Method and apparatus for manufacturing battery cells

Abstract

The present invention relates to a method and apparatus for assembling battery cells, the method comprising forming electrode layers in a paste state on a conductive carrier, the electrode layers comprising a mixture of an ionically conductive liquid electrolyte, a monomer or polymer mixture and a polymerization or cross-linking initiator for the monomer or polymer mixture, exposing the electrode layers to radiation to initiate their solidification, and then contacting them with a separator layer in a liquid state before their respective solidification is complete, thereby obtaining solid electrolyte battery cells having properties approaching those of liquid electrolyte battery cells.

Description

Invention Field

[0001] This invention relates to a method and apparatus for manufacturing battery cells, and by extension, to a battery pack consisting of several cells.

[0002] Each battery or battery pack constitutes an energy storage device. Battery packs can be formed by arranging batteries in parallel and / or series. Each battery contains a positive terminal associated with a current collector and a negative terminal associated with another current collector. The positive and negative terminals are also referred to as "cathode" and "anode." The current collectors constitute the battery's electrical terminals.

[0003] Each electrode comprises an electrode material that is capable of interacting with and retaining a given ion type, a so-called "active" electrode material, an electronic percolant or electronic conductor additive such as carbon black that provides an electronic channel from the current collector to the active material of the associated electrode, and typically, a binder that can mechanically fix the electrode and adhere the material to the current collector.

[0004] This invention particularly relates to lithium-ion, sodium-ion, or lithium sulfide type batteries.

[0005] It specifically relates to batteries that combine lithium-containing cathode materials such as NMC (nickel manganese cobalt), NCA (nickel cobalt aluminum) or Li2S (lithium sulfide), and anode materials based on carbon, silicon dioxide and silicon, transition metals or transition metal alloys combined with carbon, or composite materials of transition metals and carbon forming alloys.

[0006] More generally, the present invention also relates to batteries of the lithium metal, sodium metal, aluminum metal and magnesium metal types, and apparatus for manufacturing them.

[0007] This invention can be used to manufacture thin battery cells with a significant surface area and a solid electrolyte formed by solidifying a liquid electrolyte. It is particularly suitable for the continuous manufacture of batteries of a fixed width and extremely long length using a roll-to-roll continuous method. Batteries manufactured according to this invention can be cut, combined in series (e.g., by stacking), and / or combined in parallel. Without limitation, this invention can also be used to manufacture battery packs for use in electric vehicles, power tools, portable communication devices, drones, or even stationary facilities for storing electrical energy.

[0008] The device of the present invention can also be used to manufacture solid electrolyte supercapacitor cells obtained by solidifying a liquid electrolyte.

[0009] Related technical descriptions

[0010] Liquid electrolyte battery packs are known.

[0011] In these batteries, a liquid electrolyte provides ion conduction between and within the anode and cathode electrodes. An electrically insulating membrane is placed between the anode and cathode electrodes. This allows ion movement while preventing direct electrical contact between the cathode and anode.

[0012] Liquid electrolyte battery packs are equipped with a sealed casing to form a reservoir that can hold the electrolyte. Therefore, one of the difficulties in manufacturing these batteries involves the sealing of the casing and the achievement of its sealing.

[0013] Another challenge involves filling the battery with a liquid electrolyte, which has proven to be a dangerous, flammable, and polluting product.

[0014] Liquid electrolyte batteries can present other problems, including leakage, and the risk of the liquid electrolyte catching fire when the battery temperature rises.

[0015] Finally, the liquid electrolytes used in batteries have often proven to be harmful to health because electrolytic vapors can affect the respiratory tract. The toxicity of the electrolyte is a drawback both during battery manufacturing and recycling.

[0016] Solid electrolyte (more specifically, solidified electrolyte) battery packs that perform the same function as the liquid electrolyte in a liquid electrolyte battery pack are also known.

[0017] The manufacture of this type of battery typically involves fabricating a positive electrode on one current collector substrate, a negative electrode on another current collector substrate, and a separator layer formed of a solid electrolyte, which are then assembled into a battery pack. The fabrication of various components, particularly the solid (gel or polymer) electrolyte layer, can be achieved through cross-linking or by polymerization of an initially liquid electrolyte under ultraviolet radiation.

[0018] Similarly, positive and negative electrodes can be obtained by drying the solvent from the electrode ink, crosslinking the polymer under ultraviolet radiation, or even by heating.

[0019] For an example of this type of battery pack, see, for example, document EP 3,341,987.

[0020] Document US 2006 / 0016549 describes a method and apparatus for laminating electrode sheets onto a conductive support film that can form a current collector. This lamination is performed by heating the support film and, possibly, the electrode sheets, to soften them. After heating, the electrode sheets and the support film are assembled by passing them between pressure rollers.

[0021] Document US 2005 / 0236732 describes a method and apparatus for extruding a composite film constituting the positive electrode and calendering the film to achieve a desired thickness. The composite film comprises a mixture of active electrode material, an electronically conductive additive, and an ion-conducting polymer electrolyte. In solid electrolyte battery packs, the solid electrolyte layer separating the positive and negative electrodes has a dual function. Its primary function is to ensure ionic conductivity between electrodes of opposite polarity during charging or discharging of the battery pack. Another function is to separate electrodes of opposite polarity, thereby preventing electronic conductivity between electrodes that could short-circuit the battery. The second function, electrical insulation, is a function of the electrical separator in liquid electrolyte batteries (where the electrolyte layer is electron-permeable).

[0022] However, every battery pack has internal resistance, and it is desirable to minimize internal resistance as much as possible to increase its yield.

[0023] In addition, there is a desire to reduce the manufacturing cost of battery packs while maintaining or improving their reliability and safety levels. Invention Overview

[0025] The purpose of this invention is to reduce the internal resistance of solid electrolyte battery packs and to provide an economical method for manufacturing solid electrolyte battery packs with reduced internal resistance compared to conventional battery packs of the same type.

[0026] Therefore, this invention covers a method for manufacturing an energy storage cell in an electrochemical form, comprising the steps of: forming a first half-cell, which includes the following steps a1), a2), and a3): a1) providing a first electrically conducting support; a2) depositing a paste-like cathode layer on the surface of the first electrically conducting support, comprising an active cathode material, a carbonaceous electrically conducting filler, and a first liquid ion conducting electrolyte mixture. a mixture), a first monomer or polymer mixture and a first polymerization or crosslinking initiator for the first monomer or polymer mixture; a3) initiating the curing of the cathode layer by means of a first radiation-exposed paste state cathode layer suitable for the first polymerization or crosslinking initiator for the first monomer mixture; forming a second half cell comprising the steps b1), b2), and b3): b1) providing a second conductive carrier; b2) depositing a paste state anode layer on the surface of the second conductive carrier, comprising an active anode material, a carbonaceous conductive filler, a second liquid ion-conducting electrolyte mixture, a second monomer or polymer mixture and a second polymerization or crosslinking initiator for the second monomer or polymer mixture; b3) initiating the curing of the anode layer by means of a second radiation-exposed paste state anode layer suitable for the second polymerization or crosslinking initiator for the second monomer mixture; performing at least one of the steps a4), b4), and c4): a4) depositing and exposing a first separation layer formed of a liquid first separation mixture on the exposed cathode layer before the first exposed electrode layer is fully cured, the first separation mixture comprising a first ion-conducting separation liquid electrolyte mixture. (mixture), a first separating monomer or polymer mixture, and a first polymerization or crosslinking initiator for the first separating monomer or polymer mixture;b4) Depositing and exposing a second separator layer formed of a liquid second separator mixture on the exposed anode layer before the exposed anode layer is fully cured, the second separator mixture comprising a second ion-conducting separator liquid electrolyte mixture, a second separator monomer or polymer mixture, and a second polymerization or crosslinking initiator for the second separator monomer or polymer mixture; c4) Depositing and exposing a third separator layer formed of a liquid third separator mixture on an electrically insulating grid film, the third separator mixture comprising a third ion-conducting separator liquid electrolyte mixture, a third separator monomer or polymer mixture, and a third polymerization or crosslinking initiator for the third separator monomer or polymer mixture; wherein the exposure for steps a4), b4), and c4) is carried out by means of a third radiation suitable for the respective separator monomer or polymer mixture and suitable for initiating the curing of the first, second, and third separator layers; by inserting at least one from steps a4), b4), b4), c4) between the two half cells. Assemble the first and second half-cells using the separator layers c) and c4), wherein the assembly includes one of the following steps d1), d2), d3), and d4): d1) bringing the exposed first separator layer into direct contact with the exposed second separator layer; d2) bringing the exposed first separator layer into direct contact with the exposed anode layer; d3) bringing the exposed second separator layer into direct contact with the exposed cathode layer; and d4) encapsulating the third exposed separator layer between the exposed cathode layer and the exposed anode layer, wherein in steps d1), d2), d3), and d4), the curing of the respective contacting layers is incomplete.

[0027] The inventors began by observing that the ionic conduction between the positive and negative electrodes was imperfect through a separator layer formed of a solid electrolyte (which mechanically and electrically separates the positive and negative electrodes from each other and is hereby referred to as the separator layer).

[0028] The inventors also observed insufficient ionic conductivity between active electrode materials that are conventionally placed in sheet form and in contact with the electrolyte.

