Method for manufacturing lithium-ion batteries

Abstract

According to the method of the application: manufacturing a stack (I) comprising, in plan view, x rows and y columns so as to form (x*y) cells, this stack being formed by a succession of alternating layers (SA, SC) respectively of anode layers (SA) and cathode layers (SC), each layer (SA, SC) comprising a plurality of respective anode primary blanks (111') and cathode primary blanks (141'), a plurality of respective anode secondary blanks (112') and cathode secondary blanks (142'), these blanks forming primary and secondary bodies of the cells and so-called "empty" zones (80", 70") between these primary and secondary bodies; in plan view, making a pair of main cuts (DYn, DY'n) between two adjacent empty zones (80", 70") so as to expose an anode connection zone (1002) and a cathode connection zone (1006) of each cell and to separate a given cell formed by a given row from at least one other adjacent cell formed by at least one adjacent row.

Description

Technical Field

[0001] This invention relates to the field of batteries, and more particularly to lithium-ion batteries. The invention relates to a novel method for manufacturing batteries, and more particularly to lithium-ion batteries with a novel architecture that provides improved lifespan. Background Technology

[0002] All-solid-state rechargeable lithium-ion batteries are known. WO 2016 / 001584 (I-TEN) describes a lithium-ion battery manufactured from an anode foil (comprising a conductive substrate continuously covered by an anode layer and an electrolyte layer) and a cathode foil (comprising a conductive substrate continuously covered by a cathode layer and an electrolyte layer); these foils are cut according to a U-shaped pattern before or after deposition. These foils are then stacked alternately to form a stack of several cell units. The patterns of the cut anode and cathode foils are placed in a "head-to-tail" configuration, causing the cathode and anode stacks to be laterally offset. An encapsulation system with a thickness of approximately ten micrometers is then deposited on the stack and in available cavities present within the stack. This encapsulation system ensures the rigidity of the structure at the cut planes and protects the battery from atmospheric effects. Once the stack has been manufactured and encapsulated, the stack is cut along the cut planes to obtain cell units, with the cathode and anode connection regions of the battery exposed on each of the cut planes. It has been found that the encapsulation system can be torn during these cuts, resulting in discontinuities in the battery seal. It is also known to add terminals (i.e., electrical contacts), where these cathode and anode connection areas are readily apparent.

[0003] However, this known solution appears to have some drawbacks. In fact, depending on the electrode positioning, especially the proximity of the electrode edges in multilayer cells and the cleanliness of the cut, leakage current can typically occur at the ends in the form of creeping short circuits. Despite the use of encapsulation systems around the cell and around the cathode and anode connection areas, this creeping short circuit degrades cell performance. Furthermore, sometimes non-compliant deposits of the encapsulation system are present on the cell, particularly at the cell edges where the space is created by the lateral offset of the electrodes on the cell edges.

[0004] The present invention aims to overcome at least part of some of the deficiencies of the prior art mentioned above, and in particular aims to obtain a rechargeable lithium-ion battery with high energy density and high power density.

[0005] This invention is particularly aimed at improving the production efficiency of rechargeable lithium-ion batteries with high energy density and high power density, and at enabling more efficient packaging at a lower cost.

[0006] The present invention is particularly intended to provide a method for reducing the risk of creep or accidental short circuits and allowing the manufacture of batteries with low self-discharge.

[0007] The present invention is particularly intended to provide a method that allows for the simple, reliable and rapid manufacture of batteries with an extremely long lifespan.

[0008] The present invention also aims to provide a method for manufacturing batteries that is simple, fast and cost-effective. Summary of the Invention

[0009] The first objective of the present invention is a battery for manufacturing at least one battery (1000), each battery comprising at least one anode entity (110) and at least one cathode entity (140) arranged alternately, one on top of the other, in the positive direction (ZZ) of the battery (1000).

[0010] In the battery, the anode entity (110) includes:

[0011] The anode current collector substrate (10), at least one anode layer (20), and possibly an electrolyte material layer (30) or an electrolyte-impregnated insulating layer (31) are present.

[0012] Furthermore, in the battery, the cathode entity (140) comprises:

[0013] The cathode current collector substrate (40), at least one cathode layer (50), and possibly an electrolyte material layer (30) or an electrolyte-impregnated insulating layer (31) are present.

[0014] The battery (1000) has six sides, namely

[0015] - The two faces, referred to as the positive faces (F1, F2), are opposite to each other, and in particular parallel to each other, generally parallel to each anode entity (110) and parallel to each cathode entity (140).

[0016] - Two surfaces referred to as lateral surfaces (F3, F5), which are opposite to each other, and in particular, parallel to each other; and

[0017] - Two faces called longitudinal planes (F4, F6) that are opposite to each other, and in particular, parallel to each other.

[0018] With the first longitudinal surface (F6) of the battery including at least one anode connection region (1002) and the second longitudinal surface (F4) of the battery including at least one cathode connection region (1006), the anode connection region (1002) and the cathode connection region (1006) are laterally opposite each other.

[0019] - Each anode entity (110) and each cathode entity (140) includes a corresponding primary body (111, 141) separated from the corresponding secondary body (112, 142) by the free space (113, 143) of any material of the electrode, electrolyte and current collector substrate;

[0020] -When the battery includes a plurality of free spaces (113) in the positive direction (ZZ) of the battery;

[0021] - The free space overlap between each main body (111) and each secondary body (112) of each anode entity (110);

[0022] The free space overlap between each primary body (141) and each secondary body (142) formed in each cathode entity (140); and

[0023] The free space of each anode entity (110) and each cathode entity (140) does not overlap;

[0024] The manufacturing method includes:

[0025] a) Fabricate a stack (I) that, in a top view, comprises x rows where x is strictly greater than 1 and y columns where y is greater than or equal to 1, to form (x*y) cells.

[0026] This stack is formed by a series of alternating layers (SA, SC) that are respectively cathode layers (SC) and anode layers (SA), each cathode layer (SC) intended to form (x*y) cathode entities (140), and each anode layer (SA) intended to form (x*y) anode entities (110).

[0027] Each layer (SA, SC) includes multiple primary preforms (111', 141'), namely a primary anode preform (111') and a primary cathode preform (141'), each of which is intended to form a corresponding primary body (111, 141); multiple secondary preforms (112', 142'), namely secondary anode preforms (112') and secondary cathode preforms (142'), each of which is intended to form a corresponding secondary body (112, 142), the primary preforms (111', 141') and the secondary preforms (112', 142') being separated from each other by regions called empty regions (80", 70"), which are intended to form at least one of the free spaces (113, 143) and when the battery includes a plurality of free spaces (113) in the positive direction (ZZ) of the battery;

[0028] - The voids (80”) of different anode layers (SA) overlap;

[0029] - Overlapping voids (70”) in different cathode layers (SC); and

[0030] - The empty areas (80”, 70”) of each anode layer (SA) and each cathode layer (SC) do not overlap.

[0031] b) Perform heat treatment and / or mechanical compression on the stack (I) obtained in step a) to form a solidified stack;

[0032] c) In the top view, a pair of main cuts (DYn, DY'n) are made between two adjacent empty areas (80", 70") to expose the anode connection area (1002) and the cathode connection area (1006) and to connect the given cell formed by the given row (Rn) to the cell formed by at least one adjacent row (Rn). n+1 At least one other adjacent cell is separated from the formation.

[0033] According to the first embodiment, each layer (SA, SC) is formed from a single piece of foil, and the empty areas specifically correspond to the material drop areas (70, 80, 70', 80') in the foil.

[0034] According to another embodiment, each layer (SA, SC) consists of multiple independent strips (A1, A2, A3, A4, A5, A6, A7, A8, A9, A1, A1, A2 ... n C1, C2, C n The empty zone (113', 143') is formed between the edges (LA, LC) facing the adjacent strip.

[0035] According to a first variation of the invention, vacancy zones called small vacancy zones (80, 70) are created, which are referred to as gaps, and each of the vacancy zones is intended to form a single free space.

[0036] According to a second variation of the invention, a region called a large void (80', 70') is created, which is referred to as a notch, each large void intended to form multiple free spaces in the same row, especially all the free spaces of the same row (Rn).

[0037] According to an advantageous feature of the invention, the empty areas (70, 70', 80, 80') have a rectangular shape, especially an I-shape.

[0038] According to one feature of the invention, a pair of auxiliary cuts (DXn, DX'n) are performed after step b) during step d), thereby allowing a given column (L) belonging to the consolidated stack to be cut. n ) and at least one adjacent column (L n-1 L n+1 Separation.

[0039] According to another feature of the invention, the solidified stack obtained in step b) is impregnated with a lithium-ion support phase (e.g., a liquid electrolyte or an ionic liquid containing a lithium salt) during step e), or the column (L) of the battery (1000) obtained in step d) is impregnated when step d) is performed. n The insulating layer (31) is impregnated with an electrolyte.

[0040] According to a feature of the invention, it is performed before step c); and after step e), if step e) is performed or if step e) is not performed; after step d), if step d) is performed or if steps e) and d) are not performed; and after step b).

[0041] Solid stack or column (L) of battery (1000) n The encapsulation step f) preferably involves covering the stack (I) or the column (L) of the battery (1000) by the encapsulation system (95). n The periphery of the battery is preferably the front face (F1, F2) of the stack or the column (L) of the battery. n The positive face (FF1, FF2), stack (I), or column (L) of cell (1000) n The positive planes (F3, F5, FF3, FF5) and the longitudinal planes (F4, F6, FF4, FF6) of the network.

[0042] The packaging system (95) preferably includes:

[0043] -Optionally, deposited in the stack (I) or the column (L) of the cell (1000). n At least one first covering layer on the periphery of the ) is preferably selected from parylene, F-type parylene, polyimide, epoxy resin, silicone, polyamide, sol-gel silica, organosilicon silica and / or mixtures thereof.

[0044] -Optionally, a second capping layer, which is deposited by atomic layer deposition on the periphery of the stack (I) or the column (L) of the cell (1000). n The electrical insulation material on the periphery or the first covering layer constitutes the structure, and

[0045] - At least one third waterproof covering layer, preferably having a thickness of less than 10 -5 g / m 2 The water vapor transmission rate (WVTR) of this third capping layer is determined by deposition on the periphery of the stack (I) or the column (L) of the cell (1000). n It is composed of ceramic material and / or low-melting-point glass (preferably glass with a melting point less than 600°C) on the periphery or the first covering layer.

[0046] Given that a series of at least one second cover layer and at least one third cover layer can be repeated z times (where z≥1) and deposited on the periphery of at least the third cover layer, and the final layer of the encapsulation system is a waterproof cover layer, preferably having less than 10 -5 g / m 2 It has a water vapor transmission rate (WVTR) of .d and is made of ceramic materials and / or low melting point glass.

[0047] According to another feature of the invention, after step c), step g) is performed, wherein at least the anode connection region (1002) is covered by the anode contact member (97'), preferably including at least the first longitudinal surface (F6) of the anode connection region (1002), thereby ensuring electrical contact between the stack (I) and the external conductive element.

