Lithium ion battery and method of manufacturing the same

Abstract

The battery (1000) comprises at least one cell (100) formed of an anode (20), an electrolyte (30) and a cathode (50), defining a stack (I), said stack (I) and said battery having six faces, namely - two opposite front faces (F1, F2), - two opposite lateral faces (F3, F5), - two opposite longitudinal faces (F4, F6), it being understood that the first longitudinal face (F6) of the battery comprises at least one anode connection zone (1002) and the second longitudinal face (F4) of the battery comprises at least one cathode connection zone (1006), said anode connection zone (1002) and cathode connection zone (1006) being laterally opposite each other, characterized in that: - in a first longitudinal direction (XX') of the battery, each anode current collector substrate (10) protrudes from each anode layer (20), each electrolyte material layer (30) or separator layer (31) impregnated with electrolyte, each cathode layer (50) and each cathode current collector substrate layer (40), and - in a second longitudinal direction (XX") of the battery opposite to said first longitudinal direction (XX'), each cathode current collector substrate (40) protrudes from each anode layer (20), each electrolyte material layer (30) or separator layer (31) impregnated with electrolyte, each cathode layer (50) and each anode current collector substrate layer (10).

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 structure for lithium-ion batteries with extended lifespan. The invention also relates to a novel method for manufacturing said battery. Background Technology

[0002] Rechargeable all-solid-state lithium-ion batteries are familiar. International patent document WO 2016 / 001584 (I-TEN) describes a lithium-ion battery made of anode and cathode foils, wherein the anode foil comprises a conductive substrate sequentially covered with an anode layer and an electrolyte layer, and the cathode foil comprises a conductive substrate sequentially covered with a cathode layer and an electrolyte layer; these foils are cut into U-shapes before or after deposition. These foils are then stacked alternately to form a stack of multiple cell units. The anode and cathode foil cut patterns are placed in a “head-to-tail” configuration, thereby laterally offsetting the cathode and anode stacks. After the stacking step, a thick encapsulation system approximately ten micrometers thick is deposited in the available cavities present on and within the stack. This ensures structural rigidity at the cut planes and protects the battery from atmospheric effects. Once the stack is fabricated and encapsulated, it is cut along the cut planes to obtain cell units, exposing the cathode and anode connection regions of the battery on each cut plane. During these cuts, the encapsulation system may be torn, resulting in a break in the battery's impermeable seal. It is understood that terminals (i.e., electrical contacts) have also been added in prominent locations in these cathode and anode connection areas.

[0003] This familiar solution clearly has some drawbacks. More specifically, depending on the electrode location, particularly its distance from the edges of the multilayer battery electrodes and the cleanliness of the cut, leakage currents, typically in the form of creepage short circuits, may occur at the ends. Despite the use of encapsulation systems around the battery and near the cathode and anode connection areas, creepage short circuits still degrade battery performance. Furthermore, unsatisfactory deposition of the encapsulation system on the battery is sometimes observed, especially at the battery edges where spaces created by lateral offset of the electrodes at the battery edges exist.

[0004] Suzuki's US patent document US 2018 / 212210 also discloses a battery that initially comprises multiple cell units. The resulting stack is placed in a metal casing, and resin is inserted. This mechanically secures the cells, preventing them from moving during operation. The resin also prevents the risk of short circuits caused by the cells contacting the metal casing, especially during potential shocks or vibrations.

[0005] Finally, Japanese Patent Document JP 2007 / 005279 filed by Matsushita is cited. This document discloses an all-solid-state battery obtained by sintering. Therefore, this battery does not include either an electrolyte material or a separator layer impregnated with the electrolyte.

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

[0007] The object of this invention is particularly to increase the yield of high energy density and high power density rechargeable lithium-ion batteries, and to produce more efficient packaging at a lower cost.

[0008] Specifically, the purpose of this invention is to provide a method for manufacturing batteries with low self-discharge rates that reduces the risk of creepage short circuits or accidental short circuits.

[0009] In particular, the object of this invention is to provide a method for manufacturing batteries with very long lifespans in a simple, reliable and rapid manner.

[0010] A further objective of this invention is to propose a simple, rapid, and cost-effective method for battery manufacturing. Summary of the Invention

[0011] This invention first relates to a battery comprising at least one cell, each cell sequentially comprising an anode current collector substrate, an anode layer, at least one electrolyte material layer and / or at least one electrolyte-impregnated separator layer, a cathode layer, and a cathode current collector substrate.

[0012] Where the battery comprises multiple cell units, the cell units are stacked one below the other, i.e., according to the positive direction relative to the main plane of the battery, thus preferably:

[0013] The anode current collector substrate is the anode current collector substrate of two adjacent cell units, and in which...

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

[0015] The at least one cell or the plurality of cell units define a stack.

[0016] The stack and the battery have six sides, namely

[0017] • Two opposing positive surfaces, specifically two positive surfaces parallel to each other, which are generally parallel to one or more anode current collector substrates, one or more anode layers, one or more electrolyte material layers or one or more electrolyte-impregnated isolation layers, one or more cathode layers, and one or more cathode current collector substrates.

[0018] • Two lateral surfaces facing each other, specifically, the two lateral surfaces are parallel to each other.

[0019] • and two opposing longitudinal planes, specifically, the two longitudinal planes are parallel to each other.

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

[0021] Its features are:

[0022] - In the first longitudinal direction of the battery, each anode current collector substrate protrudes from each anode layer, each electrolyte material layer or electrolyte-impregnated separator layer, each cathode layer, and each cathode current collector substrate layer.

[0023] - In the second longitudinal direction of the battery, opposite to the first longitudinal direction, each cathode current collector protrudes from each anode layer, each electrolyte material layer or electrolyte-impregnated isolation layer, each cathode layer and each anode current collector layer.

[0024] In one specific embodiment:

[0025] - Each anode current collector substrate protrudes from a first end face, the first end face being defined by a first longitudinal end of each anode layer, each electrolyte material layer or insulating layer, each cathode layer, and each cathode current collector substrate layer, and / or

[0026] - Each cathode current collector substrate protrudes from a second end face, which is defined by the second longitudinal end of each anode layer, each electrolyte material layer or isolation layer, each cathode layer and each anode current collector substrate layer.

[0027] According to a particularly preferred embodiment of the present invention, the battery includes an encapsulation system that at least covers a portion of the outer periphery of the stack, the encapsulation system including at least one impermeable cover layer having a water vapor transmission rate (WVTR) of less than 10. -5 g / m 2 .d. The packaging system is in direct contact with at least the electrolyte material layer and / or the electrolyte-impregnated isolation layer on each longitudinal plane. Preferably, the packaging system is also in direct contact with the anode layer, the cathode layer, and the non-protruding current collector substrate on each longitudinal plane.

[0028] Preferably, the packaging system is electrically insulating, and the conductivity of the packaging system is preferably less than 10. e-11 Sm -1 Especially 10 e-12 Sm -1 .

[0029] Preferably, the packaging system covers at least a portion of the outer periphery of the stack, and the packaging system covers the front surface, side surface, and at least a portion of the longitudinal surface of the stack, thereby

[0030] -Only in the first longitudinal direction of the battery, each anode edge of each anode current collector substrate protruding from each anode layer, each electrolyte material layer or separator layer, each cathode layer, and each cathode current collector substrate layer is flush with the first longitudinal surface, and thus

[0031] -Only in the second longitudinal direction of the battery, each cathode edge of each cathode current collector substrate protruding from each anode layer, each electrolyte material layer or separator layer, each cathode layer, and each anode current collector substrate layer is flush with the second longitudinal surface, which is preferably opposite to and parallel to the first longitudinal surface.

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

[0033] According to another aspect of the invention, the packaging system comprises:

[0034] -A first capping layer optionally deposited on at least part of the outer periphery of the stack, preferably selected from parylene, parylene F, polyimide, epoxy resin, silicone resin, polyamide, sol-gel silica, organosilicon silica and / or mixtures thereof.

[0035] - An optional second capping layer, composed of an electrically insulating material, is deposited on at least a portion of the stacked periphery or on the first capping layer using atomic layer deposition.

[0036] - At least a third impermeable covering layer, preferably with a water vapor transmission rate (WVTR) of less than 10. -5 g / m 2 .d, the third capping layer is made of ceramic material and / or low-melting-point glass, preferably glass with a melting point below 600°C, and is deposited on at least a portion of the stacked outer periphery or on the first capping layer.

[0037] It should be understood that when the second overlay layer is present,

[0038] - The sequences of the second and third capping layers can be repeated z times, where z ≥ 1, and are deposited on at least the outer periphery of the third capping layer, and

[0039] - The final layer of the encapsulation system is an impermeable cover layer, preferably with a water vapor transmission rate (WVTR) of less than 10. -5 g / m 2 .d, made of ceramic materials and / or low-melting-point glass.

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

[0041] It should be understood that the anode contact element and the cathode contact element are capable of creating electrical contact between the stack and the external conductive element.

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

[0043] - A first electrical connection layer is located on at least the anode connection region and at least the cathode connection region, preferably located on a first longitudinal plane including at least the anode connection region and on a second longitudinal plane including at least the cathode connection region.

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

[0045] - A second electrical connection layer, which includes a metal foil disposed on a first material layer filled with conductive particles.

[0046] According to another aspect of the invention, the minimum distance between a first longitudinal surface including at least one anode connection region and a first end face defined by the first longitudinal ends of each anode layer, each electrolyte material layer and / or insulating layer, each cathode layer and each cathode current collector substrate layer is between 0.01 mm and 0.5 mm, and / or

[0047] The minimum distance between the second longitudinal surface including at least one cathode connection area and the second end face defined by the second longitudinal ends of each anode layer, each electrolyte material layer and / or isolation layer, each cathode layer and each anode current collector substrate layer is between 0.01 mm and 0.5 mm.

[0048] The present invention also relates to a method for manufacturing at least one battery.

[0049] Each battery includes at least one cell.

[0050] Each cell unit sequentially comprises an anode current collector substrate, an anode layer, at least one electrolyte material layer and / or at least one electrolyte-impregnated separator layer, a cathode layer, and a cathode current collector substrate.

[0051] Where the battery comprises multiple cell units, the cell units are stacked one below the other, i.e., according to the positive direction relative to the main plane of the battery, thus preferably:

[0052] The anode current collector substrate is the anode current collector substrate of two adjacent cell units, and in which...

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

[0054] The at least one cell or the plurality of cell units define a stack.

[0055] The stack and the battery have six sides, namely

[0056] - Two opposing positive surfaces, specifically two positive surfaces parallel to each other, which are generally parallel to one or more anode current collector substrates, one or more anode layers, one or more electrolyte material layers or one or more electrolyte-impregnated isolation layers, one or more cathode layers, and one or more cathode current collector substrates.

[0057] - Two opposing lateral surfaces, specifically, the two lateral surfaces are parallel to each other, and

[0058] - Two opposing longitudinal planes, specifically, two parallel longitudinal planes.

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

[0060] thereby

[0061] - In the first longitudinal direction of the battery, each anode current collector substrate protrudes from each anode layer, each electrolyte material layer or electrolyte-impregnated separator layer, each cathode layer, and each cathode current collector substrate layer.

[0062] - In the second longitudinal direction of the battery, opposite to the first longitudinal direction, each cathode current collector substrate protrudes from each anode layer, each electrolyte material layer or electrolyte-impregnated insulating layer, each cathode layer, and each anode current collector substrate layer.

[0063] The manufacturing method includes:

[0064] The first step involves providing at least one anode current collector substrate foil, hereinafter referred to as the anode foil, which has grooves, an uncoated area, and an area coated with an anode layer, optionally coated with an electrolyte material layer or an insulating layer.

[0065] The second step involves providing at least one cathode current collector substrate foil, hereinafter referred to as the cathode foil, which has grooves, uncoated areas, and areas coated with a cathode layer, optionally coated with an electrolyte material layer or an insulating layer.