[0029] The present invention also aims to provide a method for manufacturing a battery pack that improves the interface between the electrode and the separator, the interface between the active material of the electrode layer and the electrolyte, and the ionic conductivity within the active material and the separator.

[0030] Therefore, one objective of the present invention is to obtain a solid-state battery pack having ionic conductivity comparable to that of a liquid electrolyte battery.

[0031] The present invention therefore aims to obtain a battery having a separator layer containing a solid electrolyte, the electronic and ionic conductivity of which is comparable to that of a battery using a liquid electrolyte.

[0032] The present invention also aims to improve ionic conduction from one electrode through a separator layer to an electrode of opposite sign, while avoiding any electronic conduction.

[0033] The goal of this invention is to propose an "all-solid-state" battery, which means a battery without liquid electrolyte, with greatly improved safety, especially in terms of sealing, fire risk and health risk.

[0034] Battery safety is ensured at any point during its manufacturing, use, lifespan, and end-of-life period for recycling.

[0035] Another objective of this invention is to provide a method and apparatus for manufacturing battery packs, which continuously and automatically manufactures battery packs while reducing their manufacturing costs.

[0036] The present invention also aims to provide a method for manufacturing a battery pack with improved capacity per unit mass, wherein the electrodes do not have adhesives, particularly not "PVDF" (polyvinylidene fluoride) type adhesives.

[0037] Another objective of this invention is to provide a method for manufacturing battery packs, particularly by stacking solid electrolyte batteries without the need for external connecting chains. Finally, an objective of this invention is to provide an apparatus for manufacturing solid electrolyte battery packs. Invention Details

[0039] This invention implements a method to ensure excellent contact interfaces between one side of the cathode layer and the separator layer, and between the other side of the anode layer and the separator layer, and between sublayers that may be combined to form the separator layer. Furthermore, excellent ionic conductivity is ensured in the anode and cathode layers because the active cathode and anode materials and the carbonaceous conductive filler have excellent contact with the electrolyte in the cathode and anode layers. In fact, the fact that the active materials and carbonaceous conductive filler are dispersed in a liquid ionic conductive electrolyte mixture during the formation of the electrode layers not only ensures close contact with the electrolyte but also ensures a large contact surface area with the electrolyte, and these characteristics are maintained during the curing process of the electrode layers.

[0040] The method of the present invention can be implemented by forming a separator layer made of an electrolyte without active material on only the cathode layer, on only the anode layer, or on both the anode layer and the cathode layer.

[0041] To distinguish them, the separator layer is called the "first separator layer" when it is deposited on the cathode layer, and the "second separator layer" when it is deposited on the anode layer.

[0042] When both the first and second separator layers are present, the first and second half-cells are assembled by bringing the two layers into close contact.

[0043] When the first separator layer is formed only on the cathode layer of the first half-cell, the half-cell is assembled by bringing the first separator layer into contact with the anode layer of the second half-cell.

[0044] Conversely, when the second separator layer is formed only on the anode layer of the second half-cell, the half-cell is assembled by bringing the second separator layer into contact with the cathode layer of the first half-cell.

[0045] In all cases, as described again later, the layers placed in contact for the assembly of the half-cell are placed in contact before they are fully cured to achieve a certain degree of interpenetration of the materials and close contact between the layers.

[0046] Unless otherwise stated, the remainder of the specification relates to embodiments in which each half-cell comprises an electrolyte surface layer of inactive material, wherein this does not prejudge the possibility of selecting only one of the first and second electrolyte layers of inactive material.

[0047] Furthermore, the separator layer obtained at the end of the manufacturing process extends from the cathode layer to the anode layer and is not permeable to electrons but may have ionic conductivity.

[0048] The first and second carriers form the current collectors of the first and second half-cells, respectively, due to their electrical conductive properties. In this method, the objective of steps a2 and a3 is to fabricate the positive electrode (cathode) on the first conductive carrier. The function of the first conductive carrier is to form the current collector of the positive electrode of the battery pack. It may contain one or more layers of conductive material. These conductive materials may be selected from metals, conductive polymers, and woven or nonwoven carbon fiber films. Among the available metals, examples include copper, aluminum, stainless steel, and nickel. The same applies to the second conductive carrier, which is used to collect current for the negative electrode (anode) formed in steps b2 and b3. The first and second conductive carriers may be supplied, in particular, in the form of strips unwound from rollers. This aspect will be described in more detail below.

[0049] Similarly, it is not excluded that the method may be implemented by first and second conductive carriers in the form of sheets or plates, and may constitute an alternative to the roll-to-roll method described below.

[0050] Regarding operations a1 and b1, cathode and anode layers, containing active cathode material for forming the positive electrode and active anode material for forming the negative electrode, respectively, are deposited on a conductive carrier in a paste-like form similar to ink. This consistency is attributed to the solid particle content of the cathode and anode layers.

[0051] These layers are more precisely composed of a mixture containing: an active electrode material (cathode or anode, as applicable), a carbonaceous conductive additive (such as carbon black, carbon nanotubes or carbon nanofibers, graphene or graphene oxide), and a curable liquid with ionic conductivity, such as a mixture containing an ionicly conductive liquid electrolyte mixture, a monomer or polymer mixture, and a first polymerization or crosslinking initiator for the monomer or polymer mixture. This mixture can be considered a curable electrolyte mixture, or more simply, a curable electrolyte. These mixtures (liquid, semi-liquid, or paste, generally considered to be liquid-like) achieve excellent cohesion between their components to obtain a solid layer with excellent ionic conductivity after curing by polymerization or crosslinking of the monomer or polymer mixture.

[0052] It is possible to use curable liquid electrolytes with different compositions for the cathode layer, anode layer, and separator layer, for example, to optimize the individual functions of each layer.

[0053] Alternatively, the same curable liquid electrolyte, except for any additives it may contain, can be used in all operations of the method, such that the same curable liquid electrolyte is used to form the cathode layer, anode layer, and separator layer.

[0054] Using the same curable liquid electrolyte helps improve compatibility and achieve uniform cross-linking between the contacting layers, makes the manufacturing process easier to adjust, and reduces production costs.

[0055] Simply put, unless otherwise stated, the remainder of the instructions addresses this last case, and this single curable liquid electrolyte is referred to as a "curable liquid electrolyte".

[0056] The first and second mixtures can be prepared in a mixer and preferably under a neutral atmosphere, which means that one or more gases constituting the neutral atmosphere do not chemically interact with the components of the electrode, especially not with its active components.

[0057] The function of conductive additives is to improve electron conduction in the cathode and anode layers. The proportion of conductive additives is preferably less than 20% by mass of the cathode or anode layer under consideration. For example, when carbon black is involved, its content is between 5% and 20%, and when carbon nanotubes, carbon nanofibers, or graphene are involved, its content is between 1% and 5%.

[0058] Ionic conduction is provided by an electrolyte that may contain an ion-conducting salt.

[0059] In addition to its ionic conductivity within the active material, the electrolyte, incorporated into the composition of the mixture intended to form the cathode and anode layers, also participates in adhering these layers to the carriers forming the current collector. The electrolyte, still liquid, acts as a wetting agent for both the first and second carriers through its surface tension, thus improving the adhesion of the mixture containing the active material to these carriers. As a result, excellent adhesion of the anode and cathode layers to the current collector is achieved after curing.

[0060] It is appropriate to note that the term "liquid" does not predetermine viscosity and may be used to refer to paste-like or semi-liquid layers. In particular, mixtures used to form cathode and anode layers may have a paste-like consistency due to their solid element content, while electrolytes that do not contain active materials and form separator layers may be more fluid because they are deposited at a lower thickness. The qualifying term "liquid" may apply to each of these layers.

[0061] Therefore, the thickness of the anode layer can be between 50 μm and 300 μm, and the thickness of the separator layer can be between 20 μm and 60 μm.

[0062] The electrode layers—cathode and anode—may consist of a first mixture and a second mixture, each comprising 65 to 80% of electrode active material intended to store and release conductive ions during the charging and discharging cycles of the battery pack, 1 to 20% of carbonaceous conductive additives intended to improve the electronic conductivity in the layers, and 10 to 50% of a curable liquid electrolyte that supplies mobile ions and thus acts as a carrier, wherein the percentages are based on the mass proportion of the electrode layers.

[0063] The liquid electrolyte, which is a curable liquid electrolyte, may consist of a mixture comprising 10 to 30% lithium salt, 50 to 75% solvent (such as carbonate solvent or ether solvent, in which the ions are dissolved), 10 to 30% monomer, and 0.1 to 5% photoinitiator intended to crosslink or polymerize the monomer to cure the electrode layer, wherein the percentages represent the weight proportions based on the curable liquid electrolyte.

[0064] More generally, in this specification, lithium salts may be broadly replaced by alkaline salts of the battery pack electrolyte, which specifically include lithium and sodium salts.

[0065] The monomer can be optionally replaced by a mixture of monomers, which consists of several different monomers to obtain a viscosity more suitable for the intended manufacturing method.

[0066] The curable liquid electrolyte that enters the composition of the first and second mixtures forming the cathode and anode layers may contain, for example, lithium salts of the type of lithium bis(trifluoromethanesulfonyl)imide (LiTFSI), such as electrolyte gels / polymers of lithium bis(trifluoromethanesulfonyl)imide: N-butyl-N-methylpyrrolidone bis(fluorosulfonyl)imide salt sold by Solvionic, or standard liquid electrolytes containing carbonates (1M LiPF6 EC / DMC or EC / DEC).