[0048] Furthermore, the cathode contact member (97”) covers at least the cathode connection area (1006), preferably including at least the second longitudinal surface (F4) of the cathode connection area (1006), thereby ensuring electrical contact between the stack (I) and external conductive elements.

[0049] Step (i) includes:

[0050] - A first electrical connection layer of a material carrying conductive particles is deposited on at least an anode connection region (1002) and at least a cathode connection region (1006), preferably deposited on at least a first longitudinal surface (F6) including at least an anode connection region (1002) and at least a second longitudinal surface (F4) including at least a cathode connection region (1006), wherein the first layer is preferably formed of a polymeric resin and / or a material carrying conductive particles obtained by a sol-gel method;

[0051] - Optionally, when the first layer is formed from a polymeric resin and / or a material carrying conductive particles obtained by a sol-gel method, a drying step is followed by a polymerization step of the polymeric resin and / or the material obtained by the sol-gel method; and

[0052] - A second electrical connection layer, including a metal foil, is deposited on the first electrical connection layer.

[0053] - Optionally, a third electrical connection layer comprising conductive ink is deposited on the second electrical connection layer.

[0054] According to another feature of the invention, the cutting in step d), when this step is performed and / or in step c) is performed by laser ablation, preferably wherein all the cutting in step d), when this step is performed and / or in step c) is performed by laser.

[0055] The present invention also relates to a battery (1000) comprising at least one anode entity (110) and at least one cathode entity (140), said entities being alternately placed on top of each other in the positive direction (ZZ) of the main plane of the battery (1000), thereby forming a stack (I).

[0056] The anode entity (110) comprises: an anode current collector substrate (10), at least one anode layer (20), and possibly an electrolyte material layer (30) or an electrolyte-impregnated insulating layer (31).

[0057] The cathode entity (140) includes: a cathode current collector substrate (40), at least one cathode layer (50), and a possible electrolyte material layer (30) or an electrolyte-impregnated isolation layer (31);

[0058] The battery (1000) has six sides, namely

[0059] - Two faces, referred to as the positive faces (F1, F2), are opposite to each other, and in particular parallel to each other, generally parallel to each anode body (110), each cathode body (140), anode current collector substrate (10), anode layer (20), the electrolyte material layer (30) or the electrolyte-impregnated isolation layer (31), cathode layer (50), and cathode current collector substrate (40).

[0060] - The two faces, referred to as the lateral faces (F3, F5), are opposite each other, and in particular, parallel to each other.

[0061] - and two faces called longitudinal planes (F4, F6), which are opposite to each other, and in particular parallel to each other.

[0062] With the first longitudinal surface (F6) of the battery including at least one anode connection region (1002) and the second longitudinal surface (F4) of the battery including at least one cathode connection region (1006), the anode connection region (1002) and the cathode connection region (1006) are laterally opposite each other.

[0063] Make:

[0064] - Each anode entity (110) and each cathode entity (140) includes a corresponding primary body (111, 141) separated from the corresponding secondary body (112, 142) by free space (113, 143) of any material of the electrode, electrolyte, and current collector substrate.

[0065] -When the battery includes a number of free spaces (113) in the positive direction (ZZ) of the main plane of the battery,

[0066] The free space overlap between each primary body (111) and each secondary body (112) formed in each anode entity (110)

[0067] The free space overlaps between each primary body (141) and each secondary body (142) formed in each anode entity (110), and

[0068] The free spaces of each anode entity (110) and each cathode entity (140) do not overlap.

[0069] The battery is characterized in that it includes a packaging system (95) that at least partially covers the periphery of the stack (I), the packaging system (95) covering the front surface (F1, F2), the side surface (F3, F5) of the stack and at least partially covering the longitudinal surface (F4, F6), such that...

[0070] Only the anode connection region (1002) and the cathode connection region (1006) are included.

[0071] Preferably, it includes a first longitudinal surface (F6) comprising at least an anode connection region (1002) and a second longitudinal surface (F4) comprising at least a cathode connection region (1006).

[0072] Not covered by the packaging system (95), which includes:

[0073] Optionally, a first capping layer deposited on at least a portion of the periphery of the stack (I) is preferably selected from parylene, F-type parylene, polyimide, epoxy resin, silicone, polyamide, sol-gel silica, organosilicon silica, and / or mixtures thereof.

[0074] - Optionally, a second capping layer is formed of an electrically insulating material deposited by atomic layer deposition on at least a portion of the periphery of the stack (I) or on the first capping layer.

[0075] - At least one third waterproof covering layer, preferably having a thickness of less than 10 -5 g / m 2 The water vapor transmission rate (WVTR) of this third capping layer is .d. This third capping layer is composed of ceramic material and / or low-melting-point glass (preferably glass with a melting point less than 600°C) deposited on at least a portion of the periphery of the stack (I) or on the first capping layer.

[0076] Under the condition that the second covering layer is present

[0077] A series of second and third capping layers can be repeated z times (where z≥1) and deposited on the periphery of at least the third capping layer.

[0078] The final layer of the encapsulation system is a waterproof covering layer, preferably having a density of less than 10. -5 g / m 2 It has a water vapor transmission rate (WVTR) of .d and is made of ceramic materials and / or low melting point glass.

[0079] According to an advantageous feature of the battery according to the invention, the anode connection region (1002), preferably including at least a first longitudinal surface (F6) of the anode connection region (1002), is covered by the anode contact member (97').

[0080] Furthermore, at least the cathode connection area (1006), preferably including the second longitudinal surface (F4) of at least the cathode connection area (1006), is covered by the cathode contact member (97”).

[0081] Under the condition that the anode contact member (97') and the cathode contact member (97") can ensure electrical contact between the stack (I) and the external conductive element.

[0082] According to another feature of the battery according to the invention, each of the anode contact member (97') and the cathode contact member (97") comprises:

[0083] A first electrical connection layer, disposed on at least an anode connection region (1002) and at least a cathode connection region (1006), preferably disposed on a first longitudinal surface (F6) including at least a cathode connection region (1002) and a second longitudinal surface (F4) including at least a cathode connection region (1006), this first layer comprising a material carrying conductive particles, preferably a polymeric resin and / or a material carrying conductive particles obtained by a sol-gel method, and even more preferably a polymeric resin carrying graphite, and

[0084] - A second electrical connection layer, comprising a metal foil disposed on a first layer of material carrying conductive particles.

[0085] According to the first embodiment, the battery according to the invention has a capacity of less than or equal to 1 mA h.

[0086] According to an alternative embodiment, the battery according to the invention has a capacity greater than 1 mA h. Attached Figure Description

[0087] Different aspects and embodiments of the invention are illustrated with the aid of the accompanying drawings, which are provided as non-limiting examples.

[0088] [ Figure 1 [This is a perspective view of a stacked anode and cathode foils formed according to a battery manufacturing method according to the invention, the anode and cathode foils having voids, or gaps, referred to as small void areas.]

[0089] [ Figure 2 For explanation Figure 1 A top view of a foil, especially an anode foil.

[0090] [ Figure 3[A top view illustrating the stacking of the anode and cathode foils and the small voids, i.e., the voids formed in adjacent foils, according to the present invention.]

[0091] [ Figure 4 [This is a top view illustrating the small void area according to the invention, i.e., the void formed in adjacent foils, at a larger scale.]

[0092] [ Figure 5 This is also a perspective view that illustrates these small voids, i.e., the gaps formed in adjacent foils, on a large scale.

[0093] [ Figure 6 [Top view illustrating the cutting steps performed on the different gaps formed in the stack of the previous figure.]

[0094] [ Figure 7 To illustrate, based on the cutting line DX n and DX' n A top view of the column of batteries according to the invention obtained after cutting and stacking.

[0095] [ Figure 8 ] for along Figure 6 The indicator in the middle corresponds to the cutting line DX' n The cross-sectional views in columns VIII-VIII illustrate the stacking of anode and cathode foils with gaps according to the invention.

[0096] [ Figure 9 ] for along Figure 6 The indicator in the middle corresponds to the cutting line DX' n The cross-sectional views in columns VIII-VIII illustrate the stacking of anode and cathode foils with gaps, as well as the main anode body, secondary anode body, main cathode body and secondary cathode body according to the invention.

[0097] [ Figure 10 [A torn perspective view illustrating a column of batteries according to the invention encapsulated in an encapsulation system, which can be obtained particularly according to the method of the previous figures.]

[0098] [ Figure 11 [A torn perspective view illustrating the battery according to the invention, including the encapsulation system, which can be obtained particularly according to the method of the previous figures.]

[0099] [ Figure 12 [A torn perspective view is provided to illustrate the battery according to the invention, including the encapsulation system, which can be obtained particularly according to the method of the previous figures, and to illustrate the stack, the anode main body, the anode secondary body, the cathode main body, and the cathode secondary body.]

[0100] [ Figure 13[This refers to the section column VIII-VIII or the cutting line DX'] n A cross-sectional view illustrating the battery according to the invention, including the encapsulation system and contact members, which can be obtained, in particular, according to the method of the previous figures.

[0101] [ Figure 14 [Perspective view illustrating a torn battery according to the prior art.]

[0102] [ Figure 15 [A top view illustrating the anode and cathode foils of the first variant of the present invention, and the area referred to as the large void area, i.e., the stack of notches made in adjacent foils.]

[0103] [ Figure 16 To illustrate the cutting steps performed on the different notches formed in the stack of the previous figure according to the first variant of the present invention, and to show a top view of the battery obtained according to this same variant.

[0104] [ Figure 17 [A top view illustrating the anode and cathode strips of a second variation according to the present invention, and the stacking of the spacing between adjacent strips.]

[0105] [ Figure 18 ] for along Figure 17 The cutting line DX' indicated in the middle n A cross-sectional view illustrating the stacking according to a second variation of the invention.

[0106] [ Figure 19 To illustrate the variation of voids formed in a stack, similar to... Figure 6 Top view.

[0107] [ Figure 20 [For illustrative purposes only, it may be possible to obtain information based on...] Figure 19 A top view of the batteries obtained by stacking the gaps.

[0108] [ Figure 21 [To illustrate, a void variation similar to that not belonging to this invention] Figure 19 Top view.

[0109] The following references are used in these figures and in the following descriptions:

[0110] 1000 Batteries according to the present invention

[0111] 1002 Anode Connection Area

[0112] 1006 Cathode Connection Area

[0113] 100, 100', 100” cell

[0114] 10 Anode current collector substrate

[0115] 20 Anode Layer

[0116] 30 Electrolyte material layer / electrolyte layer

[0117] 31. Insulating layer / insulating layer impregnated with or subsequently impregnated with electrolyte

[0118] 50 Cathode Layer

[0119] 40 Cathode current collector substrate

[0120] 80. Voids in the anode foil, anode voids, anode small voids

[0121] The 80' anode notch / vacancy area is referred to as the anode large void region.

[0122] I 80 Total width / total lateral dimension of anode gap 80

[0123] L 80 Total length / total longitudinal dimension of anode void

[0124] L 80 Total length of the anode notch / Total longitudinal dimension

[0125] L 80 Total length of anode free space / total longitudinal dimension

[0126] 70. Voids in the cathode foil, cathode voids, and small cathode cavities.

[0127] The 70' cathode notch / vacancy is referred to as the cathode large void region.