[0066] The third step involves alternating stacking of at least one anode foil with grooves, uncoated areas, and coated areas with at least one cathode foil with grooves, uncoated areas, and coated areas to obtain at least one cell, which sequentially comprises an anode current collector substrate, an anode layer, at least one electrolyte material layer or separator layer, a cathode layer, and a cathode current collector substrate.

[0067] thereby

[0068] In the first longitudinal direction of the battery, each anode current collector substrate protrudes from each anode layer, each electrolyte material layer and / or separator layer, each cathode layer and each cathode current collector substrate layer, and

[0069] In the second longitudinal direction of the battery, opposite to the first longitudinal direction, each cathode current collector substrate protrudes from each anode layer, each electrolyte material layer and / or insulating layer, each cathode layer, and each anode current collector substrate layer.

[0070] The fourth step involves heat treatment and / or mechanical compression of the alternating foil stacks obtained in the third step, thereby forming a stable stack.

[0071] Optionally, in step five, perform the first pair of cuts to separate a given row of batteries formed by the stable stack from at least one other row of batteries.

[0072] Optionally, in step six, the solid stack obtained in step four is impregnated, or, if step five is present, the battery row obtained in step five is impregnated using a lithium-ion-carrying phase (e.g., a liquid electrolyte) or an ionic liquid containing a lithium salt, thereby impregnating the insulating layer with the electrolyte.

[0073] Choose step seven to perform the second pair of cuts to expose...

[0074] - An anode edge of each anode current collector substrate protruding from each anode layer, each electrolyte material layer or separator layer, each cathode layer, and each cathode current collector substrate layer in the first longitudinal direction of the battery, each anode edge defining at least one anode connection region, and

[0075] - A cathode edge protruding from each anode layer, each electrolyte material layer or separator layer, each cathode layer, and each anode current collector substrate layer in the second longitudinal direction of the battery, each cathode edge defining at least one cathode connection region.

[0076] When the fifth step is present, the second pair of cuts can separate a given cell formed by the battery row from at least one other cell.

[0077] In one specific embodiment of the method, after step six (if step six exists), or if step six does not exist, after step five (if step five exists), or if steps six and five do not exist, after step four and before step seven, step eight is performed to encapsulate a robust stack or battery row, preferably wherein at least a portion of the outer periphery of the stack or battery row is covered by the encapsulation system, preferably the front face, side face, and at least a portion of the longitudinal face of the stack or battery row, thereby...

[0078] Each anode edge of each anode current collector substrate protruding only from each anode layer, each electrolyte material layer or separator layer, each cathode layer, and each cathode current collector substrate layer in the first longitudinal direction of the battery is flush with the first longitudinal surface, and thus

[0079] Only in the second longitudinal direction of the battery, each cathode edge of each cathode current collector substrate protruding from each anode layer, each electrolyte material layer or separator layer, each cathode layer, and each anode current collector substrate layer is flush with the second longitudinal surface, which is preferably opposite to and parallel to the first longitudinal surface.

[0080] It should be understood that each anode edge defines an anode connection area, and each cathode edge defines a cathode connection area;

[0081] The packaging system preferably includes,

[0082] - Optionally deposited on at least a portion of the outer periphery of the stack or at least a portion of the outer periphery of the cell rows, preferably selected from parylene, parylene F, polyimide, epoxy resin, silicone resin, polyamide, sol-gel silica, organosilicon silica and / or mixtures thereof.

[0083] -Optional second capping layer, composed of electrically insulating material, deposited using atomic layer deposition.

[0084] -On at least part of the outer periphery of the stack or battery row,

[0085] -or on the first covering layer, and

[0086] - At least one third impermeable covering layer, preferably with a water vapor transmission rate (WVTR) of less than 10. -5 g / m 2 .d, the third capping layer is made of ceramic material and / or low-melting-point glass, preferably glass with a melting point below 600°C, and is deposited on at least a portion of the outer periphery of the stack or battery row or on the first capping layer.

[0087] It should be understood that the sequence of the at least one second capping layer and the at least one third capping layer can be repeated z times, where z≥1, and deposited on the outer periphery of the at least third capping layer. The last layer of the encapsulation system is an impermeable capping layer, preferably with a water vapor transmission rate (WVTR) of less than 10. -5 g / m 2 .d, made of ceramic materials and / or low-melting-point glass.

[0088] In another specific embodiment of the method described in this invention, it can be combined with the above, wherein after the seventh step, at least the anode connection region, preferably including at least the first longitudinal surface of the anode connection region, is covered by an anode contact element capable of generating electrical contact between the stack and external conductive elements.

[0089] At least the cathode connection region, preferably including at least the second longitudinal surface of the cathode connection region, is covered by a cathode contact element capable of generating electrical contact between the stack and external conductive elements.

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

[0091] - A first electrical connection layer, preferably deposited on at least the anodic connection region and at least the cathode connection region, on at least the first longitudinal surface including the at least anodic connection region and at least the second longitudinal surface including the at least cathode connection region, is made of a material filled with conductive particles. The first electrical connection layer is preferably made of a polymer resin filled with conductive particles and / or a material obtained by a sol-gel method.

[0092] -Optionally, when the first electrical connection layer is manufactured from a polymer resin filled with conductive particles and / or a material obtained by a sol-gel process, the step of polymerizing the polymer resin and / or the material obtained by the sol-gel process is performed after the drying step, and

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

[0094] -Optionally deposit a third electrical connection layer, including conductive ink, on the second electrical connection layer. Attached Figure Description

[0095] The accompanying drawings, given by way of non-limiting example, illustrate different aspects and embodiments of the invention.

[0096] [ Figure 1 [Illustration] is a perspective view of a stacked anode foil and cathode foil formed by a method of manufacturing a battery according to the present invention, the anode foil and cathode foil having a unit entity including an uncoated area, a coated area and a groove.

[0097] [ Figure 2 The image shows one of the foils, in particular Figure 1 A front view of the anode foil.

[0098] [ Figure 3 [This is a large-scale front view of a unit entity manufactured in the anode foil of the present invention or an alternative embodiment thereof, the unit entity consisting of an uncoated area (hereinafter referred to as "exclusion area"), a coated area, and a groove.]

[0099] [ Figure 4 Also a large-scale perspective view, showing the uncoated or excluded areas, coated areas, and grooves of these unit entities provided in adjacent foils.

[0100] [ Figure 5 [ ] is a top view showing the cutting steps performed on the different unit entities stacked in the aforementioned figures.

[0101] [ Figure 6 [This is a top view, showing the cuts in the unit entity at a larger scale.]

[0102] [ Figure 7 ] is along Figure 6 The cross-sectional view shown by cutting line VII-VII illustrates a stack of anode and cathode unit entities as described in the present invention or alternative embodiments thereof, each of which consists of an uncoated area, a coated area, and a groove.

[0103] [ Figure 8 ] is along Figure 6 The cross-sectional view along cut line VII-VII shows the stacking of cell entities packaged in the packaging system.

[0104] [ Figure 9 [I] is a cross-sectional view along cutting line VII-VII, showing the battery of the present invention including the encapsulation system, which can be obtained in particular according to the method shown in the foregoing figures.

[0105] [ Figure 10 The figure shows a perspective view of the battery of the present invention, which includes a packaging system, particularly obtainable according to the method shown in the foregoing figures.

[0106] [Figure 11] is a cross-sectional view along cutting line VII-VII, showing the battery of the present invention including a packaging system and contact elements, which can be obtained in particular according to the method shown in the foregoing figures.

[0107] [Figure 12] shows a perspective view of a prior art battery.

[0108] [Figure 13] is a front view showing one of the foils, particularly the anode foil, described in an alternative embodiment of the invention, wherein the anode exclusion zone is manufactured in the form of a single exclusion strip.

[0109] [Figure 14] is a top view showing the cutting steps performed on different unit entities of the stack as described in the alternative embodiment of the present invention.

[0110] [Figure 15] is a top view showing the cutting steps performed on different cell entities in the stack according to the alternative embodiment of the present invention, and showing the battery obtained according to the alternative embodiment.

[0111] [Figure 16] is a top view of the battery row described in this invention.

[0112] [Figure 17] shows a perspective view of the battery row of the present invention, which includes a packaging system, which can be obtained in particular according to the method shown in the foregoing figures.

[0113] Figures 18 through 20 are front views of the sequential steps of preparing a battery according to another embodiment of the present invention, wherein the battery comprises a single cell and current collectors form tabs.

[0114] [Figure 21] is related to Figure 8 A similar front view shows Figure 8 The battery described in the alternative embodiment.

[0115] Figures 22 to 24 are front views similar to those of Figures 18 to 21, showing the sequential steps of manufacturing the battery according to another embodiment of the present invention using a metal mesh-type electrical connection support.

[0116] [Figure 25] is a front view similar to Figure 24, showing an alternative embodiment of Figure 24.

[0117] The following reference numerals are used in these figures and the following description:

[0118] 1000,1000' The battery described in this invention

[0119] 1002 Anode Connection Area

[0120] 1002' Anode edge of each anode current collector substrate

[0121] 1006 Cathode Connection Area

[0122] 1006' Cathode edge of each cathode current collector substrate

[0123] 100, 100', 100” cell

[0124] 10 Anode Current Collector Board

[0125] 20 Anode Layer

[0126] 30 Electrolyte material layer / electrolyte layer

[0127] 31. Insulating layer / insulating layer impregnated with or subsequently impregnated with electrolyte

[0128] 40 Cathode current collector substrate

[0129] 50 Cathode Layer

[0130] 60-unit entity

[0131] 60' Anode Unit Entity

[0132] 60” cathode unit

[0133] 70 I-shaped grooves and cathode grooves in cathode foil

[0134] H 70 The total height of the I-shaped cathode groove 70

[0135] L 70 The total width of the I-shaped cathode groove 70

[0136] 71 Coated area in cathode foil

[0137] 72. Exclusion zone / Uncoated zone / Cathode exclusion zone in cathode foil

[0138] L 72 The total width of the exclusion area / uncoated area 72 in the cathode foil

[0139] H 72 Total height of the exclusion zone / uncoated zone 72 in the cathode foil

[0140] L 71 Total width of the coated area in the cathode foil

[0141] 80 I-shaped grooves and anode grooves in anode foil

[0142] H 80 The total height of the I-shaped anode groove 80

[0143] L 80 The total width of the I-shaped anode groove 80

[0144] 81 Coated area in anode foil

[0145] 82. Exclusion zone / uncoated zone / anode exclusion zone in anode foil

[0146] 82' Exclusion Clause

[0147] L 81 Total width of the coated area in the anode foil

[0148] H 81 Total height of the coated area in the anode foil

[0149] L82 Total width of exclusion area / uncoated area 82

[0150] H 82 Total height of excluded / uncoated area 82

[0151] 90 Material scraps

[0152] 95 Packaging System

[0153] 97 Contact elements

[0154] 97' Anode Contact Element

[0155] 97'a Covers the ends of the anode contact element pins of the surfaces F1, F2, F3, and F5 adjacent to the longitudinal surface F6.

[0156] 97” Cathode Contact Element

[0157] 97”a Cathode contact element pins covering the ends of surfaces F1, F2, F3, and F5 adjacent to longitudinal surface F4.

[0158] Dca includes a first longitudinal surface (F6) and a first end surface DY of a battery 1000 comprising at least one anode connection region (1002). a minimum distance between

[0159] Dcc includes the second longitudinal surface (F4) and the second end surface DY' of the battery 1000, which includes at least one cathode connection area (1006). a minimum distance between

[0160] The minimum distance between the first longitudinal surface of the battery 1000', including at least one anode connection region, and the first end face defined by the first longitudinal ends of each anode layer, each electrolyte material layer or separator layer, each cathode layer, and each cathode current collector substrate layer.