[0067] Other combinations of lithium salts, such as those with carbonate solvents, ethers, ionic liquids, ionic polymers, or ionic conductive glasses and ceramics, are not excluded.

[0068] The monomer can be, for example, ethoxylated trimethylolpropane triacrylate (ETPTA4).

[0069] Photoinitiators of curable liquid electrolytes, when exposed to radiation, particularly light radiation, initiate the polymerization or crosslinking of monomers or polymers, thereby curing the layer containing the curable liquid electrolyte by forming a polymer gel electrolyte. In the case of monomer polymerization, it involves free radical polymerization.

[0070] This involves, for example, HMPP (2-hydroxy-2-methylpropiophenone) type photoinitiators, such as those sold under the name Darocur 1173, or even 2,2-dimethoxy-2-phenylacetophenone (DMPA).

[0071] Other photoinitiators cannot be ruled out.

[0072] The first mixture used for the cathode layer may contain cathode active materials in powder form, such as NMC (nickel manganese cobalt), NCA (nickel cobalt aluminum), sulfur, or Li2S.

[0073] The curable liquid electrolyte is included in the first mixture at a ratio of 10% to 50% by volume, for example, 20%.

[0074] The proportion of carbonaceous conductive filler may be between 5% and 15% by volume in the mixture, and may specifically include carbon nanotubes, carbon nanofibers and / or carbon black.

[0075] The active powder and conductive filler are mixed with a curable liquid electrolyte.

[0076] The second mixture used for the anode layer may contain, for example, a curable liquid electrolyte and an anode active material such as graphite particles, LTO (lithium titanate), or silicon particles with or without lithium. These particles may be combined with carbonaceous particles, such as nanotubes or carbon nanofibers.

[0077] The curable liquid electrolyte is included in the second mixture at a ratio of 10% to 50% by volume, for example, 20%.

[0078] The proportion of carbonaceous conductive filler may be between 5% and 15% by volume in the second mixture, and may specifically include carbon nanotubes, carbon nanofibers and / or carbon black.

[0079] The active powder and conductive filler are mixed with a curable liquid electrolyte.

[0080] It is appropriate to specify that the method of the present invention can be reversed when it relates to the manufacture of the positive and negative electrodes of a battery.

[0081] In other words, step a2 can be implemented using an active anode material to manufacture a half-cell with a negative electrode, and step b2 can be implemented using an active cathode material to manufacture a half-cell with a positive electrode.

[0082] Advantageously, and due to the presence of a curable electrolyte in the mixture forming the cathode and anode layers, these electrodes can be formed without the use of binder-forming additives that provide mechanical strength for the electrodes. In particular, they do not contain PVDF (polyvinylidene fluoride) type binders typically used in conventional battery packs. This reduces their weight and increases the capacity per unit mass of storage devices using these electrodes, which refers to the electrical energy that can be stored per unit mass. At the same charge capacity, a weight improvement of on the order of 10% can be achieved compared to batteries whose electrodes contain PVDF-type binders.

[0083] The mixture layer is deposited on a conductive substrate when the mixture is liquid or more specifically a paste.

[0084] When implemented using a deposition head of the surface coating head type (dip coating), these layers can be continuously deposited on a conveyor belt of a conductive substrate. It should be noted that other coating techniques using extrusion heads are not excluded.

[0085] The curing of the cathode and anode layers is initiated by exposing them to photoinitiator radiation of the curable liquid electrolyte, which is sensitive to the initiator.

[0086] The radiation can be optical radiation. This includes, for example, ultraviolet (UV) radiation produced by ultraviolet lamps, ultraviolet light-emitting diodes, or ultraviolet laser beams. Optical radiation can also be radiation in the visible or near-infrared spectrum. It should be noted that the function of optical radiation is to initiate curing rather than heating. To avoid any risk of thermal changes in the curable liquid electrolyte, non-heating radiation is actually preferred.

[0087] The wavelength of the selected radiation depends on the photoinitiator contained in the curable liquid electrolyte used in the mixture that forms the anode or cathode layer.

[0088] To ensure good penetration of radiation into the material before curing, it is preferable to have a wavelength between 100 nm and 1600 nm.

[0089] Curing can also be initiated by radiation in the form of an electron beam with high energy penetration extending up to 300 keV, with the dose preferably less than 100 kGray to avoid decomposition of the layer components, especially monomers.

[0090] It is important to understand that the curing rate depends on the composition of the mixture under consideration and the dose of radiation exposed to initiate this curing process; therefore, these parameters must be adjusted to ensure that the layers are in effective contact before they are fully cured.

[0091] The cathode layer is covered by a first curable liquid electrolyte layer that does not contain an active anode or cathode material. Similarly, the anode layer is covered by a second curable liquid electrolyte layer that does not contain an active anode or cathode material.

[0092] As shown above, it is also possible to cover only one of the cathode and anode layers with a liquid electrolyte layer that does not contain active materials and is curable.

[0093] These liquid electrolyte layers are exposed to the radiation that initiates their curing, as included in steps a4 and b4 mentioned above. The electrolyte layers can be deposited using a deposition head similar to those used for depositing cathode and anode layers on the first and second supports.

[0094] The characteristics and size of the deposition head can be adapted to the more or less fluid properties of the deposition material. Due to the absence of active material and carbonaceous particles that might be present in the electrode layers (cathode and possibly anode), the electrolyte without active material is actually more fluid than the mixture used to form the cathode and anode layers. It is possible to adjust the fluidity of the electrolyte without active material as needed—by using correcting additives, such as inorganic fillers to adjust fluidity and make it more pasty.

[0095] Importantly, the deposition of the first electrolyte layer and / or the second electrolyte layer of inactive material occurs after the initiation of the curing of the cathode and anode layers, respectively, but before they are fully cured.

[0096] This feature improves the tight contact and perfect adhesion of the liquid electrolyte layer without active material to the cathode and anode layers below, which contain active material.

[0097] Therefore, the contact quality between these layers helps to improve ionic conductivity between the electrodes and the separator layer formed thereon by the liquid electrolyte layer during the charging or discharging operation of the completed battery pack.

[0098] The method of the present invention can achieve a certain degree of molecular interpenetration at the interface between the electrode layer and the separator layer to ensure the continuity of the material without barriers or boundaries.

[0099] This leads to improvements in the internal resistance, charging and discharging speed, and charging capacity of energy storage devices using this battery.

[0100] Optionally, the curable liquid electrolyte used to form the first and second separator layers may be the same as those in the composition of the first and second mixtures containing active materials and used to form the cathode and anode layers.

[0101] In fact, using the same curable liquid electrolyte makes it easier to achieve very good material continuity between successive layers.

[0102] In this way, the curable liquid electrolyte for the cathode layer, the curable liquid electrolyte for the anode layer, the curable liquid electrolyte for the first separator electrolyte layer, and the curable liquid electrolyte for the second separator layer can be the same and preferably the same.

[0103] The use of the same liquid electrolyte does not pre-determine the possibility of adding auxiliary agents of different properties or proportions to the various layers (anode layer, cathode layer, separator layer), such as thickeners or fluidizing agents, or even the aforementioned conductive nanomaterials that may be incorporated into the composition of the cathode or anode layer. These auxiliary agents may differ or may be present in different amounts, depending on the use of the electrolyte in each layer and the rheological constraints on the formation of these layers.

[0104] In particular, the first and second separator layers are preferably formed of a liquid electrolyte that does not contain active materials or any conductive / electronically conductive additives, in order to avoid the risk of self-discharge between electrodes of opposite signs in the battery pack during assembly.

[0105] First and second carriers, each having a mixture layer containing active materials and an electrolyte layer containing inactive materials, constitute a half-cell. These half-cells are assembled to form a battery pack.

[0106] The assembly—which involves bringing the first and second electrolyte layers of inactive material into contact—also takes place after the curing of the electrolyte is initiated, after its curing begins, and in any case before it is fully cured.

[0107] This measure further improves the tight contact and perfect adhesion of the electrolyte layer of inactive materials.

[0108] This measure ensures the continuity of ionic conductivity from one electrode to another through the electrolyte layer during the final battery charge and discharge cycles.

[0109] The preferred method for bringing the first electrolyte layer and the second electrolyte layer, which are made of inactive materials, into contact is direct contact.

[0110] However, as a variation, the method may include placing an additional electrically insulating grid separator film between the inactive electrolyte layers or between the inactive electrolyte layers and one of the anode and cathode layers during the assembly of the first and second half-cells. In this case, the layers are brought into contact via the film.

[0111] Specifically, an electrically insulating grid polymer separator with a coarse mesh shape having a step size of 2 to 4 mm can be inserted between the first and second electrolyte layers without active material. This separator can be impregnated with a potentially curable liquid electrolyte and can be exposed to radiation that initiates the curing of the liquid electrolyte just before it is sandwiched between the half-cells during assembly. In this particular embodiment, it involves the same liquid electrolyte without electrode active material and without carbonaceous filler, regardless of whether it is used to achieve a liquid electrolyte layer without active material covering both the cathode and anode layers.

[0112] Regardless of whether the screen separator film is pre-soaked, the electrolyte, which is still liquid and inactive, can pass through the screen separator film on both sides. This allows the inactive electrolyte layers to permeate each other through the screen separator film.