[0128] I 70 Total width / total lateral dimension of cathode gap 70

[0129] L 70 Total length of cathode gap / total longitudinal dimension

[0130] L 70 Total length of cathode notch / Total longitudinal dimension

[0131] L 70 Total length / total longitudinal dimension of cathode free space

[0132] 110 Anode Entity

[0133] 111 and 141 are the main components of 110 and 140, respectively.

[0134] 112 and 142 are the secondary subjects of 110 and 140, respectively.

[0135] 113 and 143 are in the free space between 111 and 112, and between 141 and 142, respectively.

[0136] 140 Cathode Entity

[0137] Lateral edge of LA anode strip

[0138] Lateral edge of LC cathode strip

[0139] SA,SA1,SA2,…SA n Anode layer

[0140] SC,SC1,SC2,…SC n cathode layer

[0141] 111' and 141' are the main prefabricated components of SA and SC, respectively.

[0142] 112' and 142' are secondary prefabricated parts of SA and SC, respectively.

[0143] The 80” and 70” spaces are located between 111” and 112” and between 141” and 142” respectively.

[0144] 80” is the free space formed in the longitudinal direction between two adjacent anode strips / anode free space

[0145] 70” is the free space / cathode free space formed in the longitudinal direction between two adjacent cathode strips.

[0146] L 112 The length of the secondary main body 110

[0147] L 113 The length of the free space between 111 and 112

[0148] L 142 140 secondary body length

[0149] L 143 The length of the free space between 141 and 142

[0150] C1,C2,C3,C4,C n ,C'1,C'2,C'3,C'4,C' n Cathode strip

[0151] A1, A2, A3, A4, A n ,A'1,A'2,A'3,A'4,A' n Anode strip

[0152] 90 Material Drop Zone

[0153] 95 Packaging System

[0154] 97 Contact components

[0155] 97' Anode Contact Component

[0156] 97'a Anode contact member lug at the longitudinal plane F6 covering the ends of adjacent planes F1, F2, F3, and F5

[0157] 97” Cathode Contact Component

[0158] 97”a A cathode contact member lug at the longitudinal plane F4 covering the ends of adjacent planes F1, F2, F3, and F5

[0159] L 1000 Battery length

[0160] I. A stack of anode foils and cathode foils with empty regions / a stack of at least one cell

[0161] 2e Anode foil with voids, such as gaps or notches.

[0162] 5e refers to a cathode foil with voids, such as gaps or notches.

[0163] 4. Perforated central region of an anode foil with basic solid structure

[0164] 6. The outer frame of the anode foil with basic solid structure

[0165] 7. Perforations present at the four ends of the anode and cathode foils.

[0166] 8. Material bridge between two columns

[0167] L8 Bridge Width

[0168] 9. Second material bridge between the two rows of gaps

[0169] L9 Length of the second material bridge

[0170] XX stack / battery vertical or horizontal orientation

[0171] YY stacking / battery sideways or lateral orientation

[0172] ZZ stacking / forward direction of the battery

[0173] L,L n ,L n-1 ,L n+1 Gap column / battery column

[0174] R,R n ,R n-1 ,R n+1gap line

[0175] PA,PA' Anode plane

[0176] PC,PC' cathode plane

[0177] DX n-1 ,DX' n-1 ,DX n ,DX' n ,DX n+1 ,DX' n+1 The first pair of cuts, referred to as auxiliary cuts

[0178] DY n-1 ,DY' n-1 ,DY n ,DY' n ,DY n+1 ,DY' n+1 The second pair of cuts, referred to as the primary cut.

[0179] Interface between AA packaging system and contact components

[0180] 2000 Batteries according to existing technology

[0181] 200,200',200” Cell cells according to existing technology

[0182] 2002 Anode connection region of a battery according to the prior art

[0183] 2006 Cathode connection region of a battery according to the prior art

[0184] 295 Battery packaging system according to the prior art

[0185] F1,F2 stack (I) / battery (1000) front side

[0186] Side surface of F3, F5 stack (I) / battery (1000)

[0187] Longitudinal plane of F4, F6 stack (I) / cell (1000)

[0188] FF1, FF2 Battery Rows (L) n The positive side of )

[0189] FF3, FF5 Battery Array (L) n ) lateral surface

[0190] FF4, FF6 Battery Array (L) n longitudinal plane Detailed Implementation

[0191] As is customary, the geometric names associated with this battery are as follows:

[0192] ZZ is the direction referred to as the positive direction, which is perpendicular to the plane of the different stacked layers of the battery according to the present invention.

[0193] XX is a direction referred to as the longitudinal direction, which is contained in the plane of the stacked layers and, in the top view, is parallel to the largest dimension of the stack of layers forming the battery according to the invention in the positive direction.

[0194] YY is the direction referred to as the lateral or transverse direction, which is contained in the plane of the stacked layers and is the smallest dimension parallel to these layers in the top view.

[0195] As is customary, references are reproduced thereon. Figure 11 or Figure 12 The foil plane is given two orientations associated with each of the three directions.

[0196] For direction XX, therefore, rightward orientation is associated with leftward orientation; for direction YY, forward orientation is associated with backward orientation; and for direction ZZ, upward orientation is associated with downward orientation, and references are reproduced thereon. Figure 11 or Figure 12 The foil plane.

[0197] As is customary, references are reproduced thereon. Figure 11 or Figure 12 The foil plane defines a first longitudinal orientation XX' guided from right to left and a second longitudinal orientation XX' guided from left to right, opposite to the first longitudinal orientation XX'. Reference is always made to the reproduction on it. Figure 11 or Figure 12 The foil plane defines a first lateral orientation YY' guided from front to back, a second lateral orientation YY” opposite to the first lateral orientation, a first positive orientation ZZ' guided from top to bottom, and a second positive orientation ZZ opposite to the first positive orientation.

[0198] To characterize the barrier properties of the encapsulation system, this specification refers to the WVTR (water vapor transmission rate) coefficient, which characterizes the water vapor transmission rate of the encapsulation system. A lower WVTR coefficient indicates a more waterproof encapsulation system. The water vapor transmission rate (WVTR) can be determined using a method described in US 7.624.621 and also in the publication "Structural properties of ultraviolet-cured polysilazane gas barrier layers on polymer substrates" by A. Morlier et al., published in Solid Thin Films Journal 550 (2014) 85-89.

[0199] This invention aims to manufacture such Figure 11 and Figure 12 The battery shown.

[0200] refer to Figure 11 and 12 This describes a battery 1000 according to the present invention, comprising at least one anode entity 110 and at least one cathode entity 140, which are alternately positioned on top of each other in the positive direction ZZ of the battery 1000.

[0201] Each anode entity 110 of the battery 1000 according to the present invention includes an anode current collector substrate 10, at least one anode layer 20, and possibly an electrolyte material layer 30 or an electrolyte-impregnated separator layer 31 in the forward direction ZZ of the battery 1000.

[0202] Each cathode entity 140 of the battery 1000 according to the present invention includes a cathode current collector substrate 40, at least one cathode layer 50, and possibly an electrolyte material layer 30 or an electrolyte-impregnated separator layer 31, depending on the forward direction ZZ of the battery 1000.

[0203] like Figure 11 As described herein, the battery 1000 according to the present invention has six sides. These are defined as follows:

[0204] - The two faces, referred to as the positive faces F1 and F2, are opposite each other and parallel to each other in this example, generally parallel to each anode entity 110 and parallel to each cathode entity 140.

[0205] - The two faces, referred to as lateral faces F3 and F5, are opposite each other and parallel to each other in this instance; and

[0206] - The two faces, referred to as longitudinal faces F4 and F6, are opposite to each other and parallel to each other in the instance.

[0207] like Figure 11 As indicated, the first longitudinal surface F6 of the battery 1000 includes at least one anode connection region 1002. The second longitudinal surface F4 of the battery 1000 includes at least one cathode connection region 1006. In this manner, the anode connection region 1002 and the cathode connection region 1006 are laterally opposite each other. Furthermore, each anode entity 110 and each cathode entity 140 includes corresponding main bodies 111 and 141 separated from corresponding secondary bodies 112 and 142 by free spaces 113 and 143 of any material of the electrode, electrolyte, and current collector substrate in the longitudinal direction XX' of the battery 1000. Therefore, for each cathode entity 140, the main body 141, the free spaces 143 of any material of the electrode, electrolyte, and current collector substrate, and the secondary bodies 142 are arranged adjacent to each other in the first longitudinal direction XX' of the battery 1000. Similarly, for each anode entity 110, the primary body 111, the free space 113 of any material of the electrode, electrolyte and current collector substrate, and the secondary body 112 are arranged adjacent to each other in the second longitudinal direction XX” of the battery 1000, which is opposite to the first longitudinal direction XX’.

[0208] like Figure 11 As indicated in the diagram, by means of a non-limiting example, the battery 1000 according to the present invention includes a plurality of free spaces 113, 143 in the positive direction ZZ of the battery. In this way, in a top view, the free spaces between each main body 111 and each secondary body 112 formed in each anode entity 110 overlap, and the free spaces between each main body 141 and each secondary body 142 formed in each cathode entity 140 overlap. Furthermore, the free spaces 113, 143 of each anode unit 110 and each cathode unit 140 do not coincide.

[0209] The battery according to the invention is formed by a stack I, which includes x rows with x strictly greater than 1 and y columns with y greater than or equal to 1 in the longitudinal direction XX, so as to form (x*y) batteries.

[0210] Stack I consists of cathode layers SC, SC1, SC2, ..., SC n and anode layers SA, SA1, SA2, ..., SA n A series of alternating layers are formed, each cathode layer SC, SC1, SC2, ..., SC n The aim is to form (x*y) cathode entities 140, and each anode layer SA, SA1, SA2, ..., SA n The aim is to form (x*y) anode entities 110.

[0211] Each anode layer SA, SA1, SA2, ..., SA according to the stack I of the present invention nThe stack I, which is parallel to the forward direction ZZ of the final battery 1000, includes an anode current collector substrate 10, at least one anode layer 20, and possibly an electrolyte material layer 30 or an electrolyte-impregnated separator layer 31.

[0212] Each cathode layer SC, SC1, SC2, ..., SC according to the stack I of the present invention n The stack I, which is parallel to the forward direction ZZ of the final battery 1000, includes a cathode current collector substrate 40, at least one cathode layer 50, and possibly an electrolyte material layer 30 or an electrolyte-impregnated isolation layer 31.

[0213] Each layer SA, SA1, SA2, ..., SA n SC, SC1, SC2, ..., SC n include:

[0214] - Multiple main preforms 111' and 141', namely the anode main preform 111' and the cathode main preform 141', each of which is intended to form the corresponding main body 111, 141.

[0215] - Multiple secondary preforms 112' and 142', namely anode secondary preform 112' and cathode secondary preform 142', each of which is intended to form the corresponding secondary body 112, 142.

[0216] The primary preforms 111', 141' and secondary preforms 112', 142' are separated from each other by areas called empty areas 80" and 70", which are intended to form at least one of the free spaces 113, 143 of the battery 1000.