[0161] The minimum distance between the second longitudinal surface of the battery 1000', which includes at least one cathode connection region, and the second end surface defined by the first longitudinal end of each anode layer, each electrolyte material layer or separator layer, each cathode layer, and each anode current collector substrate layer.

[0162] l 1000 Battery width

[0163] L 1000 Battery length

[0164] C 1000 Battery 1000 Center

[0165] Z 1000Parallel to the front direction of the battery (ZZ) and passing through the center C of battery 1000. 1000 axis

[0166] R 1000 1000-fold Z-shaped battery 1000 rotation

[0167] I. A stack of substrate foils covering an electrode layer (anode or cathode) and an electrolyte foil or a separator foil impregnated or subsequently impregnated with electrolyte / a stack of at least one cell.

[0168] 2e Anode foil with a single-unit structure

[0169] 5e Cathode foil with a single-unit structure

[0170] 4. Porous central region of anode foil with unitary structure

[0171] 6. The outer frame of the anode foil with a unit entity

[0172] 7. Holes present at the four ends of a substrate foil, anode foil, cathode foil, electrolyte foil, or insulating foil impregnated or subsequently impregnated with electrolyte.

[0173] 8. Material bridge between the two rows

[0174] H8 Bridge Height

[0175] 9. Material strips between the two columns

[0176] The width of L9 bar

[0177] XX stack / battery vertical or horizontal orientation

[0178] YY stacking / battery sideways or lateral orientation

[0179] ZZ stacking / forward direction of the battery

[0180] L,L n ,L n-1 ,L n+1 Cell entity row / battery row

[0181] R,R n ,R n-1 ,R n+1 Unit Entity Column

[0182] DY n-1 ,DY' n-1 ,DY n ,DY' n ,DY n+1 ,DY' n+1 Cutting

[0183] DXn-1 ,DX' n-1 ,DX n ,DX' n ,DX n+1 ,DX' n+1 Cutting

[0184] The first end face of the DYa battery is defined by the first longitudinal end of each anode layer, each electrolyte material layer or separator layer, each cathode layer and each cathode current collector substrate layer.

[0185] The second end face of the DY'a battery is defined by the second longitudinal end of each anode layer, each electrolyte material layer or separator layer, each cathode layer and each anode current collector substrate layer.

[0186] 2000 Prior Art Batteries

[0187] 200,200',200” Cellular cells of existing technology batteries

[0188] 2002 Anode connection region of existing technology batteries

[0189] 2006 Prior Art Cathode Connection Region of Battery

[0190] 295 Prior art battery packaging systems

[0191] The transverse centerline of the YH unit entity

[0192] F1,F2 stack (I) / battery (1000) front side

[0193] Side surface of F3, F5 stack (I) / battery (1000)

[0194] Longitudinal plane of F4, F6 stack (I) / cell (1000)

[0195] FF1, FF2 The positive face of the battery row (Ln)

[0196] FF3, FF5 Battery Row (Ln) Side Surface

[0197] FF4, FF6 Battery Row (L) n ) lateral surface Detailed Implementation

[0198] Generally, the following geometric names are associated with batteries:

[0199] ZZ refers to the positive direction, which is a plane perpendicular to different stacked layers;

[0200] XX refers to the longitudinal direction, which is contained in the plane of the stacked layers and is parallel to the maximum dimension of these layers when viewed from above (i.e., the forward direction);

[0201] YY refers to the lateral or transverse direction, which is contained in the plane of the stacked layers and is parallel to the smallest dimension of these layers when viewed from above.

[0202] In addition, generally speaking, two direction references are associated with each of these three directions. Figure 10 The plane of the foil is shown.

[0203] Therefore, refer to Figure 10 The plane of the foil shown is associated with the XX direction in the left-right direction, the YY direction in the front-back direction, and the ZZ direction in the up-down direction.

[0204] In addition, refer to Figure 10 The plane of the foil shown is generally defined with the first longitudinal direction XX' running from right to left, and the second longitudinal direction XX” running from left to right, opposite to the first longitudinal direction XX'. (See again...) Figure 10 The plane of the foil is shown. The first lateral direction YY' is defined as from front to back, the second lateral direction YY” is opposite to the first lateral direction, the first positive direction ZZ' is from top to bottom, and the second positive direction ZZ” is opposite to the first positive direction.

[0205] The method described in this invention first includes a step in which alternating foil stacks I are produced, these foils being referred to hereinafter as “anode foil” and “cathode foil” as appropriate. As will be seen in more detail below, each anode foil is intended to form the anode of a plurality of batteries, and each cathode foil is intended to form the cathode of a plurality of batteries. Figure 1 The example shows two cathode foils 5e with unit entities and two anode foils 2e with unit entities. In practice, the stack is formed by a greater number (typically 10 to 1000) of foils. The number of cathode foils 5e with unit entities is the same as the number of anode foils 2e with unit entities used, forming a stack I of alternating foils with opposite polarities.

[0206] In a preferred embodiment, each of these foils has holes 7 at its four ends, and when these holes 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 Figure 1 , Figure 2 and Figure 3 These holes 7 at the four ends of the foil can be made by any suitable means, particularly on the anode and cathode foils after they have been made, or on the substrate foils 10, 40 before they have been made.

[0207] Each anode foil includes an anode current collector substrate 10 at least partially coated with an active layer 20 of anode material (hereinafter referred to as anode layer 20). Each cathode foil includes a cathode current collector substrate 40 at least partially coated with an active layer 50 of cathode material (hereinafter referred to as cathode layer 50). Each of these active layers may be solid, and more particularly, may be dense or porous. Furthermore, to prevent 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 the active layer of at least one of these previously coated current collector substrates, 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 constitutes an integral part of the anode foil and / or cathode foil comprising thereto.

[0208] Preferably, at least part of both sides of the anode current collector substrate 10 or the corresponding cathode current collector substrate 40 are coated with an anode layer 20 or a corresponding cathode layer 50, and optionally an electrolyte layer 30 or an insulating layer 31 is coated on the anode layer 20 or the corresponding cathode layer 50. In this case, the anode current collector substrate 10 or the corresponding cathode current collector substrate 40 will act as a current collector for two adjacent cell units 100, 100'. Using these substrates in batteries increases the yield of rechargeable batteries with high energy density and high power density.

[0209] The mechanical structure of one of the anode foils 1 will be described below. It should be understood that the other anode foils have the same structure. Furthermore, as shown below, the cathode foil has a similar structure to the anode foil.

[0210] like Figure 2 As shown, the anode foil 2e, having unit entities 60, 60', is quadrilateral, approximately square. It defines a so-called porous central region 4 in which the unit entities are manufactured, which will be described below. Referring to the positioning of these unit entities, a so-called lateral or transverse direction YY is defined corresponding to the transverse direction of these unit entities, and a so-called horizontal direction XX is defined perpendicular to the YY direction. The central region 4 is defined by a solid, i.e., an outer frame 6 without unit entities. The function of this frame is specifically to ensure ease of handling each foil.

[0211] Unit entities 60 and 60' are distributed to rows L1 to L y Inside, one row is below another, and columns R1 to R... xWithin the structure, one column is adjacent to the other. As a non-limiting example, within the scope of manufacturing microcells of surface mount device type (hereinafter referred to as SMD), the anode and cathode foils used can be 100mm x 100mm wafers. Typically, these foils have 10 to 500 rows and 10 to 500 columns. Their dimensions can vary as a function of the desired battery capacity, and the number of rows and columns of each anode and cathode foil can be adjusted accordingly. The dimensions of the anode and cathode foils used can be adjusted as needed. Figure 2 As shown, adjacent rows are separated by material bridges 8, whose height, denoted by H8, is between 0.05 mm and 5 mm. Adjacent columns are separated by material strips 9, whose width, denoted by L9, is between 0.05 mm and 5 mm. These material bridges 8 and material strips 9 of the anode and cathode foils provide them with sufficient mechanical rigidity to facilitate handling.

[0212] As will be described in more detail below, the unit entities 60, 60', 60" include exclusion areas, namely uncoated areas 72, 82, coated areas 71, 81, and grooves 70, 80. Preferably, these grooves 70, 80 are I-shaped and through-holes, i.e., they are openings on opposite top and bottom surfaces of the foil, respectively. These grooves 70, 80 are preferably quadrilateral, generally rectangular. These grooves 70, 80 can be formed directly on the substrate in manners known per se, prior to the deposition of any anodic or cathodic material, by chemical etching, electroforming, laser cutting, micro-perforation, or stamping. These grooves 70, 80 can also be formed in the following locations:

[0213] - On a current collector substrate at least partially coated with a layer of anode or cathode material, or

[0214] - On a current collector substrate at least partially coated with an anode or cathode material layer, the anode or cathode material layer itself is coated with an electrolyte layer or an isolation layer, i.e., on the anode foil or cathode foil.

[0215] When the trenches 70 and 80 are formed in this at least partially coated substrate, the trenches 70 and 80 can be formed in a manner known per se, such as by laser cutting (or laser ablation), femtosecond laser cutting, micro-perforation, or stamping. The trenches 70 formed in all the cathode foils overlap each other. The trenches 80 formed in all the anode foils overlap each other.

[0216] Now it will be described as follows Figure 3 One of the unit entities 60 shown is shown. It should be understood that all unit entities 60 and 60' of the anode foil are the same, and all unit entities 60 and 60" of the cathode foil are the same.

[0217] Figure 3 Anode unit entities 60 and 60' are shown.

[0218] Each unit entity 60, 60', 60" includes a through groove 80, 70, preferably I-shaped, an exclusion area (i.e., an uncoated area) 82, 72, and a coated area 81, 71.

[0219] The coated area 81 of the anode unit entity 60' is understood to refer to the anode foil area covered by the anode layer 20 or by the anode layer 20 and the electrolyte layer 30 or the isolation layer 31. The excluded area or uncoated area 82 of the anode unit entity 60' refers to the anode foil area not covered by the anode layer 20 or not covered by the anode layer 20 and the electrolyte layer 30 or the isolation layer 31.

[0220] Anode exclusion regions 82 are areas free of any electrolyte material or separator and free of any anode material. When these anode exclusion regions 82 are formed on the anode foil, they are formed in a manner that removes or prevents the deposition of any electrolyte material or separator, any anode material, leaving at least a portion of the anode current collector substrate 10. Thus, in the first longitudinal direction XX' of the battery, each anode current collector substrate 10 protrudes from each anode layer 20 and from each electrolyte material layer 30 or electrolyte-impregnated separator layer 31. When the current collector substrate is completely covered by the anode layer 20, which itself is optionally covered by the electrolyte layer 30 or separator layer 31, the anode exclusion regions 82 can be formed by laser ablation, locally removing the anode layer 20 or coating the anode layer 20 with the electrolyte layer 30 or separator layer 31. Anode exclusion regions 82 can also be formed by localized slot coating of the current collector substrate in a manner known per se. Localized slot coating of the current collector substrate allows for the localized deposition (particularly) of the anode layer 20 on the substrate, optionally followed by covering the electrolyte layer 30 or separator layer 31 in the same manner. The slit-type coating on the substrate, which is symmetrical along the direction of travel of the substrate, allows uncoated areas 82 to be left directly on the substrate; this reduces the number of steps in the method of manufacturing unit entities on the anode foil.

[0221] When viewed from above, areas 82 and 72 are excluded on the one hand, and the slots 80 and 70 of the same unit entities 60, 60', and 60” are symmetrical to each other with respect to the center lines of the unit entities 60, 60', and 60” represented by YH.

[0222] Each anode exclusion zone 82 is generated in the continuation of each cathode groove 70, and each cathode exclusion zone 72 is generated in the continuation of each anode groove 80.

[0223] The anode foil obtained after forming the production tank 80, coating area 81 and removal area 82 is referred to below as the anode foil 2e with a unit entity.