[0113] Interpenetration between the electrolyte layers of inactive materials is enhanced by passing the half-cell between a pair of rollers used to assemble it.

[0114] Depositing an electrolyte layer without active material before the mixture layer containing active material fully cures, and contacting the electrolyte layer before its curing, allows for curing to be completed after battery assembly. As shown above, this results in a certain degree of molecular interpenetration and material continuity between the successive layers of the battery pack. These measures enable excellent ionic conductivity between the layers during the charging and discharging of the resulting battery pack. This also avoids short circuits between the anode and cathode layers.

[0115] Steps a1, a2, a3, and a4, as well as steps b1, b2, b3, and b4, can be performed simultaneously. Although the steps for forming the two half-cells do not have to be completely synchronized, they are completed within a sufficiently short time span to allow the layers to bond before they fully solidify.

[0116] In this respect, it can be pointed out that curing can be completed within seconds after its initiation, thus extending the concomitant nature of these steps by several seconds.

[0117] Advantageously, the method may further include:

[0118] - Sizing the thicknesses of the cathode and anode layers respectively before depositing the first electrolyte layer of inactive material and before depositing the second electrolyte layer of inactive material; and / or

[0119] - The thickness of the first electrolyte layer and the second electrolyte layer without active materials is determined before half-cell assembly.

[0120] Sizing the layers helps to ensure consistent thickness throughout the carrier and improves the electrical properties of the final battery across its entire range. Furthermore, sizing by passing the half-cell between sizing rollers during manufacturing helps to compress these layers and facilitate the permeation of the electrolyte into the active material. Undesirable porosity can also be reabsorbed.

[0121] It should be understood that sizing is not necessary for good contact between uncured layers, but it may help achieve further quality and uniformity.

[0122] These sized rolls can therefore also constitute a rolling mill. These rolls can be heated rolls, thereby activating the curing of the layer.

[0123] According to a preferred embodiment of the method, the first carrier and the second carrier can be a first carrier strip and a second carrier strip, respectively.

[0124] In this case, supplying the first carrier and supplying the second carrier may respectively include unwinding the first carrier strip from the first unwinding roller and unwinding the second carrier strip from the second unwinding roller.

[0125] All operations can be performed between the uncoiling roller and the coiling roller using the so-called roll-to-roll method.

[0126] In particular, the deposition of the cathode layer and the deposition of the anode layer can be carried out continuously by passing the first strip and the second strip in front of the first deposition head for the first mixture and the second deposition head for the second mixture, respectively.

[0127] Similarly, the deposition of a first electrolyte layer of inactive material and a second electrolyte layer of inactive material can be performed continuously by having the first and second strips pass in front of the third and fourth electrolyte deposition heads, respectively.

[0128] The organization of the deposition head and manufacturing apparatus, and the arrangement of modules corresponding to the various operations of the method are then described.

[0129] As discussed above, a deposition head can be a slot-extrusion head capable of depositing various material layers across the entire width of a strip as the strip passes in front of it. During the deposition of these layers, the material from the deposition head is a liquid with varying degrees of fluid consistency.

[0130] The deposition head can also be the type commonly used in machinery for depositing active materials in lithium-ion battery packs.

[0131] The use of the terms “deposition” and “depositing head” does not prejudge the deposition technique. These terms are understood to encompass both the function of providing material on a carrier and the function of coating the carrier, i.e., the distribution of material on the surface of the carrier on which it is deposited.

[0132] Furthermore, and depending on a specific possibility for implementing the method, the exposure of the cathode layer and the anode layer can be performed, respectively, by passing the first strip and the second strip in front of at least one first radiation source and at least one second radiation source.

[0133] Furthermore, the exposure of the first and second separation layers can be performed by having the first and second stripes pass in front of the third and fourth radiation sources, respectively.

[0134] The exposing of the aforementioned layers is understood as exposure to radiation that is suitable for use in the electrolyte of the first mixture for manufacturing the cathode layer, the electrolyte of the second mixture for manufacturing the anode layer, and / or the electrolyte of the inactive material, and facilitates the initiation of curing of these layers through polymerization and / or crosslinking.

[0135] As mentioned above, the radiation source can be a lamp, LEDs, a laser source, or an electron source capable of emitting an electron beam that sweeps across the material to be cured. It can involve light sources emitting ultraviolet light, but also visible and infrared light.

[0136] The use of infrared radiation and photoinitiators sensitive to this spectrum allows radiation to penetrate the material more effectively.

[0137] The order and sequence of the operation and method can be set by arranging the material deposition head and radiation source along the path traversed by the first and second carrier strips between the unwinding roller and the presser roller for assembling the half-cells formed on the first and second carrier strips.

[0138] When the first carrier and the second carrier are respectively a first carrier strip and a second carrier strip, the dimensional determination of the cathode layer thickness and the anode layer thickness can be achieved by passing the first carrier strip carrying the cathode layer and the second carrier strip carrying the anode layer through a first pair of dimensional determination rollers and a second pair of dimensional determination rollers, respectively. It is appropriate to indicate that the thicknesses of the cathode layer and the anode layer are not the same but may be related to each other. The thickness of each layer can also be controlled by controlling the dimensional determination rollers driven by a computer, taking into account the thickness of the carrier strips constituting the current collector.

[0139] Furthermore, the thickness of the first electrolyte layer and the second electrolyte layer without active material can be determined by passing the first half-cell and the second half-cell through the third pair of dimensional rollers and the fourth pair of dimensional rollers, respectively.

[0140] A battery assembled from these two half-cells constitutes an energy storage device. Roll-to-roll manufacturing in this manner yields strip-shaped batteries with large dimensions, particularly long lengths, and virtually unlimited energy storage capacity. Such batteries can be used to equip stationary energy storage facilities.

[0141] However, smaller cells can also be obtained simply by cutting the battery. In practice, this method may include formatting the cell after half-cell assembly, which involves cutting the battery pack cells into formatted cells. The cut passes through and is perpendicular to both the first and second carriers. This can be performed on a laser cutting stage similar to those used for cutting fabrics. Laser cutting enables cuts with localized melting of the material and helps avoid any risk of electrical short circuits, especially between current collectors. Therefore, multiple formatted cells can be obtained from a single large-size cell.

[0142] Since this battery does not have a liquid electrolyte, there is no risk of electrolyte flow to consider, and cutting therefore does not require any special precautions against electrolyte leakage.

[0143] The final formatted battery is preferably one with a rectangular main surface and rounded corners to avoid any fragility at the edges.

[0144] Finally, the method may include applying a protective coating of electrically insulating material to at least one side of the formatted battery pack cells. The protection of the sides created by cutting the cells into formatted cells is not essential to the operation of the battery itself. However, given the extremely small cell thickness of approximately a few hundred micrometers, it is desirable to avoid any risk of accidental short circuits between current collectors. The insulating material on the cut sides may also be applied in liquid form and cured by exposure to radiation. In this case, it involves a photopolymerizable electrically insulating material.

[0145] Finally, the sides of the formatted battery pack can be protected by applying adhesive ribbon to the sides, with the width of the ribbon corresponding to the thickness of the battery or several stacked batteries.

[0146] The present invention also relates to a method for manufacturing a battery pack. The method includes manufacturing a plurality of formatted battery cells and forming a stack of the formatted battery cells in the manner described above, wherein forming the stack includes contacting the free conducting surface of a first carrier of a formatted battery cell with the free conducting surface of a second carrier of a subsequent formatted battery cell in the stack.

[0147] The first carrier of the battery constitutes a current collector and has a surface in contact with the cathode layer and an opposite electrically conducting free surface. Similarly, the second carrier of the battery also constitutes a current collector and has a surface in contact with the anode layer and an opposite electrically conducting free surface. Here, "free surface" is understood to refer to the current collector support surface that does not have electrodes.

[0148] In a battery pack, the free surface of the current collector acts as a connector for the electrical interconnection of the batteries.

[0149] A battery pack can comprise alternating layers of positive and negative electrode active materials, meaning a stack of multiple formatted cells arranged in series with alternating cathodes and anodes. The fact that these formatted cells are stacked facilitates their direct interconnection by making physical and electrical contact between the free surfaces of the carriers that constitute the current collectors.

[0150] Of course, other arrangements for implementing series and / or parallel battery configurations are not excluded. When the batteries are not stacked, additional electrical conductors can be provided to electrically connect the battery current collectors according to the intended interconnection scheme.

[0151] Finally, the present invention relates to an apparatus suitable for forming the battery pack as described above. The apparatus comprises:

[0152] - The first manufacturing line used to manufacture the first half-cell;

[0153] - A second manufacturing line used to manufacture the second half-cell;

[0154] - A pair of assembly rollers for assembling a first half-cell formed on a first manufacturing line and a second half-cell formed on a second manufacturing line; and

[0155] - Battery pack winding rollers are located downstream of this pair of assembly rollers.

[0156] The take-up roller (which may be a drive roller) is designed to wind a complete battery pack consisting of a half-cell from a first manufacturing line and a second half-cell from a second manufacturing line.

[0157] The first and second manufacturing lines are understood to refer to homologous installations of the device, which are similar to each other and dedicated to the simultaneous manufacture of two half-cells. The manufacturing lines converge near the assembly rollers used to assemble the two half-cells.