[0217] According to a first embodiment of the present invention, the method according to the present invention first includes manufacturing alternating layers SA1, SA2, ..., SA1. n SC, SC1, SC2, ..., SC n The stacking process involves steps I. In this first embodiment, each of these layers is formed as a single sheet of foil. Hereinafter, these different foils will be referred to as "anode foils" or "cathode foils" as appropriate. As will be seen in more detail, 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 described illustrates two cathode foils with a small void area, i.e., a gap 5e, and two anode foils with a small void area, i.e., a gap 2e. In practice, this stack is formed using a higher number of foils, typically between ten and one thousand. The number of cathode foils with a gap 5e is the same as the number of anode foils with a gap 2e, which are used to form a stack I of alternating foils with opposite polarities.

[0218] In an advantageous embodiment, each of these foils has a perforation 7 at its four corners, such that when these perforations 7 overlap, all the cathodes and all the anodes of these foils are arranged according to the invention, as will be explained in more detail below (see [link to relevant documentation]). Figure 1 , 2 (3 and 15). These perforations 7 can be made by any suitable means, especially on the anode and cathode foils after manufacturing or on the substrate foils 10, 40 before manufacturing the anode and cathode foils.

[0219] Each anode foil includes an anode current collector substrate 10 coated with an active layer 20 of an anode material, hereinafter referred to as the anode layer 20. Each cathode foil includes a cathode current collector substrate 40 coated with an active layer 20 of a cathode material 50, hereinafter referred to as the cathode layer 50. Each of these active layers may be solid and, more particularly, dense or porous. Furthermore, to avoid any electrical contact between two active layers of opposite polarity, an electrolyte layer 30 or a subsequently electrolyte-impregnated isolation layer 31 is disposed on at least one of these current collector substrates previously coated with active layers, on the active layer in contact with the opposing active layer. The electrolyte layer 30 or the isolation layer 31 may be disposed on the anode layer 20 and / or the cathode layer 50; the electrolyte layer 30 or the isolation layer 31 is integral part of the anode foil and / or cathode foil including therefrom.

[0220] Advantageously, the anode 10, the corresponding cathode 40, and the current collector substrate are coated with an anode layer 20 on both sides, and a cathode layer 50 is correspondingly coated thereon. Optionally, an electrolyte layer 30 or an insulating layer 31 disposed on the anode layer 20 is coated on the cathode layer 50, respectively. In this case, the anode 10, the corresponding cathode 40, and the current collector substrate act as current collectors for two adjacent cell units 100, 100'. Using these substrates in the battery allows for improved production efficiency of rechargeable batteries with high energy density and high power density.

[0221] The mechanical structure of one of the anode foils is described below, assuming that the other anode foils have the same structure. Furthermore, as will be seen below, the cathode foil has a structure similar to that of the anode foil.

[0222] like Figure 2 As shown, the anode foil 2e with voids 80 has a generally rectangular quadrilateral shape. It defines a central region, referred to as the perforated central region 4, in which voids 80 are formed, i.e., voids referred to as small voids, free of any material from the electrode, electrolyte, and current collector substrate, as will be described below. Referring to the positioning of these voids, the foil has been defined in a direction corresponding to the lateral direction of these voids 80, referred to as the lateral or transverse direction YY, and in a direction perpendicular to the YY, referred to as the horizontal direction XX. The central region 4 is defined by a peripheral frame 6 that is solid, i.e., does not have voids 80. The function of this frame 6 is, in particular, to ensure easy handling of each foil.

[0223] Gap 80 along column L1 to L y One is placed below the other and along row R1 to R x They are arranged adjacent to each other. By way of a non-limiting example, in the context of manufacturing surface-mount component type microcells (hereinafter referred to as SMCs), the anode and cathode foils used can be 100mm × 100mm plates. Typically, the number of columns and rows of these foils is between 10 and 500. Depending on the desired capacity of the cell, these dimensions can be varied and the number of columns and rows of the anode and cathode foils can be adjusted accordingly. In other words, the dimensions of the anode and cathode foils used can be adjusted as needed. Figure 2 As shown, two adjacent columns can be separated by a material bridge 8, the width of which is denoted as I8 and is between 0.05 mm and 5 mm. Two adjacent rows can be separated by a second material bridge 9, the length of which is denoted as L9 and is between 0.05 mm and 5 mm. These material bridges 8 and 9 of the anode and cathode foils provide the foils with sufficient mechanical rigidity, making them easy to handle.

[0224] The gaps 70 and 80 are through gaps, meaning they open onto opposite sides of the foil (the upper and lower surfaces, respectively), as will be seen in more detail below. These gaps 70 and 80 preferably have a quadrilateral shape, typically rectangular. In the illustrated example, these gaps each have an I-shape, which makes them very easy to use. These gaps 70 and 80 can be fabricated directly on the current collector substrate in ways known per se, prior to any deposition of the anode or cathode material by chemical etching, electroforming, laser cutting, micro-perforation, or stamping.

[0225] These gaps 70 and 80 can also be manufactured in:

[0226] - On the current collector substrate coated with an anode or cathode material layer, or

[0227] - On the current collector substrate coated with an anode or cathode material layer (which itself is coated with an electrolyte layer or an isolation layer), i.e., on the anode or cathode foil.

[0228] When the voids 70 and 80 are manufactured on such coated substrates, the voids 70 and 80 can be manufactured in a manner known per se, such as by laser cutting (or laser ablation), by femtosecond laser cutting, by micro-perforation, or by stamping.

[0229] like Figure 3 As explained, each cathode foil also has cathode gaps 70 in different columns and rows, which are provided in the same number as the anode gaps 80 of each anode foil. The cathode foil obtained after manufacturing the gaps 70 is referred to below as a cathode foil with gaps 5e.

[0230] In the top view and as Figure 3 As explained, the cathode gaps 70 manufactured in all cathode foils 5e coincide, that is, they overlap each other. Similarly, the anode gaps 80 manufactured in all anode foils 2e coincide, that is, they overlap each other.

[0231] The description is as follows Figure 3 , 4 and 5 The gaps 70 and 80 described herein are provided under the condition that all gaps 80 of the anode foil are the same and all gaps 70 of the cathode foil are the same.

[0232] Preferably, each anode gap 80 has a quadrilateral shape of the typical rectangular type.

[0233] Note:

[0234] ·I 80 The width of the entire anode gap 80 is typically between 0.25 mm and 10 mm.

[0235] ·L 80 Its length is typically between 0.01mm and 0.5mm.

[0236] Especially Figure 4 and 5 As shown, the structure of each cathode gap 70 is generally similar to that of each anode gap 80, that is, each cathode gap 70 preferably has a quadrilateral shape of a generally rectangular type.

[0237] The size of the cathode gap 70 is preferably the same as the size of the anode gap 80.

[0238] Note:

[0239] ·I 70 The width of the entire cathode gap 70 is typically between 0.25 mm and 10 mm.

[0240] ·L 70Its length is typically between 0.01mm and 0.5mm.

[0241] As seen above, the anode gap 80 and the cathode gap 70 have similar structures. Furthermore, in the top view, the anode gap 80 is offset relative to the cathode gap 70 in the longitudinal direction XX. In this way, in the top view, the anode gap 80 and the cathode gap 70 do not coincide and are distinct from each other.

[0242] Stack I comprises an alternating arrangement of at least one anode foil 2e having a gap 80 and at least one cathode foil 5e having a gap 70. Thus, at least one cell 100 is obtained, which successively comprises an anode current collector substrate 10, an anode layer 20, an electrolyte material layer 30 and / or a separator layer 31 subsequently impregnated with electrolyte, a cathode layer 50, and a cathode current collector substrate 40.

[0243] This stack I is constructed such that, in the top view:

[0244] - The cathode gaps 70 created in all cathode foils 5e coincide, that is, they overlap each other.

[0245] - The anode voids 80 manufactured in all anode foils 2e coincide, that is, overlap each other, and

[0246] - The anode gap 80 and the cathode gap 70 do not overlap and are different from each other.

[0247] In the case where the battery comprises multiple cell units 100, 100', 100" , the cell units 100, 100', 100" are as follows: Figure 11 The diagram indicates that one element is positioned below the other in the positive direction ZZ of the main plane of the battery, i.e., they overlap, such that: Preferably:

[0248] The anode current collector substrate 10 is an anode current collector substrate 10 for two adjacent cell units 100, 100', 100" and

[0249] The cathode current collector substrate 40 is a cathode current collector substrate 40 for two adjacent cell units 100, 100', 100".

[0250] Suppose that the stack I described above undergoes steps designed to ensure its overall mechanical stability. These steps, of a known type, particularly involve heat treatment and / or mechanical treatment of various foils 2e, 5e with gaps 80, 70. As will be seen below, this thus solidified stack allows for the formation of individual cells, the number of which is equal to the product between the number of columns Y and the number of rows X.

[0251] For this purpose, refer to Figure 6 The three columns L have already been explained. n-1 To L n+1And three rows of R n-1 To R n+1 In the following text, a battery column will be referred to as a column belonging to a stack, which is intended to form a number of batteries. For a given column, the number of batteries formed corresponds to the number of rows in the stack. According to the invention, and when stack I is included, it will also be referred to as battery column L in the following text. n When there are several columns, perform the first pair of cuts DX. n and DX' n This allows column L of a given battery 1000 to be... n Relative to at least one other column L of the battery formed by the solidified stack n-1 L n+1 Separation, such as Figure 7 As indicated in the text. Each cut is performed in a manner known per se, extending directly beyond the entire height of the stack. By way of non-limiting examples, cuts made by sawing, particularly slitting, chopping, or even laser cutting, will be mentioned. Furthermore, the area 90 of the stacked foil, which does not form a battery, is illustrated by filling with a dotted pattern, while the volume of the gaps is left blank.

[0252] Especially Figure 6 (It is) Figure 3 As shown in a larger-scale view of the gaps formed in adjacent foils, each cut DX is made in the positive direction ZZ of the battery. n ,DX' n Regardless of which of the two orientations is necessarily upward. Cut DX n and DX' n Preferably, they are parallel to each other and preferably perpendicular to the alignment of the anode gap 80 and the cathode gap 70. Cut DX n and DX' n It is manufactured over the entire height of the stack by means of anode void 80 and cathode void 70, which limits the material drop zone 90.

[0253] Refer again Figure 6 At the rear and front, a first pair of cuts DX, preferably parallel to each other, are made. n and DX' n And on the left and right sides, a second pair of cuts DY, preferably parallel to each other, are made. n and DY' n Limited to each final battery.

[0254] Here Figure 6 In the diagram, battery 1000 is represented by a shaded column, once according to the first pair of cut DX n and DX' n And according to the second pair of cuts DY n and DY' n get.

[0255] Figure 8 For along corresponding to such Figure 6 The cutting line DX indicated in the text n The cross-sectional view taken from section VIII-VIII, which extends through battery column L n .exist Figure 8 In the figure, it represents the alternating arrangement of two anode foils with a gap 2e and two cathode foils with a gap 5e. In the same figure, according to an advantageous embodiment of the invention, reference is made to... Figure 6 The document also describes the gaps 70 and 80 and the adjacent cell units.