[0224] The following reference numerals shall be used:

[0225] ·H 80 This refers to the height of the entire anode tank, which is typically between 0.25mm and 10mm.

[0226] ·L 80 It is the width of the entire anode tank, usually between 0.25mm and 10mm;

[0227] ·H 82 It is the height of each anode exclusion zone, typically between 0.25mm and 10mm;

[0228] ·L 82 It is the width of each anode exclusion zone, typically between 0.25mm and 10mm;

[0229] Similarly, each cathode foil is also provided with cathode unit entities 60, 60” in different rows and columns, the same number as anode unit entities 60, 60’.

[0230] Especially Figure 4 As shown, the structure of each cathode unit entity 60” is basically similar to that of each anode unit entity 60’, that is, the cathode unit entity 60” includes an exclusion area or uncoated area 72, a coated area 71 and a groove 70.

[0231] The exclusion area or uncoated area 72 of the cathode unit entity 60 refers to the cathode foil area that is not covered by the cathode layer 50 or is not covered by the cathode layer 50 and the electrolyte layer 30 or the isolation layer 31.

[0232] The coating area 81 of the cathode unit entity 60 refers to the cathode foil area 5e that is covered by the cathode layer 50 or by the cathode layer 50 and the electrolyte layer 30 or the isolation layer 31.

[0233] The dimensions of the cathode removal area 72 are the same as those of the anode groove 80, and similarly, the dimensions of the anode removal area 82 are similar to those of the cathode groove 70.

[0234] When viewed from above, the cathode removal area 72 is superimposed on the anode groove 80, and the anode removal area 82 is superimposed on the cathode groove 70.

[0235] The only difference between the anode unit entity 60' and the cathode unit entity 60" is that, on the one hand, the cathode removal area 72 and the anode removal area 82 are opposite to each other. On the other hand, the cathode groove 70 and the anode groove 80 are opposite to each other. In this way, when viewed from above, each anode removal area 82 is generated in a continuation of each cathode groove 70, and each cathode removal area 72 is generated in a continuation of each anode groove 80.

[0236] The cathode exclusion region 72 is a region that contains no electrolyte material or insulation and no cathode material. When these cathode exclusion regions 72 are formed on the cathode foil, they are formed in a manner that removes or prevents the deposition of any electrolyte material or insulation and any cathode material, leaving at least a portion of the anode current collector substrate 10. In this way, in the second longitudinal direction XX” of the battery, opposite to the first longitudinal direction XX’, each cathode current collector substrate 40 protrudes from each cathode layer 50 and from each electrolyte material layer 30 or electrolyte-impregnated separator layer 31. When the current collector substrate is completely covered by the cathode layer 50, which itself is optionally covered by the electrolyte layer 30 or separator layer 31, the cathode exclusion region 72 can be generated by laser ablation to locally remove the cathode layer 50 or the cathode layer 50 coated with the electrolyte layer 30 or separator layer 31. The cathode exclusion region 72 can also be generated by local slot coating of the current collector substrate. Local slot coating of the current collector substrate allows for local deposition (in particular) of the cathode layer 50 on the substrate, optionally followed by covering the electrolyte layer 30 or separator layer 31 in the same manner. Slot coating on the substrate symmetrical along the substrate travel direction allows uncoated areas 72 to be left directly on the substrate; reducing the number of steps in the method of manufacturing a cell entity on the cathode foil.

[0237] The cathode foil obtained after forming the production tank 70, coating area 71 and removal area 72 is referred to below as cathode foil 5e with unit entity.

[0238] Then, at least one anode foil 2e having a unit body and at least one cathode foil 5e having a unit body are alternately stacked to obtain at least one unit cell, each unit cell sequentially comprising an anode current collector substrate 10, an anode layer 20, an 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.

[0239] Stack I includes at least one anode foil 2e having a groove 80, an uncoated area 82, and a coated area 81, and at least one cathode foil 5e having a groove 70, an uncoated area 72, and a coated area 71, arranged alternately. This yields at least one cell 100, which sequentially includes an anode current collector substrate 10, an anode layer 20, an electrolyte material layer 30 and / or an insulating layer 31, a cathode layer 50, and a cathode current collector substrate 40.

[0240] This stack I was prepared so that:

[0241] - In the first longitudinal direction XX' of the battery, each anode current collector substrate 10 protrudes from each anode layer 20, each electrolyte material layer 30 and / or separator layer 31, each cathode layer 50 and each cathode current collector substrate layer 40, and

[0242] - In the second longitudinal direction XX” of the battery, which is opposite to the first longitudinal direction XX’, each cathode current collector substrate 40 protrudes from each anode layer 20, each electrolyte material layer 30 and / or insulating layer 31, each cathode layer 50 and each anode current collector substrate layer 10.

[0243] In the case where the battery comprises multiple cell units 100, 100', 100" and one cell unit 100, 100', 100" is located below the other, i.e., according to relative to Figure 10 The cells shown are stacked ZZ in the positive direction of the main plane, thus the following is preferred:

[0244] The anode current collector substrate 10 is the anode current collector substrate 10 of two adjacent unit cells 100, 100', and 100" in which...

[0245] The cathode current collector substrate 40 is the cathode current collector substrate 40 of two adjacent unit cells 100, 100', 100"

[0246] Assume the aforementioned stack undergoes steps to ensure its overall mechanical stability. These steps, which are known in themselves, particularly include hot-pressing the different layers. As shown below, such a stack, stabilized in this way, can form a single cell, the number of which is equal to the product of the number of rows Y and the number of columns X.

[0247] Therefore, refer to Figure 5 It shows three lines of L n-1 To L n+1 and three columns R n-1 To R n+1 According to the present invention, when the stack I comprises multiple rows, i.e., at least two rows of cell entities, it is also referred to hereinafter as a battery row L. n Perform the first pair of cuts DX n and DX' n The battery 1000 is formed by the solid stacking of the given row L of the battery. n With at least one other row L n-1 L n+1 Separately, as shown in Figures 16 and 17. Each cut is made in a through manner, meaning it extends across the entire height of the stack, in a manner known per se. Non-limiting examples include cutting by sawing (particularly cutting into cubes), guillotine cutting, or laser cutting. Furthermore, foil areas 90 in the stack that do not form batteries are filled with solid lines, while the volume of the slots is left blank, and the volume of the exclusion areas is gray.

[0248] Especially Figure 6 As shown, this figure is Figure 5An enlarged view of one of the unit entities 60 and 60', where each cut can be made in the longitudinal direction of the battery, in the first longitudinal direction XX', or in the second longitudinal direction XX". Cut DX n and DX' n Preferably, they are parallel to each other, and preferably perpendicular to the calibration lines of the slots 80, 70 and exclusion zones 72, 82 of the unit entities 60, 60', 60”.

[0249] Back Figure 5 Each final cell is made up of two preferably parallel cuts DX at the front and back. n and DX' n Limited, and on the right and left sides by two preferred parallel second pairs of cuts DY n and DY' n limited.

[0250] exist Figure 5 In the middle, once battery 1000 is along the cutting line D n and D' n and along the cutting line DY n and DY' n Cuts are indicated by shading.

[0251] Under these conditions, refer to the non-restrictive example form. Figure 6 The following figure labels are given:

[0252] - Distance Dca corresponds to the minimum distance between the first longitudinal surface F6 and the first end surface DYa of the battery, which includes at least one anode connection region 1002. Distance Dca is between 0.01 mm and 0.05 mm. It should be understood that distance Dca is less than or equal to L. 82 / L 70 ;

[0253] - Distance Dcc, which corresponds to the minimum distance between the second longitudinal surface F4 and the second end surface DY'a of the battery, which includes at least one cathode connection region 1006. Distance Dcc is between 0.01 mm and 0.05 mm. It should be understood that distance Dcc less than or equal to L... 72 / L 80 ;

[0254] Figure 7 It is a cross-sectional view taken along the cutting line VII-VII that passes through the battery. Figure 7 The alternating arrangement of two anode foils 2e and two cathode foils 5e, each a unitary entity, is shown. In the same figure, the following reference numerals are given: grooves 70 and 80 of unitary entities 60 and 60', coating areas 71 and 81, and exclusion areas 72 and 82. Figure 6These markings are also shown in the adjacent cell of a preferred embodiment of the present invention.

[0255] The anode foil 2e, having a unitary structure, includes an anode current collector substrate 10 coated with an anode layer 20, the anode layer 20 itself optionally coated with an electrolyte layer 30 or a subsequently electrolyte-impregnated insulating layer 31. The cathode foil 5e, having a unitary structure, includes a cathode current collector substrate 40 coated with a cathode material active layer 50, the cathode material active layer 50 itself optionally coated with an electrolyte layer 30 or a subsequently electrolyte-impregnated insulating layer 31. To prevent any electrical contact between the two active layers of opposite polarities, i.e., between the anode layer 20 and the cathode layer 50, at least one electrolyte layer 30 and / or at least one electrolyte-impregnated or subsequently electrolyte-impregnated insulating layer 31 are arranged. Figure 7 A cell 100 is shown, which sequentially includes an anode current collector substrate 10, an anode layer 20, an electrolyte material layer 30 or an isolation layer 31 impregnated or subsequently impregnated with electrolyte, a cathode layer 50, and a cathode current collector substrate 40.

[0256] The anode current collector substrate 10 of the preferred cell 100' can be adjacent to the anode current collector substrate 10 of the adjacent cell 100". Similarly, the cathode current collector substrate 40 of the preferred cell 100' can be adjacent to the cathode current collector substrate 40 of the adjacent cell 100".

[0257] In a preferred embodiment, the anode current collector substrate 10 and the corresponding cathode current collector substrate 40 can serve as current collectors for two adjacent cell units, particularly as follows: Figure 7 As shown above, both sides of the anode current collector substrate 10 or the corresponding cathode current collector substrate 40 can be coated with an anode layer 20 or a corresponding cathode layer 50, and optionally coated with an electrolyte layer 30 or a separator layer 31 disposed on the anode layer 20 or the corresponding cathode layer 50. This increases the yield of the battery.

[0258] like Figure 7 As shown, each anode foil 2e having a unit entity and each cathode foil 5e having a unit entity are arranged such that each cathode exclusion region 72 is formed in the continuation of each anode groove 80, and each anode exclusion region 82 is formed in the continuation of each cathode groove 70.

[0259] In the first longitudinal direction XX', each anode current collector substrate 10 protrudes from the first end face DYa, which is defined by the first longitudinal end of each anode layer 20, each electrolyte material layer 30 or isolation layer 31, each cathode layer 50 and each cathode current collector substrate layer 40.

[0260] In the second longitudinal direction XX” of the battery, which is opposite to the first longitudinal direction XX’, each cathode current collector substrate 40 protrudes from each anode layer 20, each electrolyte material layer 30 and / or the isolation layer 31 impregnated or subsequently impregnated with electrolyte, each cathode layer 50 and each anode current collector substrate layer 10.

[0261] This is a particularly advantageous feature of the present invention because it prevents short circuits at the lateral edges of the battery, prevents leakage current, and facilitates the formation of electrical contacts in the anode connection region 1002 and the cathode connection region 1006.

[0262] In cross-section, the cathode removal area 72 is superimposed on the anode groove 80, and the anode removal area 82 is superimposed on the cathode groove 70.

[0263] Preferably, after the production of the stack of anode foil 2e and cathode foil 5e having unitary solid structures, the stack I is stabilized by heat treatment and / or mechanical treatment (the treatment may be hot pressing, including simultaneous application of pressure and high temperature). The heat treatment of the stack to enable battery assembly is preferably performed at a temperature between 50°C and 500°C, preferably at a temperature below 350°C. The mechanical compression of the stack to be assembled, consisting of anode foil 2e and cathode foil 5e having unitary solid structures, is performed at a pressure between 10 and 100 MPa, preferably between 20 and 50 MPa.

