfaces of the upper forming layer. To more intuitively understand the different areas of the battery filled with this encapsulation material, in Figure 21 The figure 380 is provided multiple times in the text.

[0156] Finally, it can be seen that, according to a preferred embodiment of the invention, the battery is also equipped with a reinforcement system, generally indicated by reference numeral 390. This reinforcement system covers the entire encapsulation system 380 opposite the support 500. Furthermore, this reinforcement material preferably occupies all or part of the free spaces 530 and 540 on the one hand, and on the other hand, it occupies the intermediate space between the support and the anode and cathode foils. In these different regions, this reinforcement material is thus tightly bonded to the encapsulation material. This tight mixture can be found at least on the surfaces, as the encapsulation material is primarily present on these surfaces, as described above. The presence of the aforementioned material ensures that the desired functionality is optimized, not only in terms of impermeability but also in terms of mechanical stiffness.

[0157] The reinforcing system 390 can be made of any material that can provide this specific mechanical stiffness function. With this in mind, for example, a resin composed of a simple polymer or a polymer filled with inorganic fillers could be chosen. The polymer matrix can be derived from, for example, families of epoxy resins, acrylates, or fluoropolymers, and the filler can be formed from particles, flakes, or glass fibers.

[0158] Advantageously, the strengthening system 390 can provide additional waterproofing. With this in mind, a low-melting-point glass can be selected, thereby ensuring mechanical strength and providing additional waterproofing. The glass can, for example, be derived from the SiO2-B2O3; Bi2O3-B2O3, ZnO-Bi2O3-B2O3, TeO2-V2O5, or the PbO-SiO2 family.

[0159] The thickness of the packaging system is preferably very low, particularly less than 50 μm, and preferably equal to 20 μm. Typically, the reinforcing system is much thicker than the packaging system. For example, the thickness of the reinforcing system is between 50 and 250 μm, typically equal to approximately 100 μm. The presence of the additional reinforcing system provides additional advantages, namely mechanical and chemical protection, optionally combined with additional gas barrier functions.

[0160] In operation, electrical energy is typically generated at the anode 3 and cathode 1. This energy is transferred via conductive members 371 and 373 to conductive regions 560 and 570 of the support 500. Since these conductive regions are insulated from each other, there is no risk of short circuit. The electrical energy is then diverted from regions 560 and 570 to any suitable type of energy-consuming device.

[0161] exist Figure 21 The energy-consuming device is illustrated graphically and designated by reference numeral 2000. It includes a body 2002 on which the bottom surface of a support rests, an energy-consuming element 2004, and an electrical connection 2006 connecting the bottom surface of the support 50 to the element 2004. Its control can be provided by any suitable means, particularly by a component (not shown) belonging to the device 2000. Alternatively, such control function can be provided by a component mounted on the aforementioned support 500.

[0162] As a non-limiting example, the energy-consuming device may be an amplifier-type electronic circuit, a clock-type electronic circuit (e.g., a real-time clock (RTC) component), a volatile memory-type electronic circuit, a static random access memory (SRAM)-type electronic circuit, a microprocessor-type electronic circuit, a watchdog timer-type electronic circuit, a liquid crystal display component, an LED (light-emitting diode)-type component, a voltage regulator-type electronic circuit (e.g., a low-dropout regulator (LDO) circuit), or a CPU (central processing unit)-type electronic component.

[0163] Now refer to Figure 25 To describe an alternative embodiment, the conductive support 750 is a multilayer type, in contrast to the single-layer type of the support 50 described above. Furthermore, this support 750 is solid, specifically in contrast to the perforated metal mesh type described above. As shown in the figure, the support 750 is formed from multiple layers of, for example, a polymer material. These layers extend one beneath another, their main planes substantially parallel to the planes forming the anode and cathode stacks. Therefore, the structure of this support is similar to that of a printed circuit board (PCB).

[0164] Figure 25 The layer 756, on which the battery stack will be deposited, is shown from top to bottom. Layer 756 is primarily made of a polymeric material such as epoxy resin and has two inserts 757. The inserts 757 are made of a conductive material, particularly a metallic material, and are designed to mate with the anode and cathode contacts of the battery. It should be noted that these inserts 757 are insulated from each other due to the epoxy resin of layer 756.

[0165] Directly below layer 756 is layer 758, also formed of a polymer material such as epoxy resin. Layer 758 is equipped with two inserts 759 made of conductive material, which are in electrical contact with the first insert 757. Like layer 756, these inserts 759 are insulated from each other.