[0158] Specifically, at least one of the first manufacturing line and the second manufacturing line may include:

[0159] An unwinding roll suitable for unwinding carrier strips; and sequentially comprising between the unwinding roll and the pair of assembly rolls:

[0160] -Suitable for the first coating module that forms the cathode layer and anode layer respectively;

[0161] - First rolling module;

[0162] -A second coating module suitable for forming an electrolyte layer of inactive materials; and

[0163] - Second rolling module.

[0164] Each module contains the necessary elements for performing one or more operations of the manufacturing method.

[0165] The various modules that make up the manufacturing line can move relative to each other and relative to the assembly roller pairs, allowing the spacing between adjacent modules to be adjusted individually.

[0166] It is known that a carrier strip and half-cells formed on the carrier strip move from one module to another at a fixed conveying speed (moving from roll to roll between the unwinding roll and the take-up roll). Changing and controlling this distance helps to set the time elapsed between operations performed by each module.

[0167] Therefore, it is possible to adjust the time elapsed between the deposition of the layer and its exposure to radiation and its rolling. It is also possible to adjust the time elapsed between the deposition of the layer and / or its exposure to radiation that induces the curing of these layers and the assembly of the half-cell.

[0168] The first coating module and the second coating module each include a cathode layer, an anode layer, a deposition head, and at least one radiation source associated with the deposition head.

[0169] The first and second rolling modules each contain a pair of sized rolls and thickness sensors associated with each pair of sized rolls. The rolling modules have several functions. The first function is to set the thickness of the deposited layer. Another function is to ensure uniform layer thickness. A further function, particularly for the second rolling module, is to press an electrolyte layer without active material onto the underlying cathode or anode layer to improve layer bonding. Finally, when heat is applied to the sized rolls, one function can be to increase the layer curing speed.

[0170] The thickness sensor associated with the sizing roll of the rolling module sends a signal, which can be combined with other thickness sensors in other modules or with the thickness sensor of the carrier strip arranged after the unwinding roll.

[0171] The combination of all these signals in the computing unit helps to determine the thickness of each layer or half-cell during the manufacturing process and adjust the spacing of the sizing rollers as needed to achieve the predetermined setting value.

[0172] The positioning and spacing of modules on the half-cell trajectory, combined with the control of the carrier belt's transport speed, helps to finely control the time interval between two different operations and thus control the degree of curing of layers deposited in liquid or paste form before subsequent operations in battery manufacturing.

[0173] Specifically, it is therefore possible to control (i) the time interval between (i) the exposure of the initially paste-like electrode layer to ultraviolet radiation or an electron beam that initiates its curing, and (ii) the time interval between (i) the contact between this layer and other layers (such as during the deposition of a curable liquid electrolyte layer intended to form a separating layer on an exposed anode or cathode layer). Controlling this time interval helps ensure that the contact between these two layers is initially completed while they are in a liquid or paste state, so that these layers can be in close contact.

[0174] The same principle applies to bringing two inactive electrolyte layers into contact after exposure, thereby forming a separator layer between the cathode and anode layers.

[0175] It is important to understand that the time interval considered corresponds to the application of a manufacturing step at a given position on the carrier strip, and the conveying speed corresponds to the displacement speed at that given position along the path from one module to another, which respectively correspond to different operations in the battery pack manufacturing method. In this way, the time interval At between the implementation of two steps in the manufacturing method is estimated as At = d / V, where d is the distance traveled by the carrier strip between the two modules used to implement the two steps of the manufacturing method, and V is the linear conveying speed of the carrier strip. Therefore, in continuous manufacturing methods, such as... Figure 1 In the method shown, the claim that two operations are applied sequentially is understood to mean that the two operations are applied sequentially at a given location on a carrier, strip, or membrane while it is being transported.

[0176] The radiation source of the coating module can be divided into several radiation sources as needed to better expose the material to be cured. Alternatively, a radiation source consisting of a group of five individual radiation sources, each with a 40mm outlet orifice in the layer transport direction, can be provided, which is equivalent to a single radiation source with a 200mm opening in the layer transport direction.

[0177] The radiation source is, for example, an ultraviolet, near-infrared, or visible light radiation source; more generally, it is a radiation source compatible with the photoinitiator present in the liquid material to be cured. Furthermore, the radiation emitted by the radiation source can be modulated to adjust its intensity based on parameters such as layer thickness, its composition and density, the transport speed of the carrier strip / half-cell in front of the module, and the module spacing.

[0178] In particular, since carbonaceous fillers tend to block ultraviolet and electron radiation, increasing the proportion of carbonaceous fillers in the layer leads to an increase in exposure dose to properly initiate curing. The dose is controlled by the power, number, and surface area of ​​the radiation source, as well as by the transport speed of the carrier directed by the drive unit during roll-to-roll manufacturing.

[0179] Sufficient transmission speeds are 1 to 10 m / min under ultraviolet radiation exposure and 3 to 30 m / min under electron beam exposure, which is more powerful and penetrating than ultraviolet radiation.

[0180] In addition, the device may include edge-cutting tools. These can be arranged between the second rolling module of each manufacturing line and the pair of assembly rolls. The edge-cutting tools may also be arranged after the pair of assembly rolls. Each edge-cutting tool may be equipped with two counter-rotating blades to simultaneously cut two opposite sides from the passing strip. This cutting helps to set the width of the two half-cells before assembly.

[0181] According to one variant, the cutting tool with a blade can be replaced by a device that cuts using a laser beam.

[0182] Two manufacturing lines, one for manufacturing the first half-cell and the other for manufacturing the second half-cell, can be integrated into one machine, with the strip moving forward in a synchronized manner.

[0183] According to an advantageous embodiment, the take-up roller can be a driving roller. The take-up roller is considered a driving roller when the winding of the battery pack cells on the take-up roller is used to apply sufficient traction to the battery pack cells and their components to unwind the strip from the unwind roller and move the strip and the half-cells formed by the strip forward from the unwind roller to the take-up roller. In particular, the forward movement of the strip can be synchronized by using a driving take-up roller.

[0184] Unwind rolls can be rolls with brakes. The use of rolls with brakes, especially in combination with drive take-up rolls, helps ensure specific tension on the strip and half-cell and helps avoid jerks during unwinding. Braking of unwind rolls can be achieved through friction braking or electromagnetic braking.

[0185] The central driver unit can also be used to synchronize other components, such as the rolling module or coating module, with the forward movement of the strip.

[0186] The central drive unit may include, for example, a dedicated electronic drive circuit configured to control various components of the device. Specifically, the device may include a drive unit for at least one of the take-up roller, the first coating module, the second coating module, the first rolling module, and the second rolling module. The drive unit may be configured to control the flow rate in the drive motor or coating module within the assembly. The drive unit may also be used to control the braking intensity of the unwind roller to control the tension in the carrier strip.

[0187] The drive unit can receive signals from one or more rotational speed sensors associated with one or more rollers in the manufacturing line. These signals can be used by the drive unit to determine the conveying speed of the strip and half-cell. These signals can also be used to control the braking of the unwind roller and / or the drive motor of the take-up roller, thereby setting a constant conveying speed and constant tension for the strip and half-cell.

[0188] As discussed above, the apparatus of the present invention is suitable for realizing solid electrolyte battery packs produced by solidifying liquid electrolytes. It also demonstrates suitability for realizing large surface area supercapacitor cells with solid electrolytes produced by solidifying liquid electrolytes according to a roll-to-roll type method.

[0189] Just as battery cells can be connected in series or in parallel to form a storage battery, supercapacitor cells can also be connected in series or in parallel to form a supercapacitor battery.

[0190] Other features and advantages of the invention will become apparent from the following description made with reference to the accompanying drawings. This description is for illustrative purposes only and not for limitation. Brief description of the attached diagram

[0192] Figure 1 This is a schematic diagram of various components of a battery manufacturing apparatus according to the present invention. It also indicates various steps of the battery manufacturing method.

[0193] Figure 2 Is with Figure 1 A schematic diagram of the manufacturing line of a battery manufacturing device, showing the components of the device organized into modules.

[0194] Figure 3 This is a schematic view along the main surface of a formatted battery pack made according to the present invention.

[0195] Figure 4 This is a schematic cross-sectional view of a portion of a stack of formatted batteries that are manufactured and constitute a storage battery according to the present invention.

[0196] The attached diagrams are shown at any scale. Invention Details

[0198] In the following description, the same, similar or equivalent parts in different figures are labeled with the same reference numerals so that reference can be made from one figure to another.

[0199] Figure 1 This invention shows an apparatus 100 for manufacturing a battery pack 10 according to the present invention.

[0200] The apparatus 100 is equipped with two manufacturing lines 110a and 110b, which contain identical components and are designed to simultaneously form two half-cells 10a and 10b. Manufacturing lines 110a and 110b converge in a pair of assembly rollers 142, which are designed to form a battery pack 10 from the half-cells 10a and 10b. These two manufacturing lines 110a and 110b are respectively configured to form a half-cell 10a having a positive electrode (cathode) and a half-cell 10b having a negative electrode (anode).

[0201] However, the choice of forming a half-cell with a positive or negative electrode does not depend on the device, but on the materials used. Therefore, the properties of the resulting half-cell (having a positive or negative electrode) do not depend on the manufacturing line. Thus, it is possible to realize a half-cell with a positive electrode on the second manufacturing line 110b and a cell with a negative electrode on the first manufacturing line 110a.