[0264] The production of the robust stacking of the layers that make up a battery has just been described. Then, when the stack I comprises multiple rows, i.e., at least two rows of cell entities, it will be referred to hereinafter as a battery row L. n The first pair of DX cutting was carried out. n and DX' n The given row L of the battery 1000 formed by the stable stacking of the batteries. n With at least one other row L n-1 L n+1 Separately. As mentioned above, each cut is carried out in a through-thrust manner, meaning its extension extends across the entire height of the stack, in a manner known per se. As shown in Figure 17, the battery row L n It has six faces, namely:

[0265] - Two opposing positive surfaces FF1 and FF2, particularly two positive surfaces parallel to each other, typically parallel to one or more anode current collector substrates 10, one or more anode layers 20, one or more electrolyte material layers 30 or one or more electrolyte-impregnated isolation layers 31, one or more cathode layers 50, and one or more cathode current collector substrates 40.

[0266] - Two opposing lateral surfaces FF3 and FF5, specifically, the two lateral surfaces are parallel to each other and parallel to the lateral surfaces F3 and F5 of battery 1000.

[0267] - and two opposing longitudinal surfaces FF4 and FF6, specifically, the two longitudinal surfaces are parallel to each other and parallel to the longitudinal surfaces F4 and F6 of battery 1000.

[0268] When the separator layer is used as the electrolyte host matrix, the initial stack I includes multiple rows of cells L. n And in order to form a given row (L) of the battery (1000) formed by the stable stacking n ) and at least one other row (L) of battery (1000) n-1 L n+1 When the first pair of cuts (DXn, DX'n) has been carried out after the separation, the previously obtained stable stack or the row L of battery 1000 can be... n Perform impregnation. Previously obtained stable stacks or rows of 1000 batteries. n The impregnation can be achieved by a phase carrying lithium ions (e.g., a liquid electrolyte) or an ionic liquid containing lithium salt, such that the insulating layer (31) is impregnated with an electrolyte.

[0269] After producing a robust stack I of optionally impregnated lithium-ion-carrying phases, the stack, or row L of battery 1000 n Encapsulation is performed using a deposition encapsulation system 95 to ensure that the cell units of the battery are protected from atmospheric effects, such as... Figure 8 As shown. The packaging system must preferably be chemically stable, able to withstand high temperatures, and impermeable to fulfill its function as a barrier layer.

[0270] The stack can be covered by a packaging system, the packaging system comprising:

[0271] - An optional first dense insulating capping layer, preferably selected from parylene, parylene F, polyimide, epoxy resin, silicone resin, polyamide, sol-gel silica, organosilicon and / or mixtures thereof, is deposited on the stack of anode and cathode foils; and

[0272] - An optional second capping layer, composed of an electrically insulating material, is deposited on the stack of anode and cathode foils or on the first capping layer by atomic layer deposition; and

[0273] - In a particularly advantageous manner, at least a third impermeable covering layer, preferably having a water vapor transmission rate (WVTR) of less than 10. -5 g / m 2 .d, the third capping layer is made of ceramic material and / or low-melting-point glass, preferably glass with a melting point below 600°C, and is deposited on the stack of anode and cathode foils or around the first capping layer.

[0274] It should be understood that the sequence of the at least one second capping layer and the at least one third capping layer can be repeated z times, where z≥1, and deposited on the periphery of at least the third capping layer. The last layer of the encapsulation system is an impermeable capping layer, preferably with a water vapor transmission rate (WVTR) of less than 10. -5 g / m 2 .d, made of ceramic materials and / or low-melting-point glass.

[0275] This sequence can be repeated z times, where z ≥ 1. It has a blocking effect, which increases with the value of z.

[0276] The result is a robust and impermeable encapsulation, which in particular prevents water vapor from passing through the interface between the encapsulation system and the contact elements (see Interface A in Figure 11).

[0277] In this invention, an impermeable layer is defined as a water vapor transmission rate (WVTR) of less than 10. -5 g / m 2 The water vapor transmission rate can be determined using the method described in U.S. Patent No. 7,624,621 and the method described by A. Mortier et al. in Thin Solid Films 6+550(2014)85-89, "Structural properties of ultraviolet cured polysilazane gas barrier layers on polymer substrates".

[0278] Typically, the first capping layer is optional and selected from: silicone resins (e.g., deposited from hexamethyldisiloxane (HMDSO) by impregnation or plasma-enhanced chemical vapor deposition), epoxy resins, polyimides, polyamides, parylene (also known as poly(p-xylene), but more commonly referred to as par-xylene), and / or mixtures thereof. When the first capping layer is deposited, it protects the sensitive elements of the battery from their environmental influences. The thickness of the first capping layer is preferably from 0.5 μm to 3 μm.

[0279] This first capping layer is particularly useful when the electrolyte and electrode layers of a battery have pores: it acts as a planarization layer and also has a barrier effect. For example, this first layer can be lining the surface of micropores that have openings on the surface of the layer, sealing their entrances.

[0280] Different parylene variants can be used in this first capping layer. Parylene C, parylene D, parylene N (CAS 1633-22-3), parylene F, or mixtures of parylene C, D, N, and / or F can be used. Parylene is a dielectric, transparent, semi-crystalline material with high thermodynamic stability, excellent solvent resistance, and extremely low permeability. Parylene also has barrier properties. Parylene F is preferred within the scope of this invention.

[0281] The first capping layer is preferably obtained by condensing gaseous cells deposited on the surface of the battery stack via chemical vapor deposition (CVD), resulting in a conformal, thin, and uniform coverage of all accessible surfaces of the stack. The first capping layer is preferably rigid; it cannot be considered a flexible surface.

[0282] The second capping layer is also optional and is formed of an electrically insulating material, preferably an inorganic material. It is deposited via atomic layer deposition (ALD), PECVD, HDPCVD (high-density plasma chemical vapor deposition), or ICP CVD (inductively coupled plasma chemical vapor deposition) to achieve conformal coverage of all accessible surfaces of the stack previously covering the first capping layer. ALD deposited layers are mechanically very fragile and require a hard surface to function properly. Depositing a fragile layer on a flexible surface can lead to crack formation, resulting in a loss of integrity in the protective layer. Furthermore, the growth of the ALD deposited layer is affected by the substrate properties. Layers deposited by ALD on substrates with different chemical properties will grow unevenly, leading to a loss of integrity in the protective layer. Therefore, this optional second layer (if present) is preferably attached to the optional first layer, ensuring a chemically uniform substrate growth.

[0283] ALD deposition techniques are particularly suitable for covering high-roughness surfaces in a completely impermeable and conformal manner. They can produce conformal layers, free of defects such as pores (so-called "pinhole-free" layers), and have very good barrier properties. Their water vapor transmission rate (WVTR) is extremely low. WVTR is used to evaluate the water vapor permeability of the encapsulation system. The lower the WVTR, the more impermeable the encapsulation system. The thickness of the second layer is preferably selected based on the desired level of impermeability (i.e., the desired WVTR) and depends on the deposition technique used, particularly those selected from ALD, PECVD, HDPCVD, and ICP CVD.

[0284] The second capping layer can be made of ceramic, vitreous, or glass-ceramic materials, such as oxides, nitrides, phosphates, oxynitrides, or siloxanes of the Al2O3 or Ta2O5 type. The thickness of the second capping layer is preferably 10 nm to 10 μm, more preferably 10 nm to 50 nm.

[0285] The second capping layer, deposited on top of the first capping layer via ALD, PECVD, HDPCVD (high-density plasma chemical vapor deposition), or ICP CVD (inductively coupled plasma chemical vapor deposition), firstly makes the structure impermeable, preventing water migration into the interior of the object, and secondly protects the first capping layer, preferably made of parylene F, from the atmosphere, especially air and water, and from the effects of heat exposure to prevent its degradation. Therefore, the second capping layer improves the lifespan of the encapsulated battery.

[0286] The second capping layer can also be deposited directly on the stack of anode and cathode foils, i.e., without depositing the first capping layer.

[0287] The third capping layer must be impermeable, preferably with a water vapor transmission rate (WVTR) of less than 10. -5 g / m 2 .d. The third capping layer is formed by depositing ceramic material and / or low-melting-point glass, preferably glass with a melting point below 600°C, around the periphery of the anode and cathode foil stack or around the first capping layer. The ceramic and / or glass material used in this third layer is preferably selected from:

[0288] - Low melting point glass (typically >600℃), preferably SiO2-B2O3; Bi2O3-B2O3, ZnO-Bi2O3-B2O3, TeO2-V2O5, PbO-SiO2,

[0289] -Oxides, nitrides, nitrogen oxides, Si x N y SiO2, SiON, amorphous silicon or SiC.

[0290] These glasses can be deposited through molding or dip coating.

[0291] Ceramic materials are preferably deposited at low temperatures via PECVD or, more preferably, HDPCVD or ICP CVD; these methods can deposit layers with good impermeability.

[0292] As described above, the battery of the present invention includes an encapsulation system, which is preferably manufactured in sequential layers. This achieves a highly impermeable encapsulation on all surfaces of the battery. Furthermore, the overall size of this encapsulation is very small, allowing for the miniaturization required for microcells.

[0293] Compared to the disclosure in US Patent Document US 2018 / 212210 filed by Suzuki, the above description of the encapsulation system and its technical effects differ significantly. In this prior art battery, the resin in contact with the battery cell does not possess an impermeable encapsulation function. More specifically, this resin does not possess the permeability characteristics described above.

[0294] Furthermore, the document submitted by Suzuki relates to a solid-state battery. In contrast, the battery described in this invention may not be an all-solid-state battery. In this case, the longitudinal end of the battery is "open." Specifically, as... Figure 9 As shown, the impermeable encapsulation system preferably makes direct contact with the ends of the electrolyte layer 30 or the separator layer 31 at opposite longitudinal faces F4 and F6. Therefore, this encapsulation system is able to “close” the pores in layers 30 and the corresponding layers 31, which in particular allows the nano-confined electrolyte inside the battery to be satisfactorily retained. In an alternative embodiment not shown, the encapsulation system does not contact other layers. However, the encapsulation preferably makes direct contact with all battery components on the stacked opposite longitudinal faces, except for the protruding substrate.

[0295] Furthermore, the battery packaging system of the present invention is preferably electrically insulating. In the present invention, this means that the conductivity of the packaging system is preferably less than 10. e-11 Sm -1 Especially less than 10 e-12 Sm -1 This feature is advantageous because it avoids short circuits while allowing the reversed positive and negative connections to be remade for compatibility with pick-and-place electronic component placement machines. This feature can be compared to the disclosure in the aforementioned patent document filed by Suzuki, in which impermeability is achieved by a metal casing.

[0296] Then, the coated stack is cut along the cutting lines DYn and DY'n by any suitable means to expose the anode connection region 1002 and the cathode connection region 1006, thus obtaining a cell, such as Figure 9 As shown.

[0297] like Figure 9 and Figure 10 As shown, a robust package stack is cut along the cutting lines DYn and DY'n, thereby:

[0298] - Only each anode edge 1002' of each anode current collector substrate 10 is from the first end face DY a The first end face is protruding and flush with the first longitudinal surface F6, which is defined by the first longitudinal end of each anode layer 20, each electrolyte material layer 30 and / or separator layer 31, each cathode layer 50 and each cathode current collector substrate layer 40 in the first longitudinal direction XX' of the battery, thereby

[0299] - Only each cathode edge 1006' of each cathode current collector substrate 40 is from the second end face (DY') a The first longitudinal surface F6 protrudes and is flush with the second longitudinal surface F4. The second end face is defined by the second longitudinal ends of each anode layer 20, each electrolyte material layer 30 and / or separator layer 31, each cathode layer 50 and each cathode current collector substrate layer 10 in the second longitudinal direction XX” of the battery. The second longitudinal surface F4 is preferably opposite to and parallel to the first longitudinal surface F6.