[0166] Then there is an intermediate layer 760, which is significantly different from layers 756 and 758 described above. More specifically, layer 760 is formed of a conductive material generally similar to that used to form the inserts 757 and 759 described above. This layer is equipped with two annular inserts 761 made of an insulating material, particularly epoxy resin as described above. These inserts 761 receive a disk 762 made of a conductive material in their hollow central portion, which contacts the adjacent conductive insert 759. It should be noted that these conductive disks are insulated from each other by the rings.

[0167] Finally, existence Figure 25 The bottom layers 764 and 766 are identical to layers 758 and 756 described above, respectively. Layer 764 is equipped with two inserts 765 that contact the disk 762, while the bottom layer 766 is equipped with two inserts 767 that contact the aforementioned inserts 765. Different conductive inserts 757, 759, 765, and 767 define conductive paths, indicated by reference numerals 753 and 754, which are electrically connected to the opposite end faces of the support 705. These conductive paths are insulated from each other through layers 756, 758, 764, and 766 or through the disk. In this embodiment, the reinforcement system may differ from the reinforcement system of the first embodiment. The protective film 780 may be deposited, in particular, by a lamination step. This barrier film is made, for example, of polyethylene terephthalate (PET) incorporating inorganic multilayers; suitable products may be Ultra Barrier Film 510 or Ultra Barrier Solar Films 510-F purchased from 3M.

[0168] Figure 25 Further illustration shows the integration of a support 705, a stack 702, conductive pads 730 and 740, an encapsulation 707, and a thin film 708 onto the energy-consuming device 2000. Similar to the first embodiment, energy generated at the stack 702 is transferred to the upper insert 757 via contact members. This energy is then transferred to the energy-consuming device 2000 along the connection paths 753 and 754 described above.

[0169] In its most common structure, the multilayer support can be formed from only two separate layers, one beneath the other, which define conductive paths, similar to conductive paths 753 and 754 described above. This particular embodiment has specific advantages because the thickness of the multilayer substrate, for example, indicated by reference numeral 750, is very small, preferably less than 100 μm. Furthermore, the support has a degree of flexibility, thus accommodating minute variations in battery size, referred to in this specification as "respirations." The support further benefits from particularly satisfactory flexural strength for integration into flexible electronic circuits.

[0170] According to other alternative embodiments not shown, Figures 18 to 20 Alternative embodiments may be with Figure 13 and Figure 14 Alternative embodiments are combined. In this case, a hole is formed between each pair of adjacent recesses 1016 belonging to groove 1014. According to other alternative embodiments not shown, the battery 100 of the first embodiment can be placed... Figure 23 On the support member 500 shown.

[0171] Figures 22 to 24 References are shown Figures 18 to 20 Alternative embodiments of the manufacturing method shown. It should be noted that... Figures 22 to 24 Battery 400 manufactured using the method described in the article and used Figures 18 to 20 The battery obtained by the method shown is similar. Figures 22 to 24 In, with Figures 18 to 20 Similar mechanical components shown are all indicated by the same reference numerals, increased by 300.

[0172] like Figure 22 and Figure 23 As shown, each anode foil 601 and cathode foil 602 has a groove or empty area, indicated by reference numerals 614 and 634 respectively; they are elongated and generally I-shaped. Special Reference Figure 23 These grooves are distributed in the horizontal rows L1 to Ln of the diagram, with one row positioned below another, and in the vertical columns R1 to Rm of the diagram, with one column positioned next to another. Adjacent rows are separated by horizontal material bridges 650, and adjacent columns are separated by vertical material bridges 660. Typically, the width of these different material bridges is between 0.05 mm and 5 mm. These different material bridges provide sufficient mechanical rigidity to the different foils, making them easy to handle.

[0173] When viewed from a top view, as Figure 23As shown, the different cathode grooves 614 are aligned, i.e., they overlap each other. Similarly, the different anode grooves 634 are also aligned. In contrast, the anode and cathode grooves are not aligned; they are offset from each other. Therefore, these grooves create multiple intermediate spaces 635, along which holes 661 are formed. The shape and size of these holes are generally consistent with... Figures 18 to 20 Holes 361 and 363 are similar. (And...) Figures 18 to 20 As in the embodiment shown, the hole 661 receives material suitable for forming conductive member 371 or 373.