[0256] Anode foil 2e with small voids, i.e., gaps, includes an anode current collector substrate 10 coated with an anode layer 20, which optionally has an electrolyte layer 30 or a subsequently electrolyte-impregnated isolation layer 31. Each cathode foil 5e with small voids, i.e., gaps, includes a cathode current collector substrate 40 coated with an active layer 50 of cathode material, which optionally has an electrolyte layer 30 or a subsequently electrolyte-impregnated isolation layer 31. To avoid any electrical contact between two active layers of opposite polarity, i.e., between the anode layer 20 and the cathode layer 50, at least one electrolyte layer 30 and / or at least one isolation layer 31 impregnated or subsequently electrolyte-impregnated are disposed. Figure 8 In the text, a cell 100 is defined as continuously comprising an anode current collector substrate 10, an anode layer 20, at least one electrolyte material layer 30 or an isolation layer 31 impregnated or subsequently impregnated with an electrolyte, a cathode layer 50, and a cathode current collector substrate 40.

[0257] Advantageously, the anode current collector substrate 10 of cell 100' can be bonded to the anode current collector substrate 10 of adjacent cell 100". Similarly, the cathode current collector substrates of two adjacent cells 100, 100' can be bonded to each other.

[0258] In an advantageous embodiment, the anode 10, the corresponding cathode 40, and the current collector substrate can serve as current collectors for two adjacent cell units, especially as... Figure 8 As explained earlier, the anode 10, the corresponding cathode 40, and both sides of the current collector substrate are coated with an anode layer 20, and correspondingly coated with a cathode layer 50. Optionally, an electrolyte layer 30 or a separator layer 31 disposed on the anode layer 20 and the cathode layer 50 are also coated. This allows for improved battery production efficiency.

[0259] like Figure 8 As shown in the diagram, each anode foil with a gap 2e and each cathode foil with a gap 5e are arranged such that, in the top view:

[0260] - The cathode gaps 70 created in all cathode foils 5e coincide, that is, they overlap each other.

[0261] - The anode voids 80 manufactured in all anode foils 2e coincide, that is, overlap each other, and

[0262] - The anode gap 80 and the cathode gap 70 do not overlap and are different from each other.

[0263] exist Figure 9 The figure shows an alternating arrangement of two anode foils with a gap 2e and two cathode foils with a gap 5e. In the same figure, according to an advantageous embodiment of the invention, reference allows for the connection of battery 1000 with battery array L. n Other battery separation cut lines DY n 、DY' n The length L of the battery 1000 , Figure 6 The document also describes the gaps of 70 and 80, as well as the adjacent cell units. Figure 9 In, just like in Figure 8 In this context, it should be noted that the second pair of cuts (DY) is performed through both the anode entity 110 and the cathode entity 140. n 、DY' n ,Right now:

[0264] - Distance L from the cathode gap 70 142 So that each cathode entity 140 of the battery 1000 has a main body 141 separated from the secondary body 142 by free spaces 143, 70 of any material of the electrolyte, separator, current collector substrate and electrodes (especially cathodes), and

[0265] - Distance L from the anode gap 80 112 So that each anode entity 110 of the battery 1000 has a main body 111 separated from the secondary body 112 by free space 113, 80 of any material of electrolyte, separator, current collector substrate and electrodes (especially anode).

[0266] This feature is particularly advantageous because it allows for improved cutting quality compared to existing technologies and avoids short circuits at the longitudinal faces F6 and F4 of the battery, prevents leakage current, and promotes electrical contact between the anode connection region 1002 and the cathode connection region 1006.

[0267] refer to Figure 9 And for each cell, 1000, note:

[0268] • 70 is the cathode gap, corresponding to the free space 143 between the main body 141 and the secondary body 142 of the cathode entity 140;

[0269] ·L 70The length L of the entire cathode gap 70 is typically between 0.01 mm and 0.5 mm. 70 The length L of the free space 143 corresponding to the space between the main body 141 and the secondary body 142 of the cathode entity 140. 143 ;

[0270] ·L 142 The length of the secondary body 142 of the cathode unit 140 is typically between XXXX mm and XXXXX mm;

[0271] • 80 is the anode void, corresponding to the free space 113 between the main body 111 and the secondary body 112 of the anode entity 110;

[0272] ·L 80 The length L is typically between 0.01 mm and 0.5 mm, representing the entire anode void 80. 80 The length L of the free space 113 corresponding to the space between the main body 111 and the secondary body 112 of the anode entity 110. 113 ;

[0273] ·L 112 The length of the secondary body 112 of the anode entity 110 is typically between 0.01 mm and 0.5 mm.

[0274] Advantageously, after manufacturing the stack of anode foil with a void 2e and cathode foil with a void 5e, the stack I is solidified by heat treatment and / or mechanical treatment (this treatment may be hot pressing, including simultaneous application of pressure and high temperature). The heat treatment of the stack, which allows for battery assembly, is advantageously carried out at a temperature between 50°C and 500°C, preferably below 350°C. The mechanical compression of the stack of anode foil with a void 2e and cathode foil with a void 5e to be assembled is carried out at a pressure between 10 MPa and 100 MPa, preferably between 20 MPa and 50 MPa.

[0275] The solid-state stacking of the foils that make up the battery has just been described. Next, when stack I is included, it will also be referred to below as battery column L. n When there are several columns, it is possible to perform the first pair of cuts DX, which is called auxiliary cut. n and DX' n This allows a given column L of battery 1000 to be... n With at least one other column L of the battery formed by the solidified stack n-1 L n+1 Separate. Each cut is performed in a manner known per se, which is executed directly, extending beyond the entire height of the stack, as indicated above.

[0276] When the separator layer is used as the main matrix of the electrolyte, several battery columns L can be included in the initial stack I. n Impregnate previously obtained solidified stacks or column L of battery 1000. n And perform the first pair of cuts (DX) n ,DX' n ) so that the given column (L) of battery (1000) can be used to select the battery (1000). n ) and at least one other column (L) of the battery (1000) formed by the solidified stack. n-1 L n+1 Separation. Previously obtained solidified stack or column L of battery 1000. n The impregnation can be carried out using a lithium ion carrier phase, such as a liquid electrolyte or an ionic liquid containing lithium salt, so that the isolation layer (31) is impregnated with the electrolyte.

[0277] Generally, within the scope of this invention, it is possible to impregnate the insulating layer and the electrodes. The structure may also include a combination of impregnated solid and / or mesoporous electrodes and / or may include a solid electrolyte and / or an impregnated insulating layer.

[0278] In manufacturing solid-state stacks I or battery 1000 that may be impregnated with lithium-ion carrier phases, column L n After that, this stack or battery 1000 in this column L n A 95% encapsulation system using deposition encapsulation ensures the battery is protected from atmospheric effects, such as... Figure 10 As indicated in the text.

[0279] Therefore, the packaged battery array L n It has six faces, namely:

[0280] - The two faces, referred to as the positive faces FF1 and FF2, are opposite each other and parallel to each other in this example. They are generally parallel to the anode entity, generally parallel to the cathode entity, and generally parallel to the anode current collector substrate 10, anode layer 20, electrolyte material layer 30 or electrolyte-impregnated isolation layer 31, cathode layer 50, and cathode current collector substrate 40.

[0281] - The two surfaces referred to as side surfaces FF3 and FF5 are opposite to each other, and in particular, they are parallel to each other and parallel to the side surfaces F3 and F5 of battery 1000.

[0282] - and two surfaces called longitudinal surfaces FF4 and FF6, which are opposite to each other, and in particular parallel to each other and parallel to the longitudinal surfaces F4 and F6 of battery 1000.

[0283] The packaging system must be chemically stable, heat resistant, and atmospheric impermeable in order to perform its function as a barrier layer.

[0284] The stack can be covered by a packaging system, including:

[0285] Optionally, a first dense and insulating capping layer, preferably selected from parylene, F-type parylene, polyimide, epoxy resin, silicone, polyamide, sol-gel silica, organosilicon silica, and / or mixtures thereof, is deposited on the periphery of the stack I of the anode foil 2e and the cathode foil 5e; and preferably also deposited in the free spaces 113, 143 between the primary bodies 111, 141 and the secondary bodies 112, 142 of each anode entity 110 and each cathode entity 140; and

[0286] - Optionally, the second capping layer is composed of an electrically insulating material deposited by atomic layer deposition on the periphery of the stack I of the anode foil 2e and the cathode foil 5e, and preferably also deposited in the free spaces 113, 143 between the main bodies 111, 141 and the secondary bodies 112, 142 of each anode entity 110 and each cathode entity 140, or deposited on the first capping layer; and

[0287] - Particularly advantageously, at least one third waterproof covering layer, which preferably has a density of less than 10 -5 g / m 2 The WVTR coefficient of .d, this third capping layer is composed of ceramic material and / or low melting point glass (preferably glass with a melting point less than 600°C) deposited on the periphery of the stack I of anode foil 2e and cathode foil 5e, and preferably also deposited in the free spaces 113, 143 between the main bodies 111, 141 and the secondary bodies 112, 142 of each anode entity 110 and each cathode entity 140, or on the first capping layer.

[0288] The encapsulation system comprises at least one second cover layer and at least one third cover layer, which can be repeated z times (where z≥1) and deposited on the periphery of at least the third cover layer, with the final layer being a waterproof cover layer (which preferably has less than 10...). - 5 Under the condition that the WVTR coefficient is g / m2.d and the material is composed of ceramic material and / or low melting point glass.

[0289] This sequence can be repeated z times, where z ≥ 1. It exhibits a barrier effect, and the higher the z value, the more significant the barrier effect.

[0290] This results in a rigid and waterproof encapsulation, which in particular prevents water vapor from entering at the interface between the encapsulation system and the contact components (see...). Figure 13 The interface AA, as indicated in the text, is passed.

[0291] Typically, the optional first capping layer is selected from the group consisting of: silicones (e.g., deposited from hexamethyldisiloxane (HMDSO) by impregnation or by plasma-enhanced chemical vapor deposition), epoxy resins, polyimides, polyamides, parylene (also known as poly(p-xylylene), but more preferably parylene), and / or mixtures thereof. When the first capping layer is deposited, it allows protection of the battery's sensitive components from their environmental influences. The thickness of the first capping layer is preferably between 0.5 μm and 3 μm.

[0292] This first capping layer is particularly useful when the electrolyte and electrode layers of the battery have porosity: it acts as a planarization layer that also has a barrier effect. By way of example, this first layer can be applied to stacks or columns of 1000 batteries. n All accessible surfaces, especially stacks or columns of 1000 batteries. n The outer periphery is lined with an inner liner to enclose the column L present in the stack I or battery 1000. n The entry of micropores through the surface.

[0293] Different variants of parylene can be used in this first capping layer. It can be made from C-type parylene, D-type parylene, N-type parylene (CAS 1633-22-3), F-type parylene, or mixtures of C, D, N, and / or F-type parylene. Parylene is a dielectric, transparent, semi-crystalline material with high thermodynamic stability, excellent solvent resistance, and extremely low permeability. Parylene also possesses barrier properties. Within the scope of this invention, F-type parylene is preferred.