[0300] It should be understood that each anode edge 1002' defines an anode connection region 1002, and each cathode edge 1006' defines a cathode connection region 1006.

[0301] Contact elements 97, 97', 97" (electrical contacts) are added where the cathode connection region 1006 or the corresponding anode connection region 1002 is clearly visible. These contact regions are preferably located on opposite sides of the battery stack for collecting current (lateral current collectors). Contact elements 97, 97', 97" are arranged at least on the cathode connection region 1006 and at least on the anode connection region 1002, preferably on a coated and cut stack surface including at least the cathode connection region 1006 and on a coated and cut stack surface including at least the anode connection region 1002 (see [link to documentation]). Figure 11 ).

[0302] Therefore, at least the anode connection region 1002, preferably including at least the first longitudinal surface F6 of the anode connection region 1002, more preferably including at least the first longitudinal surface F6 of the anode connection region 1002, and the ends 97'a of the surfaces F1, F2, F3, F5 adjacent to the first longitudinal surface F6, are covered by anode contact elements 97' capable of generating electrical contact between the stack I and the external conductive element. Furthermore, at least the cathode connection region 1006, preferably including at least the second longitudinal surface F4 of the cathode connection region 1006, more preferably including at least the second longitudinal surface F4 of the cathode connection region 1006, and the ends 97"a of the surfaces F1, F2, F3, F5 adjacent to the second longitudinal surface F4, are covered by cathode contact elements 97" capable of generating electrical contact between the stack I and the external conductive element.

[0303] Preferably, the contact elements 97, 97', 97" are formed by stacked layers I near the cathode connection region 1006 and the anode connection region 1002. The stacked layers I sequentially include a first electrical connection layer and a second layer composed of metal foil disposed on the first layer. The first electrical connection layer includes a material filled with conductive particles, preferably a polymer resin filled with conductive particles and / or a material obtained by the sol-gel method, more preferably a polymer resin filled with graphite.

[0304] When the circuit is subjected to thermal stress and / or vibration stress, the first electrical connection layer allows the subsequent second electrical connection layer to be secured, while providing "flexibility" at the connection without disrupting the electrical contact.

[0305] The second electrical connection layer is a metal foil. This second electrical connection layer provides durable waterproof protection for the battery. Generally, for a given material thickness, metals can be used to create highly impermeable films, more impermeable than ceramic films, and even more impermeable than polymer films, which are typically not very impermeable to water molecules. This extends the battery's calendar life by reducing the water-to-vitality ratio (WVTR) at the contact elements.

[0306] Preferably, a third electrical connection layer comprising conductive ink is deposited on the second electrical connection layer; the purpose is to reduce WVTR, thereby extending the battery's lifespan.

[0307] Contact elements 97, 97', 97" allow for alternating electrical connections between the positive and negative terminals at each end. These contact elements 97, 97', 97" enable parallel electrical connections between different battery elements. For this purpose, only the cathode connection protrudes at one end, while the anode connection is available at the other end.

[0308] International patent application WO 2016 / 001584 describes a stack of multiple cell units consisting of anode and cathode foils stacked alternately and laterally offset (see [link to patent application]). Figure 12 The cells of battery 2000 are encapsulated in encapsulation system 295 to protect them from environmental influences. Cutting these encapsulated stacks to obtain cells with exposed anode connection regions 2002 and cathode connection regions 2006 is performed along a cutting plane that passes through alternating, continuous electrodes and the encapsulation system. Due to the density difference between the electrodes and the encapsulation system in prior art batteries, cutting along such a cutting plane can result in the encapsulation system being torn apart near the cutting plane, creating a risk of short circuits. In international patent application WO 2016 / 001584, during the encapsulation process, the encapsulation layer fills the gaps in a foil stack with U-shaped cuts. The encapsulation layer inserted into these gaps is thick and does not adhere well to the stack, resulting in a risk of the encapsulation system 2095 being torn apart during subsequent cutting.

[0309] According to the present invention, this risk is eliminated by using a foil having a unit entity, wherein:

[0310] - In the first longitudinal direction XX', each anode current collector substrate 10 protrudes from the first end face DYa, the first end face being defined by the first longitudinal end of each anode layer 20, each electrolyte material layer 30 or isolation layer 31, each cathode layer 50 and each cathode current collector substrate layer 40.

[0311] In the second longitudinal direction XX” of the battery, which is opposite to the first longitudinal direction XX’, each cathode current collector substrate 40 protrudes from each anode layer 20, each electrolyte material layer 30 and / or the isolation layer 31 impregnated or subsequently impregnated with electrolyte, each cathode layer 50 and each anode current collector substrate layer 10.

[0312] Because the cathode and anode foils are stacked alternately, the thermo-pressed mechanical structure of the unit cell is very robust near the cut. Using this rigid structure, along with the foil sheets containing the unit cells, reduces the number of defects during the cutting process, increases cutting speed, and thus improves battery production.

[0313] According to the present invention, DY' is cut n and DY n This is achieved by using anode foil 2e with a unitary structure and cathode foil 5e with a similar density, resulting in a cleaner cut of higher quality. Furthermore, in the cutting plane DY' n and DY n Nearby, an anode current collector substrate 10, which contains no anode material, electrolyte, or impregnated or unimpregnated electrolyte, and an isolation, cathode, and cathode current collector substrate, are located in the first longitudinal direction XX'. A cathode current collector substrate 40, which contains no anode material, electrolyte, or impregnated or unimpregnated electrolyte, and an isolation, cathode, and anode current collector substrate, is located in the second longitudinal direction XX”. This arrangement prevents any risk of short circuits and leakage currents and facilitates the formation of electrical contacts at connection regions 1002 and 1006. The anode connection region 1002 and the cathode connection region 1006 are preferably laterally opposite each other.

[0314] The unique structure of the battery described in this invention prevents short circuits at the longitudinal surfaces F4 and F6, prevents leakage current, and facilitates the formation of electrical contacts between the anode connection region 1002 and the cathode connection region 1006. More specifically, there are no electrode materials or electrolyte materials on the longitudinal surfaces F4 and F6 of the battery, including the anode and cathode connection regions, preventing lateral leakage of lithium ions and facilitating battery balance; Figures 7 to 1 0 As shown, the effective surfaces of the electrodes that are in contact with each other and defined by the first and second end faces DYa and DY'a are substantially the same.

[0315] Or, such as Figure 5 As shown in Figure 16, batteries 1000' can be obtained according to the present invention. These batteries 1000' correspond to batteries about axis Z. 1000 Battery 1000 rotated 180°, axis Z 1000 It is with the battery center C 1000The positive axis ZZ is parallel to the axis. Batteries 1000 and 1000' can have the same dimensions. Batteries 1000 and 1000' can have the same or different longitudinal dimensions. Producing batteries 1000 and 1000' in the same stack optimizes battery yield while minimizing material scrap 90.

[0316] The battery described in this invention can be manufactured from the cell entities described in different alternative embodiments of this invention. In non-limiting examples, such as Figure 13 As shown, the coating areas 71 and 81 of the cell entities can be created on the current collector substrates 40 and 10 by symmetrical slit coating in the substrate traveling direction. This allows uncoated areas 72 and 82 to be directly left on the substrate, thereby reducing the number of steps in the method of manufacturing cell entities on the cathode and anode foils. The exclusion area of ​​each cell entity in the same row R can be common, forming exclusion strips 82' (see...). Figures 13 and 14 ).

[0317] like Figure 15 As shown, other batteries 1000' can be obtained according to the present invention and the same alternative embodiments thereof. These batteries 1000' correspond to those around axis Z. 1000 Battery 1000 rotated 180°, axis Z 1000 It is with the battery center C 1000 The positive direction ZZ is parallel to the axis. Producing batteries 1000 and 1000' in the same stack optimizes battery yield while minimizing material scrap 90.

[0318] In an alternative embodiment not shown, line R n The exclusion region of each unit entity can be formed by the same row R n Each unit entity shares a common exclusion strip, thereby optimizing battery yield while preventing the generation of scrap 90. Therefore, the entire central portion 4 of the alternating foil stack is used to manufacture the battery of the present invention.

[0319] Figures 18 to 20 illustrate another embodiment of the invention. In these figures, any components similar to those in the first embodiment are indicated by the same reference numerals increased by 300.

[0320] The battery 1300 shown in Figure 20 differs from the battery 1000 described above, primarily in that it includes a single cell 400 covered by the encapsulation system 395. In Figure 20, the single cell comprises, from top to bottom:

[0321] -Anode current collector substrate 310

[0322] -Anode layer 320

[0323] - The electrolyte-impregnated insulating layer 331, as described above, can be replaced by an electrolyte material layer.

[0324] - Cathode layer 350, and

[0325] -Cathode current collector substrate 340

[0326] Referring to Figure 18, the different components of the battery are first placed one on top of the other in sequence. This structure is typically achieved through localized deposition on a substrate. A portion of the current collector is not covered by the deposition. Current collector substrates 310 and 340, disposed on opposite frontal surfaces F1 and F2, are arranged such that their opposite ends protrude from other layers on opposite longitudinal surfaces F4 and F6. Then, as shown in Figure 19, these components are covered by encapsulation system 395.

[0327] Then, cuts are made along vertical lines 392 and 393 as shown in Figure 19. As shown in Figure 20, the cuts expose the edges 311 and 341 of the corresponding current collector substrates 310 and 340. It should be noted that these edges are covered by regions 394 and 396 of the packaging system 395, which protrude in two opposite directions in the longitudinal direction XX.

[0328] Figure 21 illustrates another embodiment of the invention. In these figures, any components similar to those in the first embodiment are indicated by the same reference numerals increased by 400.

[0329] Similar to battery 1000, battery 1400 in Figure 21 has multiple cell units 500, which are arranged vertically in the front direction ZZ. Unlike battery 1000, battery 1400 has a packaging system 495, similar to 395 just described above. Specifically, system 495 has multiple regions 494 and 496 protruding in the direction XX. Like battery 1300, regions 494 and 496 are formed by making cuts 492 and 493, as shown by the vertical dashed lines in Figure 21. These cuts expose edges 411 and 441 belonging to different current collector substrates 410 and 440.

[0330] Figures 22 to 24 illustrate another embodiment of the invention, which must be compared with the embodiments shown in Figures 18 to 20. In Figures 22 to 24, components similar to those shown in the embodiments of Figures 18 to 20 are indicated by the same reference numerals increased by 200.

[0331] Similar to battery 1300, battery 1500 shown in Figure 24 includes a single cell 600 covered by packaging system 595. In Figure 24, the single cell comprises, from top to bottom:

[0332] -Anode current collector substrate 510

[0333] -Anode layer 520

[0334] - The electrolyte-impregnated insulating layer 531, as described above, can be replaced by an electrolyte material layer.

[0335] - Cathode layer 550, and

[0336] -Cathode current collector substrate 540

[0337] However, battery 1500 differs from 1300 in that, firstly, the current collector substrates 510 and 540 do not protrude from other layers in the longitudinal direction XX. Furthermore, battery 1500 is equipped with two additional components, namely electrical connection elements 560 and 570, which are disposed on opposite front surfaces of battery 600. Each of these connection elements, especially those identical to each other, typically has a thickness of less than 300 μm, preferably less than 100 μm.

[0338] Each connecting element is preferably made of a conductive material (typically a metal). This includes, in particular, aluminum, copper, or stainless steel. To improve its solderability, these materials may be coated with a thin layer of gold, nickel, or tin.

[0339] The connection means between connection element 560 and current collector 510 on one side and connection element 570 and current collector 540 on the other side will now be described. These connection means are typically formed of conductive adhesive, particularly graphite adhesive, or adhesive filled with copper or aluminum nanoparticles. The typical thickness of the conductive adhesive layer, not shown in Figure 24, is 0.1 micrometers to several micrometers. Alternatively, this conductive adhesive layer can be replaced by soldering.