[0174] Assuming the above conditions, the stack formed by foils 601 and 602 is operated to ensure its overall stability. Then, a so-called pre-cut pair is manufactured, where one cut DX can be... Figure 22 I saw it there. More specifically, Figure 23 Several such cuts are shown. Each pair of cuts DX1, DX2, or DX3 insulates the battery in a given row from the adjacent row. For this purpose, these cuts are formed near the opposite longitudinal ends of each I-shaped slot, i.e., at... Figure 23 The cells are located near their top and bottom, respectively. The number of cells in a single row specifically corresponds to... Figure 22 The column numbers shown.

[0175] Then, a cut is made to form what is called the main cut, separating each cell belonging to a given row from its adjacent cells. For this purpose, as follows: Figure 24 As shown, these main cuts DY are formed in the intermediate space defined above through holes 661. As in the previous embodiment, each cut preferably extends through the middle of these holes.

[0176] After these slits (DY) are formed, the different cells are separated from each other. Furthermore, each slit defines two conductive components, each belonging to its respective cell. Figure 4 In the diagram, conductive members belonging to three adjacent cells 400, 400', and 400'' are referenced. Conductive members 373' and 371 are insulated from each other by a first cut DY, while conductive members 373' and 371'' are insulated from each other by adjacent cuts DY'.

[0177] According to other alternative embodiments, also not shown, the hole may be empty. This possibility has specific advantages because it improves the cutting operation. More specifically, the cutting operation is faster due to the presence of the hole. Furthermore, it advantageously reduces the heating of the cutting tool.

[0178] According to the present invention, the battery may include any technically compatible combination of the described packaging system, anode and cathode conductive devices, and terminals.

[0179] The battery described in this invention can be a lithium-ion microcell, a lithium-ion mini-cell, or a high-power lithium-ion battery. In particular, the battery can be designed and sized to have a capacity of less than or equal to about 1 mA h (commonly referred to as a "microcell"), a power greater than about 1 mA h to about 1 Ah (commonly referred to as a "mini-cell"), or a capacity greater than about 1 Ah (commonly referred to as a "high-power battery"). Typically, microcells are designed to be compatible with methods of manufacturing microelectronic products.

[0180] We can produce every type of battery in these three power ranges: - A layer of "solid" type, i.e., a liquid or paste phase without impregnation (the liquid or paste phase may be a lithium-ion conductive medium capable of acting as an electrolyte). - Or a layer of mesoporous "solid" type, impregnated with a liquid or paste phase, typically a lithium-ion conductive medium, which spontaneously permeates through the layer and no longer emerges from it; therefore, the layer can be considered a quasi-solid. Or it may have an impregnated porous layer (i.e., a layer with an open network of pores, which may be impregnated with a liquid or paste phase, thereby giving these layers wet properties).

Claims

1. A battery (100) comprising at least one anode (3) and at least one cathode (1), alternating on top of the other, the battery (100) comprising lateral edges (101, 102) and longitudinal edges (103, 104), the lateral edges comprising at least one anode connection region and at least one cathode connection region laterally opposite the anode connection region, wherein the anode (3) comprises: -Current collector substrate, and -At least one anode layer, The cathode (1) includes: -Current collector substrate, and -At least one cathode layer At least one of the anode (3) and cathode (1) includes an electrolyte material layer or an electrolyte-impregnated insulating layer. Thus, the battery comprises a stack of cells sequentially consisting of at least one anode layer, at least one electrolyte material layer or an electrolyte-impregnated separator layer, and at least one cathode layer. Its features are: - Each anode and each cathode includes a respective first body (111, 131) which are separated from the corresponding second body (112, 132) by free spaces (113, 133) free of any electrode material and current collector substrate, the free spaces connecting the opposite longitudinal edges (103, 104) of the battery. When viewed from a top view, each anode and each cathode includes at least one first through-hole (51, 53) formed in the first body and at least one second through-hole (52, 54) formed in the second body. The first through hole (51) formed in the first cathode body extends in the continuation of the second through hole (54) formed in the second anode body, so that these holes (51, 54) extend in the continuation of each other, forming a first through channel (61) through the battery from one end to the other. The first through hole (53) formed in the first anode body extends in the continuation of the second through hole (52) formed in the second cathode body, so that these holes (52, 53) extend in the continuation of each other, forming a second through channel (63) through the battery from one end to the other. The battery further includes at least one cathode conductive device (71, 71', 71'') housed in the first through channel (61) and at least one anode conductive device (73, 73', 73'') housed in the second through channel (63), wherein the anode conductive device (73, 73', 73'') is capable of collecting at least a portion of the battery current flowing to at least one anode connection region, and the cathode conductive device (71, 71', 71'') is capable of collecting at least a portion of the battery current flowing to at least one cathode connection region.