[0294] This first capping layer is advantageously obtained from the condensation of gaseous cells deposited on the surface of the battery stack via chemical vapor deposition (CVD), which allows for a conformal, thin, and uniform coverage of the entire accessible surface of the stack. This first capping layer is advantageously rigid; it cannot be considered a soft surface.

[0295] The optional second capping layer is composed of an electrically insulating material, preferably an inorganic material. This layer is deposited by atomic layer deposition (ALD), PECVD, high-density plasma chemical vapor deposition (HDPCVD), or inductively coupled plasma chemical vapor deposition (ICPCVD) to achieve conformal coverage of the entire accessible surface of the stack previously covered by the first capping layer. Layers deposited by ALD are mechanically very fragile and require a rigid support surface to ensure their protective function. Deposition of a fragile layer on a flexible surface will cause cracks, resulting in a loss of the integrity of this protective layer. Furthermore, the growth of layers deposited by ALD is affected by the substrate properties. Layers deposited by ALD on substrates with different chemical properties will exhibit uneven growth, which can also lead to a loss of the integrity of this protective layer. For this reason, if a second optional layer is present, it is preferable to support it on the first optional layer, which ensures chemically uniform growth of the substrate.

[0296] ALD deposition technology is particularly well-suited for covering highly rough surfaces in a completely hermetically sealed and compliant manner. This technology allows for the fabrication of defect-free, pore-free conformal layers (known as "pinhole-free" layers, i.e., layers without pores) and represents an excellent barrier. The WVTR coefficient of these layers is extremely low. The thickness of this second layer is advantageously selected based on the desired hermeticity level, i.e., the desired WVTR coefficient, and also depends on the deposition technology used, particularly ALD, PECVD, HDPCVD, and ICPCVD.

[0297] The second capping layer may be made of ceramic, vitreous, or glass-ceramic materials, for example, in the form of oxides, Al2O3, Ta2O5, nitrides, phosphates, oxynitrides, or siloxanes. This second capping layer preferably has a thickness between 10 nm and 5 μm, and more preferably between 10 nm and 50 nm.

[0298] This second capping layer, deposited on the first capping layer via ALD, PECVD, HDPCVD, or ICPCVD, ensures the structure's water resistance, preventing water migration from the interior, and protects the first capping layer, preferably F-type parylene, from atmospheric (especially air and humidity) and heat exposure to prevent its degradation. This second capping layer thus improves the lifespan of the encapsulated battery.

[0299] The second capping layer can also be deposited directly on the stack of anode and cathode foils, i.e., before the first capping layer has been deposited.

[0300] The third covering layer must be waterproof and preferably has a density of less than 10. -5 g / m 2The WVTR coefficient of .d. This third capping layer consists of ceramic material and / or low-melting-point glass (preferably glass with a melting point less than 600°C) deposited on the periphery of the stack of anode and cathode foils or on the first capping layer. The ceramic and / or glass materials used in this third layer are advantageously selected from:

[0301] - Low melting point glass (typically <600℃), preferably SiO2-B2O3; Bi2O3-B2O3, ZnO-Bi2O3-B2O3, TeO2-V2O5, PbO-SiO2,

[0302] -Oxides, nitrides, nitrogen oxides, Si x N y SiO2, SiON, amorphous silicon or SiC.

[0303] These glasses can be deposited by molding or by dip coating.

[0304] Ceramic materials are advantageously deposited at low temperatures via PECVD or preferably via HDPCVD or ICP CVD; these methods allow the deposition of layers with good sealing properties.

[0305] Especially Figure 10 As indicated in the text, the stack of therefore packaged cells or the column L of therefore packaged cells 1000 n Then, by any suitable means, cut the second pair of DY. n and DY' n Cutting is performed to obtain individual cells and expose the anode connection region 1002 and cathode connection region 1006 of each individual cell 1000. Advantageously, and as Figure 10 As indicated in the text, battery 100 is listed in column L. n According to the cutting pair DY n-1 and DY' n-1 DY n and DY' n DY n+1 and DY' n+1 Cut to obtain 1000 unit cells. In this way, the cutting line DY' is used. n-1 DY n Overlap, just like the cutting line DY' n and DY n+1 This allows for a reduction in the number of effective cuts, and thus improves battery production efficiency.

[0306] According to the invention, and in a particularly advantageous manner, the process is carried out through the anode body 110 and the cathode body 140 as follows: Figure 11 The second pair of cuts DY represented in the text n 、DY' n ,Right now:

[0307] - Distance L from the cathode gap 70 142 So that each cathode entity 140 of the battery 1000 has a main body 141 separated from the secondary body 142 by free spaces 143, 70 of any material of the electrolyte, separator, current collector substrate and electrodes (especially cathodes), and

[0308] - Distance L from the anode gap 80 112 So that each anode entity 110 of the battery 1000 has a main body 111 separated from the secondary body 112 by free space 113, 80 of any material of electrolyte, separator, current collector substrate and electrodes (especially anode).

[0309] Figure 11 and 12 This refers to a battery with a tear according to the present invention.

[0310] Contact members 97, 97', 97" (electrical contacts) are added to the cathode connection region 1006 and the corresponding anode connection region 1002 in readily visible locations. These contact regions are preferably positioned on opposite sides of the battery stack to collect current (lateral current collectors). Contact members 97, 97', 97" are disposed on at least the cathode connection region 1006 and at least the anode connection region 1002, preferably on the packaged and cut-stack surface including at least the cathode connection region 1006 and the coated and cut-stack surface including at least the anode connection region 1002 (see [reference]). Figure 13 ).

[0311] Therefore, by covering at least the anode connection area 1002 with the anode contact member 97', preferably including at least the first longitudinal surface F6 of the anode connection area 1002, and more preferably including at least the first longitudinal surface F6 of the anode connection area 1002 and the ends 97'a of the surfaces F1, F2, F3, and F5 adjacent to this first longitudinal surface F6, electrical contact between the stack I and the external conductive element can be ensured. Furthermore, by covering at least the cathode connection area 1006 with the cathode contact member 97", preferably including at least the second longitudinal surface F4 of the cathode connection area 1006, and more preferably including at least the second longitudinal surface F4 of the cathode connection area 1006 and the ends 97"a of the surfaces F1, F2, F3, and F5 adjacent to this second longitudinal surface F4, electrical contact between the stack I and the external conductive element can be ensured (see [link to documentation]). Figure 13 ).

[0312] Preferably, in the vicinity of the cathode connection region 1006 and the anode connection region 1002 as previously indicated, the contact members 97, 97', 97" are composed of a stack of electrical connection layers, the stack continuously comprising a first electrical connection layer comprising a material carrying conductive particles, preferably a polymeric resin and / or a material carrying conductive particles obtained by a sol-gel method and even more preferably a polymeric resin carrying graphite, and a second layer composed of metal foil disposed on the first electrical connection layer.

[0313] When the circuit is subjected to thermal and / or vibration stress, the first electrical connection layer allows the subsequent second electrical connection layer to be secured, while providing "flexibility" for connectivity without breaking the electrical contact.

[0314] The second electrical connection layer is advantageously a metal foil. This second electrical connection layer is used to permanently protect the battery from moisture. Generally, for a given material thickness, metal allows for the fabrication of a very waterproof membrane, more waterproof than those based on ceramics and even more waterproof than those based on polymers, which are generally not very airtight for water molecules. This allows for an extended battery calendar life by reducing the WVTR coefficient at the contact members.

[0315] Advantageously, a third electrical connection layer, including conductive ink, can be deposited on the second electrical connection layer; it is used to reduce the WVTR coefficient, which extends the battery life.

[0316] Contact members 97, 97', 97" allow for the restoration of alternating positive and negative electrical connections at each of the ends. These contact members 97, 97', 97" allow for parallel electrical connections between different battery elements. For this purpose, only the cathode connection is available at one end, and the anode connection is available at the other end.

[0317] Application WO 2016 / 001584 describes a stack of several cell units, which are stacked alternately and laterally offset (see [link to application]). Figure 14 The anode and cathode foils encapsulated in the encapsulation system 2095 constitute a structure designed to protect the battery 2000 from atmospheric influences. These encapsulation stacks are cut according to alternating, continuous cross-sectional planes across the electrodes and encapsulation system, thereby allowing for cell assembly that exposes the anode connection region 2002 and the cathode connection region 2006. Due to the density difference between the electrodes and the encapsulation system in prior art batteries, cutting according to this cross-sectional plane induces a risk of tearing of the encapsulation system near the cross-sectional plane, thus causing a short circuit. In application WO 2016 / 001584, during encapsulation, the encapsulation layer fills the gaps in the foil stacks with U-shaped cuts. This encapsulation layer introduced at these gaps is thick and does not adhere well to the stack, thus inducing this risk of tearing of the encapsulation system 2095 during subsequent cutting.

[0318] According to the invention, this risk is eliminated by using a foil with gaps according to the invention, wherein, in a top view:

[0319] - The cathode voids 70 created in all cathode foils 5e (which will form the free space 143, 70 of any material of the electrolyte, insulating layer, current collector substrate and electrode, especially the cathode) overlap, i.e., they overlap each other.

[0320] - The anode voids 80 (which will form the free space 113, 80 of any material of the electrolyte, insulating layer, current collector substrate and electrode, especially the anode) manufactured in all anode foils 2e coincide, that is, overlap each other, and

[0321] - The anode gap 80 and the cathode gap 70 do not overlap and are different from each other.

[0322] In this manner, each cathode entity 140 of the battery 1000 includes a main body 141 separated from the secondary body 142 by free spaces 143, 70 of the electrolyte, separator, current collector substrate, and electrodes, especially any material of the cathode. Similarly, each anode entity 110 of the battery 1000 includes a main body 111 separated from the secondary body 112 by free spaces 113, 80 of the electrolyte, separator, current collector substrate, and electrodes, especially any material of the anode (see...). Figure 11 ).

[0323] Due to the alternating overlap of the cathode and anode foils, the stacked thermo-pressed mechanical structure along the cutting line DY' n and DY n The area around the cut is extremely rigid. By using foil with gaps, this rigid structure allows for a reduction in the number of defects during cutting, thereby increasing cutting speed, improving battery production efficiency, and minimizing material drop zones.

[0324] According to the present invention, cutting DY' is performed by passing through an anode foil with a gap of 2e and a cathode foil with a gap of 5e of comparable density. n and DY n This results in a cleaner cut with better quality. Furthermore, the presence of free space in any material of the electrodes, electrolyte, and / or current collector substrate prevents any risk of short circuits.

[0325] like Figure 11 As indicated, each cathode entity 140 comprises a primary body 141, a secondary body 142, and a space 143 free of any material containing electrodes, electrolytes, and / or current collector substrates. Length L 70 L 143The space corresponding to the cathode gap 70 described above extends in the lateral direction YY beyond the entire width of the battery 1000. Similarly, each anode entity 110 includes a main body 111, a secondary body 112, and a space 113 containing no material of electrodes, electrolytes, and / or current collector substrates. Length L 80 L 113 The space corresponding to the anode gap 80 described above extends in the lateral direction YY beyond the entire width of the battery 1000.

[0326] The anode connection region 1002 and the cathode connection region 1006 are preferably laterally opposite each other, such as Figure 11 and 12 As explained in the text.