[0340] As shown in Figure 22, each connecting element 560, 570 is positioned offset in the longitudinal direction on its respective current collector substrate 510, 540. More precisely, the first ends of these connecting elements define tabs 562, 572 protruding in two opposite directions from the longitudinal surfaces F4 and F6 of the cell. Furthermore, at their ends opposite these tabs, each connecting element is positioned rearward from the cell unit, thereby defining corresponding shoulders 564, 574. This arrangement is an advantageous optional feature, making it easy to visually distinguish the connecting elements from other layers.

[0341] The battery 600 equipped with the connecting element is then covered using an encapsulation system. As shown in FIG23, the longitudinal and lateral surfaces of the battery, as well as shoulders 564 and 574, are first partially covered by the encapsulation system 595'. Referring to FIG24, the front surface of the connecting element is then covered, forming the final encapsulation system 595. Finally, a cut is made, not shown in the figure, but similar to cuts 392 and 393 in FIG19. This exposes the edges 566 and 576 of the connecting element. In this example, the encapsulation system is provided in two consecutive steps; it should be understood that it can also be provided in a single step.

[0342] Figure 25 illustrates an alternative embodiment of the embodiments shown in Figures 22 to 24. In Figure 25, components similar to those shown in Figures 22 to 24 are indicated by the same reference numerals increased by 100. As described above, electrical connection elements 560 and 570 protrude from the battery in two opposite directions in the longitudinal direction. Conversely, electrical connection elements 660 and 670 of the battery 1600, as shown in Figure 25, both protrude in the same direction, i.e., to the right in this figure.

[0343] The embodiments shown in Figures 18-20 and 22-25 have specific advantages. More specifically, they relate to "single-cell" type batteries, which are well-suited for certain applications requiring high energy density. Furthermore, such a structure facilitates packaging operations.

[0344] Finally, the embodiments shown in Figures 22 to 25 involve the use of electrical connection elements that also have specific advantages. Therefore, localized deposition on the substrate is unnecessary, allowing the entire surface of this current collector substrate to be coated with electrode material. Due to the lateral offset generated at the connection elements, localized deposition on the current collector is no longer required, particularly for the embodiments in Figures 18, 19, and 20.

[0345] Referring to the embodiments in Figures 22 to 25, the present invention further relates to a battery (1500) comprising a stack of at least one cell, particularly a single cell (600), each cell sequentially comprising an anode current collector substrate (510), an anode layer (520), at least one electrolyte material layer (530) and / or at least one electrolyte-impregnated separator layer (531), a cathode layer (550), and a cathode current collector substrate (540).

[0346] The stack and the battery have six sides, namely

[0347] - Two opposing positive surfaces (F1, F2), typically parallel to the layer and the current collector substrate.

[0348] - Two opposing longitudinal surfaces (F4, F6), comprising the anode connection region and the cathode connection region, respectively.

[0349] - Two opposing lateral surfaces,

[0350] The battery is characterized in that it further includes two electrical connection elements (560, 570) disposed on opposite front surfaces of the stack, with the first end (562, 572) of each electrical connection element extending beyond the corresponding longitudinal surface (F4, F6) of the stack in the longitudinal direction (XX).

[0351] Other features of the battery according to other purposes of the invention:

[0352] - The first end (562) of the connecting element (560) protrudes in a first direction beyond the first longitudinal surface (F4), while the first end (572) of the other connecting element (570) protrudes in the opposite direction from another longitudinal surface (F6).

[0353] - The first ends (662, 672) of the two connecting elements (660, 670) protrude in the same direction, exceeding one and the same longitudinal surface (F4).

[0354] - Each electrical connection element is connected to a corresponding current collector substrate, particularly by means of conductive adhesive.

[0355] - The current collector substrate, as well as the anode, cathode, and isolation layers, do not extend beyond the vertical plane of the stack.

[0356] - Opposite to the protruding end, each electrical connection element is defined by the stacked shoulder (564, 574).

[0357] The method of the present invention is particularly suitable for manufacturing all-solid-state batteries, i.e., batteries whose electrodes and electrolytes are solid and do not include a liquid phase, or even batteries immersed in a solid phase.

[0358] The method of the present invention is particularly suitable for manufacturing quasi-solid-state batteries comprising at least one separator layer 31 impregnated with an electrolyte. The separator layer is preferably a porous inorganic layer having:

[0359] - Porosity, preferably mesoporous, greater than 30%, more preferably 35% to 50%, and even more preferably 40% to 50%.

[0360] -Average diameter of the hole D 50 Less than 50nm.

[0361] The thickness of the separator layer is preferably less than 10 μm, more preferably between 2.5 μm and 4.5 μm, thereby reducing the final thickness of the battery without compromising its performance. The pores of the separator layer are impregnated with an electrolyte, preferably a lithium-ion carrying phase (e.g., a liquid electrolyte) or an ionic liquid containing a lithium salt. The liquid in the pores, especially the mesopores, is "nano-confined" or "nano-trapped," preventing further escape. It is bound by a phenomenon known here as "mesopore structure absorption" (which does not appear to be described in the literature related to lithium-ion batteries) and cannot escape, even when the battery is placed in a vacuum. This type of battery is therefore considered a quasi-solid-state battery.

[0362] The battery described in this invention can be a lithium-ion microcell, a lithium-ion mini-cell, or a high-power lithium-ion battery. In particular, the battery can be designed and sized to have a capacity of less than or equal to about 1 mA h (commonly referred to as a "microcell"), a power of greater than about 1 mA h to about 1 Ah (commonly referred to as a "mini-cell"), or a capacity of greater than about 1 Ah (commonly referred to as a "high-power battery"). Typically, microcells are designed to be compatible with methods of manufacturing microelectronic products.

[0363] We can produce every type of battery in these three power ranges:

[0364] - A layer of "solid" type, i.e., a liquid or paste phase without impregnation (the liquid or paste phase may be a lithium-ion conductive medium capable of acting as an electrolyte).

[0365] - Or a layer of mesoporous "solid" type, impregnated typically with a liquid or paste phase of a lithium-ion conductive medium, which spontaneously permeates through the layer and no longer emerges from it; therefore, this layer can be considered quasi-solid.

[0366] -Or have impregnated porous layers (i.e., layers with open-cell networks, which can be impregnated with liquid or paste phases to give these layers wet properties).

Claims

1. A battery (1000), comprising at least one cell (100). Each cell (100) sequentially includes an anode current collector substrate (10), an anode layer (20), at least one electrolyte material layer (30) and / or at least one electrolyte-impregnated separator layer (31), a cathode layer (50) and a cathode current collector substrate (40). in, In the case where the battery comprises multiple cell units (100, 100', 100''), the cell units (100, 100', 100'') are stacked one below the other, i.e., according to the positive direction (ZZ) relative to the main plane of the battery, thereby: - The anode current collector substrate (10) is the anode current collector substrate (10) of two adjacent cell units (100, 100', 100''), and thus - The cathode current collector substrate (40) is the cathode current collector substrate (40) of two adjacent cell units (100, 100', 100''). The at least one cell or the plurality of cell units (100, 100', 100'') define a stack (I). The stack (I) and the battery have six sides, namely - Two opposing so-called positive surfaces (F1, F2). - Two opposing lateral surfaces (F3, F5), and - Two opposing longitudinal planes (F4, F6). It should be understood that the first longitudinal surface (F6) of the battery includes at least one anode connection region (1002), and the second longitudinal surface (F4) of the battery includes at least one cathode connection region (1006), wherein the anode connection region (1002) and the cathode connection region (1006) are laterally opposite each other. Its features are: - In the first longitudinal direction (XX') of the battery, each anode current collector substrate (10) protrudes from each anode layer (20), each electrolyte material layer (30) or electrolyte-impregnated separator layer (31), each cathode layer (50) and each cathode current collector substrate layer (40), and - In the second longitudinal direction (XX'') of the battery opposite to the first longitudinal direction (XX'), each cathode current collector substrate (40) protrudes from each anode layer (20), each electrolyte material layer (30) or electrolyte-impregnated isolation layer (31), each cathode layer (50) and each anode current collector substrate layer (10).

2. The battery according to claim 1, characterized in that, Each anode current collector substrate (10) is located from the first end face (DY). a The first end face is defined by the first longitudinal end of each anode layer, each electrolyte material layer or isolation layer, each cathode layer and each cathode current collector substrate layer.

3. The battery according to claim 1, characterized in that, Each cathode current collector substrate (40) is located from the second end face (DY' a The second end face is defined by the second longitudinal end of each anode layer, each electrolyte material layer or isolation layer, each cathode layer and each anode current collector substrate layer.

4. The battery according to claim 1, characterized in that, The battery includes an encapsulation system that covers at least a portion of the outer periphery of the stack (I), the encapsulation system including at least one impermeable cover layer having a water vapor transmission rate (WVTR) of less than 10. -5 g / m 2 .d, the encapsulation system is in direct contact with at least the electrolyte material layer (30) and / or the electrolyte-impregnated isolation layer (31) at each longitudinal surface (F4, F6).

5. The battery according to claim 4, characterized in that, The packaging system also makes direct contact with the anode layer, cathode layer and non-protruding current collector substrate at each longitudinal surface (F4, F6).

6. The battery according to claim 4, characterized in that, The packaging system is electrically insulating, and the conductivity of the packaging system is less than 10. e-11 Sm -1 .

7. The battery according to claim 4, characterized in that, The packaging system (95) covers the front face (F1, F2), side face (F3, F5), and at least part of the longitudinal face (F4, F6) of the stack, thereby - Each anode edge (1002') of each anode current collector substrate (10) protruding from each anode layer (20), each electrolyte material layer (30) or separator layer (31), each cathode layer (50) and each cathode current collector substrate layer (40) in the first longitudinal direction (XX') of the battery is flush with the first longitudinal surface (F6), and thus - Only in the second longitudinal direction (XX'') of the battery, each cathode edge (1006') of each cathode current collector substrate (40) protruding from each anode layer (20), each electrolyte material layer (30) or separator layer (31), each cathode layer (50) and each anode current collector substrate layer (10) is flush with the second longitudinal surface (F4), which is opposite to and parallel to the first longitudinal surface (F6). It should be understood that each anode edge (1002') defines an anode connection region (1002), and each cathode edge (1006') defines a cathode connection region (1006).

8. The battery according to claim 4, characterized in that, The packaging system (95) includes: - At least an impermeable coating layer, said impermeable coating layer being made of ceramic material and / or glass with a melting point below 600°C, or - A capping layer, selected from parylene, parylene F, polyimide, epoxy resin, silicone resin, polyamide, sol-gel silica, organosilica, and / or mixtures thereof, is deposited on at least the periphery of the partially stacked (I). - At least an impermeable capping layer, said impermeable capping layer being made of ceramic material and / or glass with a melting point below 600°C, deposited on the capping layer. or - A capping layer, composed of an electrically insulating material, is deposited on at least the periphery of the partial stack (I) using atomic layer deposition. - At least an impermeable capping layer, said impermeable capping layer being made of ceramic material and / or glass with a melting point below 600°C, deposited on at least the periphery of the partial stack (I), It should be understood that when a covering layer composed of electrically insulating material is present, - The sequence of the capping layer and the impermeable capping layer is repeated z times, where z≥1, and is deposited on the outer periphery of at least the impermeable capping layer, and - The final layer of the encapsulation system is an impermeable cover layer made of ceramic material and / or glass with a melting point below 600°C. or - A first capping layer, selected from parylene, parylene F, polyimide, epoxy resin, silicone resin, polyamide, sol-gel silica, organosilica, and / or mixtures thereof, is deposited on at least the periphery of the partial stack (I). - A second capping layer, composed of an electrically insulating material, is deposited on at least the periphery of the partial stack (I) or on the first capping layer by atomic layer deposition. - At least a third impermeable capping layer, said third impermeable capping layer being made of ceramic material and / or glass with a melting point below 600°C, deposited on at least the periphery of the partial stack (I) or on the first capping layer, It should be understood that when a second overlay layer exists, - The sequence of the second and third impermeable capping layers is repeated z times, where z≥1, and is deposited on the periphery of the third impermeable capping layer. - The final layer of the encapsulation system is an impermeable cover layer made of ceramic material and / or glass with a melting point below 600°C.