2. The battery according to claim 1, wherein each through channel extends at a distance from the opposite lateral edges (101, 102).

3. The battery according to claim 2, wherein the shortest distance (D) separating each through channel (61) from the opposite lateral edge 59 / D 56 The thickness ranges from 0.04 mm to 1.95 mm.

4. The battery according to claim 1, wherein each through channel is formed directly in the lateral edges (401, 402), and the cathode or anode conductive device is flush with the lateral edges respectively.

5. The battery according to claim 1, wherein the anode and cathode conductive devices are independently selected from: -A rod made of conductive material - Tightly fitted metal rod - A metal rod encased in a conductive sheath material.

6. The battery of claim 5, wherein the two opposite ends of the rod or the metal bar define fastening heads.

7. The battery according to claim 1, further comprising: - Electrical connection support components made at least partially of conductive material. - An electrical insulation device that insulates the two distal regions of the connecting support from each other, these distal regions forming their respective electrical connection paths. - The cathode conductive device is in electrical contact with the first electrical connection path, while the anode conductive device is in electrical contact with the second electrical connection path.

8. The battery according to claim 7, wherein the electrical connection support is of a single-layer type.

9. The battery of claim 8, wherein the electrical connection support comprises a plurality of layers, wherein one layer is disposed below another layer.

10. The battery according to claim 1, wherein the lateral dimension or width (L) of the free space 113 The value is 0.01 mm to 0.5 mm.

11. The battery according to claim 1, wherein the lateral dimension or width (L) of the second body is... 112 The value is 0.05 mm to 2 mm.

12. The battery according to claim 1, wherein the free surfaces of the second body of the cathode (112') and anode (132') opposite to the free space are respectively flush with the free surfaces of the first body of the anode (131') and cathode (111').

13. The battery of claim 1, comprising a packaging system that covers four of the six sides of the battery and partially covers two other sides, the other two sides being opposite to and perpendicular to the first and second through channels (61, 63) of the battery, the battery comprising at least one anode connection region and at least one cathode connection region.

14. The battery of claim 13, wherein the packaging system comprises: - At least one first coating layer deposited on the battery - At least one second capping layer composed of an electrically insulating material is deposited on the at least one first capping layer by atomic layer deposition or PECVD, HDPCVD or ICPCVD.

15. The battery of claim 14, wherein the sequence of at least one first covering layer and at least one second covering layer is repeated z times, wherein z ≥ 1.

16. The battery of claim 14, wherein the first covering layer is repeated z' times, where z' ≥ 1.

17. The battery of claim 13, wherein the packaging system comprises: - At least one first overlay layer with a WVTR less than 10 -5 g / m 2 ·d, deposited on the periphery of the anode foil and cathode foil stack.

18. The battery of claim 17, wherein the at least one first covering layer comprises: - Ceramic materials, and / or - Glass with a melting point of less than 600℃.

19. The battery of claim 1, comprising a terminal system covering at least the anode connection regions (75, 75') and at least the cathode connection regions (76, 76').

20. The battery according to claim 19, wherein the terminal system comprises, in sequence: - Conductive polymer first layer, -A second nickel layer disposed on the first layer of the terminal system, and - A third layer of tin is placed on the second layer of the terminal system.

21. A method for manufacturing a battery according to any one of claims 1 to 20, the method comprising: a) Providing a stack of alternating foils (I), the stack comprising a first foil or anode foil, each first foil or anode foil intended to form an anode layer of a plurality of batteries, and a second foil or cathode foil, each second foil or cathode foil intended to form a cathode layer of a plurality of batteries. Each anode foil includes at least one anode groove (34) without any anode, and each cathode foil includes at least one cathode groove (14) without any cathode. Each anode groove and each cathode groove defines at least a portion of the free space free of any electrode material and current collector substrate. b) Perform heat treatment and / or mechanical compression on the previously provided alternating foil stacks. c) For each anode and each cathode, at least one first through hole (51, 53) is formed in the first body and at least one second through hole (52, 54) is formed in the second body. - The first through hole (51) formed in the first cathode body extends in the continuation of the second through hole (54) formed in the second anode body, so that these holes (51, 54) extend in the continuation of each other, forming a first through channel (61) through the battery from one end to the other. - The first through hole (53) formed in the first anode body extends in the continuation of the second through hole (52) formed in the second cathode body, so that these holes (52, 53) extend in continuation of each other, forming a second through channel (63) through the battery from one end to the other. Step c) is performed on the anode foil and cathode foil before step a) or after step b). d) Inserting cathode conductive devices (71, 71', 71'') into the first through-channel (61) and inserting anode conductive devices (73, 73', 73'') into the second through-channel (63), each of these conductive devices being capable of collecting at least a portion of the battery current, e) Making an incision (D) n ,D' n ), to insulate the given battery.