[0327] The single structure of the battery according to the invention allows for the avoidance of short circuits at the longitudinal surfaces F4 and F6, avoidance of leakage current, and facilitates the electrical contacts at the anode connection region 1002 and the cathode connection region 1006.

[0328] Batteries according to the present invention can be manufactured according to different variations. Figure 15 and 16 Variations of the first embodiment of the present invention will be described. These Figure 15 and 16 The only difference between this variant and the main variant described above is that the anode and cathode foils no longer have voids 70, 80 (voids referred to as small voids, containing no material of the electrode, electrolyte, and / or current collector substrate), but instead have notches 70', 80'. These notches form areas referred to as large voids, containing no material of the electrode, electrolyte, and / or current collector substrate. In this variant, the anode notches 80' and the corresponding cathode notches 70' are distributed adjacent to each other in row R1. These anode notches 80' and the corresponding cathode notches 70' preferably have a quadrilateral shape of a generally rectangular type. In the illustrated example, these notches also have an I-shape, similar to the voids in the first embodiment. However, as is apparent from the above, these notches 70', 80' are significantly more elongated than the voids, i.e., they have a much larger longitudinal dimension than these voids. Therefore, Figure 15 and 16 The variant differs from the main variant described above in that each anode notch 80' and each cathode notch 70' are both positioned below each other in all columns L1 to L2. y For the common good.

[0329] In this way, it is positioned in column L. n The gaps 70 and 80 in the middle are located in column L. n-1 and / or L n+1 At least one of the adjacent gaps in the [space] overlaps. In this case, and as follows: Figure 15 As explained in the document, two adjacent columns are not separated by a material bridge.

[0330] However, the two adjacent rows are separated by material bridge 9, which gives the anode and cathode foils sufficient mechanical rigidity to make them easy to handle.

[0331] Assume that the stacking of the anode and cathode foils described above undergoes steps designed to ensure their overall mechanical stability. These steps, of a type known per se, particularly involve heat treatment and / or mechanical compression of the stack of different foils, as previously described. As previously indicated, this stacking allows the formation of individual cells, the number of which is equal to the product between the number of columns Y and the number of rows X.

[0332] For this purpose, refer to Figure 16 The three columns L have already been explained. n-1 To L n+1 And three rows of R n-1 To R n+1 According to the present invention, each column undergoes a first pair of cuts DX. n and DX' n Each cut is performed in a manner known per se, which is executed directly, extending beyond the entire height of the stack, as indicated above.

[0333] Advantageously, as previously performed, impregnation, encapsulation, and DY along the cut line. n and DY' n The subsequent steps include cutting and depositing contact members on at least the anode and cathode connection areas. The fact that the gaps 70, 80 are replaced by notches 70', 80' according to the first variant allows for a reduction in the material drop area 90 and thus optimizes the production of the cell 1000. The cell 1000 obtained according to the first variant of the invention is identical in every aspect to the cell obtained according to the invention, even if the arrangement of the notches 70', 80' is different.

[0334] Figure 17 and 18 A second embodiment of the invention will now be described. The main difference between this second embodiment and the first embodiment described above lies in the shape of the stacked layers. As seen above, the first embodiment uses layers each formed from a single piece of foil. However, in the second embodiment, each layer is formed from a series of strips arranged adjacent to each other according to the anode plane PA and the cathode plane PC corresponding to the plane formed by the foil in the first embodiment.

[0335] exist Figure 18 In this text, only the first four layers are represented: the first two anode layers SA1 and SA2, and the first two cathode layers SC1 and SC2. Each anode layer is formed by a series of anode strips A1 to Ax and A'1 to A'x, of which only the first four, A1 to A4 and A'1 to A'4, are represented in [the text is missing here]. Figure 17 and 18In this diagram, each cathode layer is formed by a series of cathode strips C1 to Cx and C'1 to C'x, with only the first four C1 to C4 and C'1 to C'4 shown in the figure. For each layer, both the anode and cathode layers, the number of strips corresponds to the number of rows. Furthermore, for each layer, the relative lateral edges LA and LC of adjacent strips define free spaces 80” and 70”, respectively.

[0336] These anode strips A1, A2, A3, A4, and the corresponding cathode strips C1, C2, C3, C4 preferably have a quadrilateral shape of the typical rectangular type.

[0337] These anode strips and corresponding cathode strips have the same chemical structure as the anode, corresponding cathode, and foil used according to the present invention or the first variant thereof.

[0338] Therefore, in other words, the difference between this second embodiment and the first embodiment is essentially that the different strips (anode and cathode strips, respectively) are independent of each other.

[0339] In this way, each anode strip A1, A2, A3, A4 and the corresponding cathode strip C1, C2, C3, C4 are not connected to the solid peripheral frame in order to form the anode foil and the corresponding cathode foil as previously indicated.

[0340] According to a second embodiment of the present invention, for a given row Rx, anode strips A1, A2, A3, A4 correspond to all columns L1 to L4 below one another. y For common purposes, and for all columns L1 to L4 of the cathode strips C1, C2, C3, C4 placed below each other. y For the common good.

[0341] According to the second embodiment of the present invention and as follows Figure 18 As described, the anode strips A1, A2, A3, and A4 aligned along the anode plane PA parallel to the main plane of the battery, and the cathode strips C1, C2, C3, and C4 aligned along the cathode plane PC parallel to the main plane of the battery, are arranged such that:

[0342] -Location in R n Each anode strip A in n Partially used for positioning in line R n-1 The battery 1000 is a secondary component and is partially used for positioning in line R. n The main body of the battery 1000, and

[0343] - Each cathode strip C n+1Partially used for positioning in line R n+1 The battery 1000 is a secondary component and is partially used for positioning in line R. n The main body of the battery 1000.

[0344] Suppose that the stacking of the anode and cathode strips described above undergoes steps designed to ensure their overall mechanical stability. These steps, of a type known per se, particularly involve heat treatment and / or mechanical compression of the stacked strips, as previously described. As previously indicated, this stacking allows the formation of individual cells, the number of which is equal to the product between the number of columns Y and the number of rows X.

[0345] For this purpose, refer to Figure 17 The three columns L have already been explained. n-1 To L n+1 And three rows of R n-1 To R n+1 According to the present invention, each column undergoes a first pair of cuts DX. n and DX' n Each cut is performed in a manner known per se, extending beyond the entire height of the stack, as previously indicated.

[0346] Advantageously, as previously instructed, impregnation, encapsulation, and DY along the cut line are performed. n and DY' n Cutting (e.g.) Figure 18 (As described in the text) the subsequent step of depositing contact members on at least the anode and cathode connection areas. The fact that the anode strips A1, A2, A3, A4 and the cathode strips C1, C2, C3, C4 according to the second variant allows for a reduction in the material drop area 90 and thus optimizes the production of the cell 1000. The cell 1000 obtained according to the second embodiment of the invention is identical in every aspect to the cell obtained from a foil having small or large empty areas according to the first embodiment, even if the arrangement of the anode strips A1, A2, A3, A4 and the cathode strips C1, C2, C3, C4 is different.

[0347] Figure 19 illustrate Figure 6 Variations of the embodiments described herein. Figure 19 Stacking and Figure 6 The difference in the stacking described is that each empty zone 70, 80 extends through a corresponding channel 75, 85. Each channel extends laterally from the empty zone beyond the relative cutting line DY1 or DY2. In this way, the channel can be passed through when making this cut.

[0348] Different possibilities regarding the structure of these channels can be considered. Typically, the anode channels 85 overlap each other, as do the cathode channels 75. Furthermore, where an offset arrangement is possible, each anode channel is typically located within an extension of the cathode channel. Additionally, several anode channels and / or several cathode channels can be provided for the same empty area. In the Z direction, it is possible that each channel extends beyond the entire height of the empty area. Alternatively, this channel may extend only a portion beyond this height in the upper portion, the lower portion, or even the middle portion.

[0349] The presence of both anodic and cathode channels offers specific advantages. In fact, these channels particularly facilitate electrolyte impregnation.

[0350] Figure 20 The final battery capacity is 1000, once determined according to... Figure 19 The foil shown in the middle section is manufactured using a method implemented therein. Each cell includes an anode cavity 115 and a cathode cavity 145, extending from corresponding free spaces 113 and 143 into secondary bodies 112 and 142. It should be noted, however, that these cavities formed by the aforementioned channels have a shorter length. In fact, as already mentioned, the channels extend beyond the cut lines. However, cavities 115 and 145 extend only to the opposing longitudinal surfaces F4 and F6 of the cell defined by these cuts.

[0351] Figure 21 Additional variations that are not within the scope of this invention are shown. These variations are particularly based on the teachings of International Patent Application WO 2020136313, representing the applicant, in which the empty regions have an overall H-shape. According to the teachings of this document, each empty region, for example… Figure 21 The empty area 570 or 580 includes two main recesses 571 or 581 and 572 or 582, which are connected to each other by a connecting conduit 573 or 583.

[0352] according to Figure 21 A variation thereof, manufacturing channels 575 and 585, each of which extends a corresponding conduit 573 and 583 parallel to the main recess. As in Figure 19 In this embodiment, each channel extends beyond the corresponding cutting lines DY1 and DY2. The associated technical effect is compared to... Figures 19 to 20 In some embodiments, the presence of channels 575 or 585 ensures better impregnation of the electrolyte.

[0353] The method according to the invention is particularly suitable for manufacturing completely solid-state batteries, i.e., batteries in which the electrodes and electrolytes are solid and do not include a liquid phase, or even batteries immersed in a solid phase.

[0354] The method according to the invention is particularly suitable for manufacturing quasi-solid batteries comprising at least one separator layer 31 impregnated with an electrolyte. The separator layer is preferably a porous inorganic layer having the following characteristics:

[0355] - Porosity greater than 30%, preferably between 35% and 50%, and even more preferably between 40% and 50%, preferably mesopore porosity.

[0356] -Average diameter D 50 Pores smaller than 50 nm.

[0357] The thickness of the separator is advantageously less than 20 μm and preferably between 5 μm and 10 μm to reduce the final thickness of the battery without compromising its properties. The pores of the separator are impregnated with an electrolyte, preferably with a lithium-ion support phase, such as a liquid electrolyte or an ionic liquid containing lithium salts. The liquid that is “nanoporously confined” or “nanoporously trapped” in the pores, especially in the mesopores, is no longer present. This liquid relates to a phenomenon referred to herein as “absorption in the mesoporous structure” (which does not appear to be described in the literature in the context of lithium-ion batteries) and is no longer present even when the battery is placed in a vacuum. The battery is then considered a quasi-solid.

[0358] The battery according to the invention can be designed and sized to have:

[0359] - Capacity less than or equal to approximately 1 mA h (commonly referred to as "micro battery")

[0360] - or a capacity greater than approximately 1 mA h.

[0361] Typically, micro batteries are designed to be compatible with microelectronics manufacturing methods.

[0362] Batteries capable of being manufactured in each of these power ranges can be fabricated:

[0363] - It has an "all-solid" type layer, that is, it does not have an impregnating liquid or paste phase (the liquid or paste phase may be a conductive medium of lithium ions that can act as an electrolyte).