[0202] Each manufacturing line 110a, 110b includes an unwinding roller, which is designed to provide a conductive carrier for collecting current from the half-cell involved.

[0203] The first unwind roller 112a thus conveys the first carrier strip 14a, and the second unwind roller 112b conveys the second carrier strip 14b. The operations of supplying the first carrier 14a and the supplying the second carrier 14b are symbolically represented by arrows marked 214a and 214b, respectively.

[0204] For simplicity, the first and second carriers, and the strips forming them respectively, are labeled with the same reference numerals 14a and 14b. The carrier strips 14a and 14b are intended to form current collectors for the battery pack 10. They can be metal films, such as copper, aluminum, stainless steel, or nickel, or conductive polymer films, conductive fiber webs, or may contain several material layers providing mechanical strength and electrical conductivity. The thickness of the carrier strips may be approximately 10 to 200 μm.

[0205] The strip can be long, for example, several hundred meters. It is not limited by the size of the roller. Furthermore, in the described embodiment, the width of the carrier strip is 1200 mm. Other widths, larger or smaller, can be selected.

[0206] Downstream of the unwinding rollers 112a and 112b, each manufacturing line may include a set of return idlers (not shown) for controlling the tension of the carrier strips 14a and 14b of the roller conveyor, as well as thickness sensors 118a and 118b.

[0207] Other conveyor rollers, not shown, may be provided to support the carrier strip along the manufacturing line.

[0208] Conveyor tables covered with stainless steel or PVC-type polymer sheets can also be provided to support the carrier strips.

[0209] The carrier strips 14a and 14b reach the first deposition head 120a and the second deposition head 120b of the first and second manufacturing lines, respectively.

[0210] A first mixture comprising cathode active material, carbonaceous conductive filler, and liquid electrolyte, and a second mixture comprising anodic active material, carbonaceous conductive filler, and liquid electrolyte are supplied to these deposition heads respectively.

[0211] Furthermore, as the first carrier strip 14a passes in front of the first deposition head 120a and the second carrier strip 14b passes in front of the second deposition head 120b, a first layer containing a first mixture of cathode active materials is simultaneously deposited on the first carrier strip 14a: this is the cathode layer 16a.

[0212] In the same manner, a second layer comprising a second mixture of anodic active materials is simultaneously deposited on the second carrier strip 14b: this is the anodic layer 16b. These layers are not shown in detail. Figure 1 In, but can be seen in Figure 4 .

[0213] It can be noted that the return rollers 122a and 122b of the strip face each deposition head 120a and 120b respectively to ensure good support of the carrier strips 14a and 14b during coating.

[0214] The first and second mixtures forming the cathode and anode layers exit the deposition head with a paste-like consistency. In addition to the active materials and possibly carbonaceous conductive fillers mentioned above, they each contain a curable liquid electrolyte.

[0215] The thickness of the cathode layer and the thickness of the anode layer can be approximately 50 to 300 μm.

[0216] The deposition of the cathode and anode layers is symbolically indicated by arrows 220a and 220b. Deposition can be performed across the entire width of the carrier strip. However, in the example described, deposition is limited to a width of 1160 mm, leaving the edges of strips 14a and 14b untouched.

[0217] This method avoids the potential risk of liquid mixture spilling onto the sides of the strip.

[0218] First ultraviolet radiation sources 124a are located on both sides of the first deposition head 120a to apply radiation to the cathode layer 16a to initiate the solidification of the layer. Figure 1 In one embodiment, separate radiation sources are involved to expose both surfaces of the cathode layer 16a.

[0219] The curing of layer 16a is attributed to the curing of the curable liquid electrolyte it contains. This electrolyte actually contains a photoinitiator compatible with radiation from the first radiation source 124a.

[0220] Similarly, on the second manufacturing line 110b, second ultraviolet radiation sources 124b are provided on both sides of the second deposition head 120b to induce the curing of the anode layer 16b.

[0221] The operation of exposing the cathode layer 16a and the anode layer 16b to radiation that induces their curing is indicated by arrows 224a and 224b.

[0222] Interestingly, in the described embodiment, it can be noted that the irradiation of the layer occurs simultaneously with its deposition onto the carrier strip or immediately after such deposition.

[0223] Post-deposition exposure is also possible, but it is not possible to expose both surfaces of the deposited layer.

[0224] After these operations, the strips from the two manufacturing lines 110a and 110b pass between the first pair of dimensional rollers 126a and the second pair of dimensional rollers 126b, respectively.

[0225] Strips with layers containing active electrode materials (meaning the cathode layer and the anode layer, respectively) are calendered to quantify the thickness of the mixed layer and avoid porosity.

[0226] The thickness of the sheet with the electrode layer is measured at the output end of the sizing roller using thickness sensors 128a and 128b. The thickness sensors are, for example, triangular beam sensors.

[0227] The thickness of the mixture layer can be determined by the difference between the measurement results obtained by the thickness sensors 128a and 128b at the exit of the fixed-size roller and the measurement results obtained by the thickness sensors 118a and 118b at the exit of the unwinding roller 112a and 112b.

[0228] This thickness can be compared with a pre-planned thickness in order to control it in conjunction with the spacing of the fixed-size rollers 126a, 126b and the deposition heads 120a, 120b.

[0229] The thickness of the layer forming the positive electrode (cathode) and the thickness of the layer forming the negative electrode can be between 60 and 300 μm.

[0230] The operation of calibrating the thickness of cathode layer 16a and anode layer 16b is indicated by arrows 226a and 226b.

[0231] After this initial thickness determination, carrier strips 14a and 14b, containing cathode 16a and anode 16b layers comprising active electrode materials, pass in front of the third deposition head 130a and the fourth deposition head 130b, respectively. The third deposition head 130a is part of the first manufacturing line 110a, and the fourth deposition head 130b is part of the second manufacturing line 110b. These deposition heads deposit a first separator layer 18a in the form of an electrolyte without active material onto the cathode layer 16a of the first carrier strip 14a, and deposit a second separator layer 18b in the form of an electrolyte without active material onto the anode layer 16b of the second carrier strip 14b, respectively.

[0232] The deposition of separator layers 18a and 18b formed by the electrolyte is indicated by arrows 230a and 230b, respectively. The electrolyte is deposited in liquid form, preferably on an area equal to that of the cathode layer 16a and the anode layer 16b. A single curable liquid electrolyte can be used for the deposition of separator layers 18a and 18b on these two manufacturing lines 110a and 110b. This may particularly involve a curable liquid electrolyte incorporated into the composition of the underlying cathode layer 16a and anode layer 16b. This electrolyte contains a photoinitiator, thereby initiating curing of the electrolyte under the action of light radiation. For example, it can be ultraviolet, visible, or near-infrared radiation.

[0233] The thickness of the electrolyte layer without active material is, for example, about 10 to 60 μm.

[0234] On the one hand, the distance between the first and third deposition heads and on the other hand, the distance between the second and fourth deposition heads are short enough, and the transport speed of the carrier strip is high enough, so that the separator layers 18a and 18b are deposited before the underlying cathode 16a and anode 16b layers are fully cured. The curing of the layers may occur within seconds, corresponding to the forward movement of the strip along the manufacturing lines 110a and 110b by several meters.

[0235] Immediately after deposition, the separation layers 18a and 18b are cured by re-exposure to light radiation. The strips pass in front of the third ultraviolet radiation source 134a and the fourth ultraviolet radiation source 134b, which are respectively arranged after the third and fourth deposition heads 130a and 130b.

[0236] The exposure of separator layers 18a and 18b is indicated by arrows 234a and 234b. The effect of this exposure is to induce the curing of separator layers 18a and 18b.

[0237] At the output of these operations, the first carrier strip 14a and the second carrier strip 14b, carrying the aforementioned layers, pass again through the sizing rollers. More specifically, this involves the third pair of sizing rollers 136a and the fourth pair of sizing rollers 136b, respectively.

[0238] Just like the first and second pairs of sizing rollers, thickness sensors 138a and 138b follow the third and fourth pairs of sizing rollers. Measurements from these thickness sensors, compared with measurements from sensors 128a and 128b associated with the first and second sizing rollers, help to set the thickness of the separator layers 18a and 18b and adjust the spacing of the sizing rollers as needed.

[0239] The dimensionalization of the thickness of the separator layers 18a and 18b is indicated by arrows 236a and 236b, respectively. The final thickness can be, for example, between 10 and 60 μm. It is preferably 30 μm.

[0240] After being sized, carrier strips 14a and 14b, each containing layers 16a and 16b of active electrode materials and separator layers 18a and 18b, are used to form half-cells 10a and 10b.

[0241] Following this operation, the strip-form half-cells 10a and 10b arrive at the discussed pair of assembly rollers 142. The half-cells are assembled by bringing their respective separator layers 18a and 18b into contact. This assembly can be direct assembly or assembly accompanied by the insertion of an additional electrically insulating grid membrane 20 layer from the unwinding roller 112c. This can involve, for example, a grid of electrically insulating polymer wires. The operation of assembling the half-cells is indicated by arrow 242. The insertion of the membrane 20 must never prevent direct contact between the separator layers 18a and 18b to ensure a good contact interface between these layers.