22. The method of claim 21, wherein the through channel is formed at a distance from the lateral edge.

23. The method of claim 21, wherein at least one hole is formed along the path of each cut, each hole defining at least a portion of each through channel.

24. The method of claim 21, wherein the anode trench and the cathode trench each comprise two at least partially overlapping longitudinal portions (16, 36) for defining longitudinal edges (103, 104) of the battery, and a transverse portion (18, 38) connecting the two longitudinal portions, the transverse portion of the anode trench (38) and the transverse portion of the cathode trench (18) being offset from each other, a first cut extending between the transverse portion of the anode trench and the end facing the longitudinal portion, and a second cut extending between the transverse portion of the cathode trench and the end facing the longitudinal portion.

25. The method of claim 24, wherein each anode groove and each cathode groove has an integral H-shape, with the longitudinal portion forming a vertical main groove of the H and the transverse portion forming a channel of the H.

26. The method of claim 21, wherein the anode groove and the cathode groove are elongated, the anode grooves are stacked on top of each other, the cathode grooves are stacked on top of each other, the anode grooves are offset relative to the cathode grooves to define a plurality of intermediate spaces, and the cut is formed in the intermediate spaces.

27. The method of claim 21, further comprising step f) after step b) or after step e), impregnating the stack with a lithium-ion-carrying phase.

28. The method of claim 21, further comprising, after step e) or after step f), encapsulating the stack by depositing the following layer: - Deposit at least one first cover layer on the battery. - At least one second capping layer composed of an electrically insulating material is deposited on the at least one first capping layer by atomic layer deposition or PECVD, HDPCVD or ICPCVD.

29. The method of claim 21, wherein the two incisions (D) n D' n It passes through at least most of the anode and cathode.

30. The method of claim 28, wherein the sequence of at least one first covering layer and at least one second covering layer is repeated z times, where z ≥ 1.

31. An energy-consuming device (2000) comprising a body (2002) and a battery according to any one of claims 7 to 9, the battery being capable of supplying electrical energy to the energy-consuming device, and the electrical connection support of the battery being fixed to the body.

32. A method of manufacturing a battery, the battery comprising at least one anode (3) and at least one cathode (1), which are alternately disposed on top of each other, the battery (100) comprising longitudinal edges (103, 104) and transverse edges (101, 102), The anode (3) comprises: -Current collector substrate, and -At least one anode layer, The cathode (1) includes: -Current collector substrate, and -At least one cathode layer At least one of the anode (3) and cathode (1) includes an electrolyte material layer or an electrolyte-impregnated insulating layer. Thus, the battery comprises a stack of cells sequentially consisting of at least one anode layer, at least one electrolyte material layer or an electrolyte-impregnated separator layer, and at least one cathode layer. Each anode (3) includes an anode connection region located near the first lateral edge of the battery, while each cathode (1) includes a cathode connection region located on the second lateral edge of the battery opposite to the first lateral edge. Each anode and each cathode includes a respective first body (111, 131), which are separated from the corresponding second body (112, 132) by free spaces (113, 133) free of any electrode material and current collector substrate, the free spaces connecting the opposite longitudinal edges (103, 104) of the battery. The method for manufacturing the battery includes: a) Providing a stack of alternating foils (I), the stack comprising a first foil or anode foil, each first foil or anode foil intended to form an anode layer of a plurality of batteries, and a second foil or cathode foil, each second foil or cathode foil intended to form a cathode layer of a plurality of batteries. Each anode foil includes at least one anode groove (34) without any anode, and each cathode foil includes at least one cathode groove (14) without any cathode. Each anode groove and each cathode groove defines at least a portion of the free space free of any electrode material and current collector substrate. b) Perform heat treatment and / or mechanical compression on the previously provided alternating foil stacks. c) Create two cuts (D) that extend at least partially within the anode and cathode trenches. n D' n The first cut extends between the transverse portion of the anode tank and the end facing the longitudinal portion, while the second cut extends between the transverse portion of the cathode tank and the end facing the longitudinal portion. The method is characterized in that at least one hole is formed along the path of each cut so that the cut can be easily made using a cutting tool.

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