[0364] - A layer with mesoporous "all-solid" characteristics, impregnated with a liquid or paste phase, typically a lithium-ion conductive medium, spontaneously penetrates the interior of the layer and does not reappear from it, thus allowing this layer to be considered a quasi-solid.

[0365] -Or have impregnated porous layers (i.e., layers with an open pore network, the pores of which can be impregnated with a liquid or paste phase and give these layers wetting properties).

Claims

1. A method for manufacturing at least one battery (1000), each battery comprising at least one anode entity (110) and at least one cathode entity (140) arranged alternately one on top of the other in the positive direction (ZZ) of the battery (1000). In the battery, the anode entity (110) includes: Anode current collector substrate (10), at least one anode layer (20), Furthermore, in the battery, the cathode entity (140) comprises: Cathode current collector substrate (40), at least one cathode layer (50), At least one of the anode body (110) and the cathode body (140) includes an electrolyte material layer (30) or an electrolyte-impregnated insulating layer (31). The battery (1000) has six sides, namely - Two faces, referred to as the positive faces (F1, F2), are opposite each other and are generally parallel to each anode entity (110) and parallel to each cathode entity (140). - Two faces, referred to as lateral faces (F3, F5), are opposite each other; and - Two faces called longitudinal planes (F4, F6), which are opposite each other. With the first longitudinal surface (F6) of the battery including at least one anode connection region (1002) and the second longitudinal surface (F4) of the battery including at least one cathode connection region (1006), the anode connection region (1002) and the cathode connection region (1006) are laterally opposite each other. - Each anode entity (110) and each cathode entity (140) includes a corresponding primary body (111, 141) separated from the corresponding secondary body (112, 142) by the free space (113, 143) of any electrode, electrolyte and current collector substrate material; -When the battery includes a plurality of free spaces (113) in the positive direction (ZZ) of the battery; -The free space overlap formed between each main body (111) and each secondary body (112) of each anode entity (110); -The free space overlap formed between each primary body (141) and each secondary body (142) of each cathode entity (140); and - The free spaces of each anode entity (110) and each cathode entity (140) do not overlap; Manufacturing methods include: a) Fabricate a stack (I) which in a top view includes x rows where x is strictly greater than 1 and y columns where y is greater than or equal to 1, in order to form (x*y) cells; This stack is formed by a series of alternating layers (SA, SC) that are respectively cathode layers (SC) and anode layers (SA), each cathode layer (SC) intended to form (x*y) cathode entities (140), and each anode layer (SA) intended to form (x*y) anode entities (110). Each layer (SA, SC) includes a plurality of primary preforms (111', 141'), namely a primary anode preform (111') and a primary cathode preform (141'), each of which is intended to form a corresponding primary body (111, 141); and a plurality of secondary preforms (112', 142'), namely secondary anode preforms (112') and secondary cathode preforms (142'), each of which is intended to form a corresponding secondary body (112, 142), the primary preforms (111', 141') and the secondary preforms (112', 142') being separated from each other by regions called empty regions (80'', 70''), which are intended to form at least one of the free spaces (113, 143), and when the battery includes a plurality of free spaces (113) in the positive direction (ZZ) of the battery: - The empty regions (80'') of the different anode layers (SA) overlap; - The empty regions (70'') of the different cathode layers (SC) overlap; and - The empty regions (80'', 70'') of each anode layer (SA) and each cathode layer (SC) do not overlap. b) Perform heat treatment and / or mechanical compression on the stack (I) obtained in step a) to form a solidified stack; c) In the top view, a pair of master cuts (DYn, DY'n) are made between two adjacent empty areas (80'', 70'') to expose the anode connection area (1002) and the cathode connection area (1006) and will be defined by a given row (R). n A given cell formed by at least one adjacent row (R) and a given cell formed by at least one adjacent row (R) n+1 At least one other adjacent cell is separated from the formation.

2. The method according to claim 1, characterized in that, Each layer (SA, SC) is formed from a single sheet of foil.

3. The method according to claim 1, characterized in that, Each layer (SA, SC) consists of multiple independent stripes (A1, A2, A...). n C1, C2, C n The empty area (113', 143') is formed between the edges (LA, LC) facing the adjacent strip.

4. The method according to claim 1, characterized in that, Create voids called small voids (80, 70), which are called gaps. Each void is designed to form a single free space.

5. The method according to claim 1, characterized in that, Create gaps called large gaps (80', 70'), which are referred to as notches. Each large gap is designed to create multiple free spaces in the same row.

6. The method according to claim 4 or 5, characterized in that, The empty area (70, 70', 80, 80') has a rectangular shape.

7. The method according to claim 1, characterized in that, A pair of auxiliary cuts (DXn, DX'n) are performed after step b) but during step d), thereby allowing a given column (L) belonging to the consolidated stack to be cut. n ) and at least one adjacent column (L n-1 L n+1 Separation.

8. The method according to claim 7, characterized in that, During step e), the column (L) of the battery (1000) obtained in step d) is processed using a lithium-ion carrier phase. n The impregnation is performed such that the isolation layer (31) is impregnated with electrolyte.

9. The method according to claim 7, characterized in that, The consolidation stack or the column (L) of the battery (1000) is implemented before step c) and after step d). n The packaging step f).

10. The method according to claim 1, characterized in that, Following step c), step g) is performed, wherein at least the anode connection area (1002) is covered by the anode contact member (97'), thereby ensuring electrical contact between the stack (I) and external conductive elements. Furthermore, the cathode connection area (1006) is covered by a cathode contact member (97''), thereby ensuring electrical contact between the stack (I) and external conductive elements. Step (i) includes: - A first electrical connection layer of material carrying conductive particles is deposited on at least the anode connection region (1002) and at least the cathode connection region (1006); - Optionally, when the first electrical connection layer is formed of a polymeric resin and / or a material carrying conductive particles obtained by a sol-gel method, the drying step is followed by a polymerization step of the polymeric resin and / or the material obtained by the sol-gel method; and - A second electrical connection layer, comprising a metal foil, is deposited on the first electrical connection layer; - Optionally, a third electrical connection layer comprising conductive ink is deposited on the second electrical connection layer.

11. The method according to claim 7, characterized in that, The cutting in step d) is performed by laser ablation.

12. The method according to claim 1, characterized in that, At least one lateral channel (75, 85) is formed from at least one empty area (70, 80), the lateral channel extending at least to the adjacent main cutting line (DY1, DY2) to facilitate the impregnation of the electrolyte.

13. The method according to claim 1, characterized in that, During step e), the solidified stack obtained in step b) is impregnated with the lithium-ion carrier phase, such that the isolation layer (31) is impregnated with the electrolyte.

14. The method according to claim 8 or 13, characterized in that, The consolidation stack or the column (L) of the battery (1000) is implemented before step c) and after step e). n The packaging step f).

15. The method according to claim 1, characterized in that, The consolidation stack or the column (L) of the battery (1000) is implemented before step c) and after step b). n The packaging step f).

16. The method according to claim 1 or 11, characterized in that, The cutting in step c) is performed by laser ablation.

17. A battery (1000) comprising at least one anode entity (110) and at least one cathode entity (140), wherein the at least one anode entity (110) and the at least one cathode entity (140) are arranged alternately on top of each other in a positive direction (ZZ) of the main plane of the battery (1000), thereby forming a stack (I). The anode entity (110) includes: Anode current collector substrate (10), at least one anode layer (20), The cathode entity (140) includes: a cathode current collector substrate (40) and at least one cathode layer (50); At least one of the anode body (110) and the cathode body (140) includes an electrolyte material layer (30) or an electrolyte-impregnated insulating layer (31). The battery (1000) has six sides, namely - Two faces, referred to as the front faces (F1, F2), are opposite each other and generally parallel to each anode entity (110), each cathode entity (140), the anode current collector substrate (10), the anode layer (20), the electrolyte material layer (30) or the electrolyte-impregnated isolation layer (31), the cathode layer (50), and the cathode current collector substrate (40). - The two faces, referred to as the positive faces (F3, F5), are opposite each other. - and two faces called longitudinal planes (F4, F6), which are opposite to each other. With the first longitudinal surface (F6) of the battery including at least one anode connection region (1002) and the second longitudinal surface (F4) of the battery including at least one cathode connection region (1006), the anode connection region (1002) and the cathode connection region (1006) are laterally opposite each other. Make: - Each anode entity (110) and each cathode entity (140) includes a corresponding primary body (111, 141) separated from the corresponding secondary body (112, 142) by the free space (113, 143) of any electrode, electrolyte and current collector substrate material; -When the battery includes a plurality of free spaces (113) in the positive direction (ZZ) of the main plane of the battery, The free space overlaps between each primary body (111) and each secondary body (112) formed in each anode entity (110). The free space formed between each primary body (141) and each secondary body (142) of each cathode entity (140) overlaps, and The free spaces of each anode entity (110) and each cathode entity (140) do not overlap. The battery is characterized in that it includes an encapsulation system (95) that at least partially covers the periphery of the stack (I), the encapsulation system (95) covering the front surfaces (F1, F2), the front surfaces (F3, F5) of the stack and at least partially covering the longitudinal surfaces (F4, F6), such that: Only the anode connection region (1002) and the cathode connection region (1006) Not covered by the packaging system (95), which includes: - Optionally, a first capping layer is deposited on at least a portion of the periphery of the stack (I). - Optionally, a second cover layer is formed of an electrically insulating material deposited by atomic layer deposition on at least a portion of the periphery of the stack (I) or on the first cover layer. - At least one third waterproof coating layer with a density of less than 10 -5 g / m 2 • Water vapor transmission rate (WVTR) d, this third waterproof coating is composed of ceramic material and / or glass with a melting point of less than 600°C deposited on at least a portion of the periphery of the stack (I) or on the first coating. Under the condition that the second covering layer is present A series of second and third waterproof coating layers can be repeated z times, where z≥1, and are deposited on at least the periphery of the third waterproof coating layer. The final layer of the encapsulation system is a waterproof covering layer.

18. The battery according to claim 17, characterized in that, At least the anode connection area (1002) is covered by the anode contact member (97'). Furthermore, at least the cathode connection area (1006) is covered by the cathode contact member (97''). Under the condition that the anode contact member (97') and the cathode contact member (97'') can ensure electrical contact between the stack (I) and the external conductive element.

19. The battery according to claim 18, characterized in that, Each of the anode contact member (97') and the cathode contact member (97'') includes: - A first electrical connection layer is disposed on at least the anode connection region (1002) and at least the cathode connection region (1006). This first electrical connection layer includes a material carrying conductive particles, and - A second electrical connection layer, comprising a metal foil disposed on the first electrical connection layer of a material carrying conductive particles.

20. The battery according to any one of claims 17 to 19, characterized in that, The battery has a capacity of less than or equal to 1 mA h.

21. The battery according to any one of claims 17 to 19, characterized in that, The battery has a capacity greater than 1 mA h.

22. The battery according to any one of claims 17 to 19, characterized in that, At least one free space (113, 143) extends through a cavity (115, 145) designed to facilitate the impregnation of the electrolyte, the cavity extending through the secondary body (112, 142) to the opposite longitudinal surface (F4, F6).

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