[0242] Optionally, it is possible to continue the operation of depositing the separator layer 18c on the electrically insulating diaphragm 20, as indicated by arrow 230c. While passing in front of the fifth deposition head, an electrolyte is deposited in liquid form on the membrane 20 via the fifth deposition head 130c, preferably deposited over a width equal to and completely saturating the electrically insulating grid diaphragm 20. The same liquid electrolyte used for depositing separator layers 18a, 18b can be used, and the operation is similar to that of these layers, with curing of the membrane 20 initiated immediately after deposition by exposure to light radiation. The membrane 20 passes in front of a fifth ultraviolet radiation source 134c arranged after the fifth deposition head 130c to be exposed to radiation during the exposure operation indicated by arrow 234c.

[0243] The assembly rollers 142 are spaced sufficiently close to the third, fourth, and fifth radiation sources, respectively, and the conveying speed of the strips is sufficiently high, so that the assembly of the half-cells occurs before the complete curing of the separator layers 18a, 18b, and possibly 18c. In this way, curing continues for a short time after cell assembly.

[0244] It should be noted that the separator layers 18a, 18b, and 18c can be used individually or in combination with one or the other two separator layers. Therefore, two directly contacting layers 18a and 18b, individual layers 18a, 18b, and 18c, layer 18c combined with one or the other of layers 18a and 18b, or layer 18c combined with both layers 18a and 18b can be used. It is important to ensure that separator layers (which can be composed of any combination of layers 18a, 18b, and 18c) exist between the cathode 16a and anode 16b layers, and that these layers are in close contact to ensure good continuity of ion movement between the cathode and anode.

[0245] The separator layers may have the same or different compositions, but each contains a curable liquid electrolyte mixture comprising an ionically conductive separator liquid electrolyte, a separator monomer or polymer mixture, and a polymerization or crosslinking initiator for the first separator monomer or polymer mixture. Similar to the cathode and anode layers, the presence of the monomer or polymer along with the polymerization or crosslinking initiator ensures the curability of the separator layer.

[0246] The thickness sensor 144, located after the assembly roller 142, is used to measure the thickness of the assembled battery and adjust the spacing of the assembly roller 142 as needed.

[0247] After the first and second half-cells are assembled, an electrically insulating film 30 provided by the unwinding roller 160 can be applied to the first or second carrier; the assembled first and second half-cells and the electrically insulating film applied to the first or second carrier to insulate them from each other can be wound around the take-up roller 150. This is particularly advantageous when the battery pack is of the sodium sulfide or lithium sulfide type, as they are charged during manufacturing and therefore preferably insulated from each other to prevent possible discharge.

[0248] After the half-cells 10a and 10b are assembled, the battery 10 passes through a trimming tool 140. This involves a tool or laser head with a rotating blade. Cuts, indicated by arrow 238 in the figure, are made on the sides of the battery to set its width. This is used to eliminate the sides of the carrier strips 14a and 14b that may not receive active electrode material and / or electrolyte, thus retaining only the central portion, where the battery is intact and without rough edges.

[0249] The assembled battery 10 is now finally wound onto the take-up roller 150. The take-up roller 150 has several functions. The first function is to wind the assembled battery pack cells. Another function is to drive the assembly. In fact, the rotation of the take-up roller 150 has the effect of applying traction to the assembled battery pack cells, and therefore to the half-cells, the carrier strip, and, if applicable, the electrically insulating grid diaphragm 20. Thus, the rotation of the take-up roller ensures that the on-strip components move forward along the manufacturing line.

[0250] The unwinding roll can be a driven and / or brake roll, or a free-spinning roll. In the case of a free-spinning roll, unwinding is simply attributed to the traction force applied by the drive take-up roll 150. When the unwinding roll is a brake or driven roll, braking or driving may be subject to the rotation of the drive take-up roll 150 to regulate the tension of the carrier strip and the components on the strip conveyed along the manufacturing line.

[0251] The drive unit 101 of the device can be used to coordinate various parameters, such as the take-up speed, the tension of the carrier strip, and the coating or calendering operation of the carrier strip. The drive unit thereby controls at least one of the take-up roller, the first coating module, the second coating module, the first rolling module, and the second rolling module.

[0252] The drive unit controls, for example, the drive take-up roller 150 by applying a speed setting to its drive motor M.

[0253] Therefore, in Figure 1In step 248, indicated by the arrow, the drive unit 101 controls the conveying speed of the carrier strip by controlling the winding speed of the drive take-up roller 150, and thus controls the time interval between two successive operations of the manufacturing method applied at a given position on the carrier strip.

[0254] By controlling (i) the exposure of the two liquid layers to radiation that induces the curing of these layers, and (ii) the time interval between bringing the two layers into contact, the liquid interface between the two layers can be ensured by making their contact occur before their respective complete curing.

[0255] Specifically, during step 248, the following steps can be implemented using the drive unit 101:

[0256] -d1) Directly contact the first separator layer (18a) with the second separator layer (18b) and control (248): a first time interval between the exposure of the cathode layer in (i) step a3) and the deposition of the first separator layer in (ii) step a4) to allow the cathode layer to not be fully cured when the first separator layer is deposited, and a second time interval between the exposure of the anode layer in (i) step b3) and the deposition of the second separator layer in (ii) step b4) to allow the anode layer to not be fully cured when the second separator layer is deposited, a third time interval between the exposure of the first separator layer in (i) step a4) and the contact placement in (ii) step d1), and a fourth time interval between the exposure of the second separator layer in (i) step b4) and the contact placement in (ii) step d1) to allow the curing of the first and second separator layers respectively to not be fully cured when the contact placement in step d1);

[0257] -d2) Directly contact the first separator layer (18a) with the anode layer (16b) and control (248): a first time interval between the exposure of the cathode layer in step (i) a3) and the deposition of the first separator layer in step (ii) a4) to allow the cathode layer to not be fully cured during the deposition of the first separator layer, and a second time interval between the exposure of the first separator layer in step (i) a4) and the contact placement in step (ii) d2) and a third time interval between the exposure of the anode layer in step (i) b3) and the contact placement in step (ii) d2) to allow the first separator layer to not be fully cured during the contact placement in step d2);

[0258] -d3) Directly contact the second separator layer (18b) with the cathode layer (16a) and control (248): a first time interval between the anode layer exposure in step b3) and the deposition of the second separator layer in step b4) to allow the curing of the anode layer to be incomplete during the deposition of the second separator layer; a second time interval between the second separator layer exposure in step b4) and the contact placement in step d3) and a third time interval between the cathode layer exposure in step a3) and the contact placement in step d3) to allow the curing of the second separator layer to be incomplete during the contact placement in step d3); and

[0259] -d4) Encapsulate the third separator layer (18c) between the cathode layer (16a) and the anode layer (16b) and make the third separator layer contact the cathode layer and the anode layer and control (248): a first time interval between the cathode layer exposure in (i) step a3) and the contact placement in (ii) step d4), a second time interval between the anode layer exposure in (i) step b3) and the contact placement in (ii) step d4), and a third time interval between the third separator layer exposure in (i) step c4) and the contact placement in (ii) step d4), so that the respective curing of the cathode layer, the anode layer and the third curing layer is not yet complete when contact placement is performed in step d4).

[0260] Preferably, all manufacturing equipment can be installed indoors with an anhydrous atmosphere to avoid any reaction between the still liquid electrolyte and moisture in the air (which could lead to battery breakdown).

[0261] refer to Figure 1 The various components described can be grouped into several independent modules, and their positioning and spacing on the manufacturing line can be changed as needed.

[0262] exist Figure 2 The central labeling module, which displays one of manufacturing lines 110a and 110b, corresponds to to some extent to the half-manufacturing machine for a half-cell. Due to the symmetry of the device and the great similarity between the two manufacturing lines, the reference numerals for the two manufacturing lines 110a and 110b are displayed in the same diagram. Figure 2 In the middle. It is important to understand that, according to... Figure 2 One of the manufacturing lines can be used to manufacture half-cells containing cathodes and half-cells containing anodes.

[0263] In the unwinding rollers 112a, 112b and the assembly roller 142 (only one in Figure 2(As can be seen in the image) The strip passes through several modules. These include, in sequence, first coating modules 320a and 320b, first rolling modules 326a and 326b, second coating modules 330a and 330b, and second rolling modules 336a and 336b. The first coating modules 320a and 320b contain reference... Figure 1 The description includes a first coating head 120a or a second coating head 120b and associated radiation sources 124a, 124b. It can be noted that the radiation sources associated with the coating head of the first module are separate. The use of a single radiation source is also conceivable.

[0264] The second coating modules 330a and 330b include references. Figure 1 The third coating head 130a or the fourth coating head 130b and the associated radiation sources 134a, 134b are described.

[0265] The first rolling modules 326a and 326b include sizing rolls 126a and 126b, which are designed to set the thickness of the anode or cathode layer according to the manufacturing line involved. The first rolling module also includes thickness sensors 128a and 128b disposed after the sizing rolls to measure the thickness of the half-cell at the output end of the sizing rolls during manufacturing.

[0266] The second rolling modules 336a and 336b include sizing rollers 136a and 136b, designed to measure the thickness of the half-cell after the deposition of an electrolyte layer containing inactive material during manufacturing. Similar to the first rolling module, the second rolling module includes thickness sensors 138a and 138b immediately following the sizing rollers. The thickness sensors are used to measure the thickness of the half-cell just before assembly.