9. The battery according to claim 1, characterized in that, At least the anode connection area (1002) is covered by the anode contact element (97'). Furthermore, it is characterized in that at least the cathode connection area (1006) is covered by the cathode contact element (97''). It should be understood that the anode contact element (97') and the cathode contact element (97'') are capable of creating electrical contact between the stack (I) and the external conductive element.

10. The battery according to claim 9, characterized in that, The first longitudinal surface (F6), including at least the anode connection area (1002), is covered by the anode contact element (97').

11. The battery according to claim 9, characterized in that, Each of the anode contact element (97') and the cathode contact element (97'') includes: - A first electrical connection layer is located on at least the anode connection region (1002) and at least the cathode connection region (1006). The first electrical connection layer includes a material filled with conductive particles. - A second electrical connection layer, comprising a metal foil disposed on a first material layer filled with conductive particles.

12. The battery according to any one of claims 1-11, characterized in that, A first longitudinal surface (F6) including at least one anode connection region (1002) and a first end surface (DY) defined by the first longitudinal ends of each anode layer (20), each electrolyte material layer (30) and / or isolation layer (31), each cathode layer (50) and each cathode current collector substrate layer (40). a The minimum distance (Dca) between them is between 0.01 mm and 0.5 mm, and / or is characterized by, The second longitudinal surface (F4) including at least one cathode connection region (1006) and the second end surface (DY') defined by the second longitudinal ends of each anode layer (20), each electrolyte material layer (30) and / or isolation layer (31), each cathode layer (50) and each anode current collector substrate layer (10) a The minimum distance (Dcc) between them is between 0.01 mm and 0.5 mm.

13. A method for manufacturing at least one battery (1000), Each battery includes at least one cell (100). Each cell (100) sequentially includes an anode current collector substrate (10), an anode layer (20), at least one electrolyte material layer (30) and / or at least one electrolyte-impregnated separator layer (31), a cathode layer (50) and a cathode current collector substrate (40). in, In the case where the battery (1000) comprises multiple cell units (100, 100', 100''), the cell units (100, 100', 100'') are stacked one below the other, i.e., according to the positive direction (ZZ) relative to the main plane of the battery, thereby: - The anode current collector substrate (10) is the anode current collector substrate (10) of two adjacent cell units (100, 100'), and thus - The cathode current collector substrate (40) is the cathode current collector substrate (40) of two adjacent cell units (100, 100'). The at least one cell (100) or the plurality of cell units (100, 100', 100'') defines a stack (I). The stack (I) and the battery (1000) have six sides, namely - Two opposing so-called positive surfaces (F1, F2). - Two opposing lateral surfaces (F3, F5), and - Two opposing longitudinal planes (F4, F6). It should be understood that the first longitudinal surface (F6) of the battery includes at least one anode connection region (1002), and the second longitudinal surface (F4) of the battery includes at least one cathode connection region (1006), wherein the anode connection region (1002) and the cathode connection region (1006) are laterally opposite each other. thereby - In the first longitudinal direction (XX') of the battery, each anode current collector substrate (10) protrudes from each anode layer (20), each electrolyte material layer (30) or electrolyte-impregnated separator layer (31), each cathode layer (50) and each cathode current collector substrate layer (40), and - In the second longitudinal direction (XX'') of the battery, opposite to the first longitudinal direction (XX'), each cathode current collector substrate (40) protrudes from each anode layer (20), each electrolyte material layer (30) or electrolyte-impregnated isolation layer (31), each cathode layer (50) and each anode current collector substrate layer (10), The manufacturing method includes: (i) Provide at least one anode current collector substrate foil (10), hereinafter referred to as anode foil (2e), the anode current collector substrate foil (10) having a groove (80), an uncoated area (82) and an area (81) coated with an anode layer (20). (ii) Provide at least one cathode current collector substrate foil (40), hereinafter referred to as cathode foil (5e), ​​the cathode current collector substrate foil (40) having a groove (70), an uncoated area (72) and an area (71) coated with a cathode layer (50). (iii) Producing at least one anode foil (2e) having a groove (80), an uncoated area (82), and a coated area (81) and at least one cathode foil (5e) having a groove (70), an uncoated area (72), and a coated area (71) in alternating stacks (I) to obtain at least one cell, which sequentially comprises an anode current collector substrate (10), an anode layer (20), at least one electrolyte material layer (30) or an insulating layer (31), a cathode layer (50), and a cathode current collector substrate (40), and thereby - In the first longitudinal direction (XX') of the battery, each anode current collector substrate (10) protrudes from each anode layer (20), each electrolyte material layer (30) and / or separator layer (31), each cathode layer (50) and each cathode current collector substrate layer (40), and - In the second longitudinal direction (XX'') of the battery, opposite to the first longitudinal direction (XX'), each cathode current collector substrate (40) protrudes from each anode layer (20), each electrolyte material layer (31) and / or insulating layer (31), each cathode layer (50) and each anode current collector substrate layer (10), (iv) The alternating foil stacks (I) obtained in the heat treatment and / or mechanical compression step (iii) form a stable stack. (vii) Create a second pair of cuts (DYn, DY'n), exposing - An anode edge (1002') of each anode current collector substrate (10) protruding from each anode layer (20), each electrolyte material layer (30) or separator layer (31), each cathode layer (50), and each cathode current collector substrate layer (40) in the first longitudinal direction (XX') of the battery, wherein each anode edge (1002') defines at least one anode connection region (1002), and - A cathode edge (1006') of each cathode current collector substrate (40) protruding from each anode layer (20), each electrolyte material layer (30) or separator layer (31), each cathode layer (50) and each anode current collector substrate layer (10) in the second longitudinal direction (XX'') of the battery, each cathode edge (1006') defines at least one cathode connection region (1006).

14. The method according to claim 13, characterized in that, Including step (v): manufacturing the first pair of cuts (DXn, DX'n), allowing a given row (L) of the battery (1000) formed by the stable stack to be... n ) and at least one other row (L) of battery (1000) n-1 L n+1 The second pair of cuts (DYn, DY'n) can separate the rows (L) of the battery (1000). n The given cell formed is separate from at least one other cell.

15. The method according to claim 13, characterized in that, The step (vi) involves using the stable stack obtained in the lithium-ion-carrying phase impregnation step (iv) to impregnate the isolation layer (31) with an electrolyte.

16. The method according to claim 14, characterized in that, Including step (vi): using the lithium-ion-carrying phase impregnation step (v) to obtain the row (L) of the battery (1000). n ), thereby impregnating the isolation layer (31) with electrolyte.

17. The method according to claim 13, characterized in that, After step (vi), Before step (vii), Step (viii) involves encapsulating a robust stack or battery (1000) rows (L) n ), wherein the packaging system (95) covers the stack or battery (1000) rows (L n At least a portion of the periphery, thus Each anode edge (1002') of each anode current collector substrate (10) protruding from each anode layer (20), each electrolyte material layer (30) or separator layer (31), each cathode layer (50) and each cathode current collector substrate layer (40) in the first longitudinal direction (XX') of the battery is flush with the first longitudinal surface (F6, FF6), and thus Only in the second longitudinal direction (XX'') of the battery, each cathode edge (1006') of each cathode current collector substrate (40) protruding from each anode layer (20), each electrolyte material layer (30) or separator layer (31), each cathode layer (50) and each anode current collector substrate layer (10) is flush with the second longitudinal surface (F4, FF4). It should be understood that each anode edge (1002') defines an anode connection region (1002), and each cathode edge (1006') defines a cathode connection region (1006). The packaging system (95) includes one, two, or none of the following: - Deposited on at least a portion of the outer periphery of the stack (I) or at least a portion of the cell (1000) rows (L) n At least one first capping layer and a second capping layer on the outer periphery, composed of an electrically insulating material, are deposited by atomic layer deposition. - In the stack (I) or battery (1000) row (L) n At least part of the periphery, -or on the first covering layer, and - At least one third impermeable capping layer, the third capping layer being made of ceramic material and / or glass with a melting point below 600°C, deposited on the stack (I) or cell (1000) rows (L) n On at least part of the outer periphery or on the first covering layer, It should be understood that when a second cover layer is present, the sequence of the at least one second cover layer and the at least one third cover layer is repeated z times, where z≥1, and is deposited on the outer periphery of the at least third cover layer. The last layer of the encapsulation system is an impermeable cover layer made of ceramic material and / or glass with a melting point below 600°C.

18. The method according to claim 17, characterized in that, Including step (v): manufacturing the first pair of cuts (DXn, DX'n), allowing a given row (L) of the battery (1000) formed by the stable stack to be... n ) and at least one other row (L) of battery (1000) n-1 L n+1 The second pair of cuts (DYn, DY'n) can separate the rows (L) of the battery (1000). n The given cell formed is separate from at least one other cell.

19. The method according to claim 17, characterized in that, The step (vi) involves using the stable stack obtained in the lithium-ion-carrying phase impregnation step (iv) to impregnate the isolation layer (31) with an electrolyte.

20. The method according to claim 18, characterized in that, Including step (vi): using the lithium-ion-carrying phase impregnation step (v) to obtain the row (L) of the battery (1000). n ), thereby impregnating the isolation layer (31) with electrolyte.

21. The method according to claim 18, characterized in that, Step (viii) is performed after step (v) and before step (vii).

22. The method according to claim 17, characterized in that, In a robustly packaged stack or battery (1000) row (L) n In step (viii), stack (I) or battery (1000) rows (L) n At least part of the outer periphery of the ) is covered by the encapsulation system (95).

23. The method according to claim 22, characterized in that, In step (viii), the stacked front faces (F1, F2) or battery rows (L) n The front face (FF1, FF2) and side face (F3, F5, FF3, FF5) and at least part of the longitudinal face (F4, F6, FF4, FF6) of the package system (95) are covered by the package system (95).

24. The method according to any one of claims 13-20 and 21-23, characterized in that, After step (vii), at least the anode connection area (1002) is covered by an anode contact element (97') capable of creating electrical contact between the stack (I) and the external conductive element. The feature is that at least the cathode connection region (1006) is covered by a cathode contact element (97'') capable of generating electrical contact between the stack (I) and external conductive elements. The fabrication of the anode contact element (97') and the cathode contact element (97'') includes: - A first electrical connection layer made of a material filled with conductive particles is deposited on at least the anode connection region (1002) and at least the cathode connection region (1006), and, - A second electrical connection layer is deposited on the first layer, the second electrical connection layer comprising a metal foil disposed on the first electrical connection layer.

25. The method according to claim 24, characterized in that, A first longitudinal surface (F6) including at least an anode connection area (1002) is covered by an anode contact element (97') capable of generating electrical contact between the stack (I) and external conductive elements.

26. The method according to claim 24, characterized in that, The second longitudinal surface (F4), which includes at least a cathode connection area (1006), is covered by a cathode contact element (97'') capable of generating electrical contact between the stack (I) and external conductive elements.

27. The method according to any one of claims 14, 18, 20, and 21, characterized in that, The cutting performed in step (v) and / or step (vii) is carried out by laser ablation.

28. The method according to any one of claims 13, 15-17, 19, 22 and 23, characterized in that, The cutting performed in step (vii) is carried out by laser ablation.

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