[0267] Various modules 320a, 320b, 326a, 326b, 330a, 330b, 336a, 336b, as well as unwinding rollers 112a, 112b and take-up roller 150, are connected to a drive unit 101, shown schematically, for synchronizing the various components.

[0268] As shown above, it is possible to implement the present invention by covering only one of the anode and cathode layers with an electrolyte layer containing no active material. In this case, one of the second coating modules 330a and 330b and one of the second rolling modules 336a and 336b can be omitted.

[0269] The take-up roller 150 is a drive roller driven by a motor M, which is symbolically indicated.

[0270] For simplicity, see reference Figure 1 Some optional components described are not shown. Figure 2 middle.

[0271] Figure 3Displays formatted battery pack battery 1010. (Source: [Original Source Name]) Figure 1 The strip-shaped battery 10 is formatted at the end of the formatting operation, symbolically indicated by reference numeral 250 in the attached drawing. Figure 3 In the example shown, this operation specifically involves cutting the outer peripheral edge of the formatted battery 1010. The battery is cut from one side to the other, that is, through the entire thickness of the battery, which is approximately several hundred micrometers.

[0272] This cutting can be advantageously performed on a laser cutting table. Cutting with a knife is also an option.

[0273] exist Figure 3 The example shown depicts a formatted battery 1010 with a rectangular main surface and rounded corners. It is entirely possible to cut it according to another, more complex pattern, which could improve, for example, the ability to house the battery within a space dedicated to the device.

[0274] Since this battery does not contain liquid, especially liquid electrolyte, no specific precautions are required for the cutting operation. Due to the presence of the solid electrolyte layer, the conductive carrier acting as the current collector remains electrically insulating, meaning it is isolated to prevent the conduction of current. In this respect, it is preferable to perform cutting after these layers have completely cured.

[0275] From Figure 3 In one embodiment, the outer peripheral edges of the formatted battery 1010 produced by cutting are covered with an electrically insulating protective coating 1024 (e.g., varnish). This varnish may be reinforced with, for example, glass or basalt fibers. The protective coating may preferably be formed after stacking multiple identical formatted batteries 1010 to cover the sides of the stack.

[0276] Figure 4 Display and Figure 3 The visible battery 1010 is part of a stack of multiple formatted batteries 1011, 1012, 1013, 1014, and 1015, identical to the one shown in the reference. Each formatted battery can be cut into pieces as shown in the reference. Figure 1 The discussion focuses on the strip-shaped battery pack, battery 10. Figure 4 The stacked components form a 1000-cell battery.

[0277] For several formatted batteries Figure 4 The first and second conductive carriers 14a and 14b, cathode layer 16a and anode layer 16b, first separator layer 18a and second separator layer 18b are shown.

[0278] The layers constituting each formatted battery are substantially the same and are indicated by the same reference numerals. However, it can be seen that the first conductive carrier 14a of the first formatted battery 1011 and the second conductive carrier 14b of the last formatted battery 1015 of the stack are thicker than the other conductive carriers. These thicker conductive carriers are formed by several conductive sublayers. They have higher mechanical strength to suit their function as the outer envelope of the battery pack 1000. The thicker conductive carriers of the first and last batteries in the stack also constitute the exterior electrical connection terminals of the battery pack 1000.

[0279] In the stack, the cathode and anode layers of each formatted cell, i.e., the positive and negative electrodes, alternate. Each cell in the stack is thus connected in series with the other cells in the stack via conductive carriers 14a and 14b that form its current collector. The voltage at the terminals of the conductive layers 14a and 14b of the end cells 1011 and 1015 is equal to the sum of the voltages of the individual cells and corresponds to the battery pack voltage of 1000.

[0280] It should be noted that other connection methods for formatted batteries are possible, particularly parallel, or series / parallel or parallel / series combinations. In such cases, additional conductors can be provided for connecting the current collectors of the individual formatted batteries.

[0281] The implementation scheme detailed above is a roll-to-roll type, employing a continuous transport method. Alternatively, sequential manufacturing can be implemented by manufacturing individual plates. Plate handling can be performed using conventional methods, such as a robotic arm equipped with a gripping device. In this case, timing is ensured by controlling the timing of plate handling.

[0282] The present invention is by no means limited to the embodiments disclosed above, and modifications may be made thereto without departing from the scope of the present invention.

Claims

1. A method for manufacturing an electrochemical energy storage battery, comprising the steps of: - Forming a first half-cell (10a), which includes the following steps a1), a2), a3): a1) Provides (214a) a first conductive carrier (14a); a2) Deposit (220a) a cathode layer (16a) in a paste state on the surface of the first conductive carrier (14a), which comprises an active cathode material, a carbonaceous conductive filler, a first liquid ion conductive electrolyte mixture, a first monomer or polymer mixture and a first polymerization or crosslinking initiator for the first monomer or polymer mixture; and a3) The cathode layer (16a) is exposed to a first radiation (224a) suitable for use with a first polymerization or crosslinking initiator for the first monomer mixture to initiate the curing of the cathode layer (16a). - Forming a second half-cell (10b), its Includes the following steps: b1), b2), b3): b1) Provides (214b) a second conductive carrier (14b); b2) Deposit (220b) an anode layer (16b) in a paste state on the surface of the second conductive carrier (14b), which comprises an active anode material, a carbonaceous conductive filler, a second liquid ion-conductive electrolyte mixture, a second monomer or polymer mixture and a second polymerization or crosslinking initiator for the second monomer or polymer mixture; and b3) Initiate the curing of the anode (16b) layer by means of a second radiation exposure (224b) paste state of the anode layer suitable for a second polymerization or crosslinking initiator for the second monomer mixture; - Perform at least one of the following steps: a4), b4), and c4): a4) Deposit (230a) and expose (234a) a first separator layer (18a) formed of a liquid first separator mixture on the exposed cathode layer before the exposed cathode layer is fully cured, the first separator mixture comprising a first ion-conductive separator liquid electrolyte mixture, a first separator monomer or polymer mixture and a first polymerization or crosslinking initiator for the first separator monomer or polymer mixture; and c4) Deposit (230c) and expose (234c) a third separator layer (18c) formed of a liquid third separator mixture on an electrically insulating grid film (20), the third separator mixture comprising a third ion-conductive separator liquid electrolyte mixture, a third separator monomer or polymer mixture and a third polymerization or crosslinking initiator for the third separator monomer or polymer mixture; b4) Depositing (230b) and exposing (234b) a second separator layer (18b) formed of a liquid second separator mixture on the exposed anode layer before the exposed anode layer is fully cured, the second separator mixture comprising a second ion-conductive separator liquid electrolyte mixture, a second separator monomer or polymer mixture, and a second polymerization or crosslinking initiator for the second separator monomer or polymer mixture; and The exposures used in steps a4), b4) and c4) are carried out by a third radiation, which is suitable for the polymerization or crosslinking initiator for each separator monomer or polymer mixture and is suitable for initiating the curing of the first, second and third separator layers. - The first half-cell (10a) and the second half-cell (10b) are assembled (242) by inserting at least one separator layer (18a, 18b, 18c) from steps a4), b4) and c4) between the two half-cells (10a, 10b), wherein the assembly includes one of the steps d1), d2), d3) and d4): d1) Make the first separation layer (18a) exposed to the second separation layer (18b) in direct contact; d2) Make the first separation layer (18a) exposed to be in direct contact with the exposed anode layer (16b); d3) Make the exposed second separator layer (18b) directly contact the exposed cathode layer (16a); and d4) The third exposure separator layer (18c) is encapsulated between the exposed cathode layer (16a) and the exposed anode layer (16b). In steps d1), d2), d3) and d4), the curing of the layers in contact is incomplete.

2. The method according to claim 1, comprising: - The thicknesses (226a, 226b) of the cathode layer (16a) and the anode layer (16b) are sized respectively before the deposition of the first separator layer (18a) (230a) and before the deposition of the second separator layer (18b) (230b); and / or - Before assembling the (242) half-cells (10a, 10b), the thicknesses of the first separator layer (18a) and the second separator layer (18b) are sized (236a, 236b).

3. The method according to any one of the preceding claims, wherein the first carrier (14a) and the second carrier (14b) are respectively a first carrier strip and a second carrier strip, and wherein: The supply (214a) of the first carrier (14a) and the supply (214b) of the second carrier (14b) respectively include unwinding the first carrier strip from the first unwinding roller (112a) and the second carrier strip from the second unwinding roller (112b).

4. The method according to any one of the preceding claims, comprising the steps of: - After assembling the first half-cell (10a) and the second half-cell (10b), an electrically insulating film (30) is applied to the first or second carrier; and - A first half-cell (10a) and a second half-cell (10b) assembled around a take-up roller (150) and an electrically insulating film (30) applied to a first carrier or a second carrier.

5. The method according to claim 3 or 4, wherein the deposition (220a) of the cathode layer and the deposition (220b) of the anode layer can be carried out continuously by passing the first strip and the second strip in front of the first deposition head (120a) for the first mixture and the second deposition head (120b) for the second mixture, respectively.

6. The method according to any one of claims 3 to 5, wherein: The deposition of the first separator layer (18a) (230a) and the deposition of the second separator layer (18b) (230b) are carried out continuously by passing the first strip and the second strip in front of the third electrolyte deposition head (130a) and the fourth electrolyte deposition head (130b), respectively.

7. The method according to any one of claims 3 to 6, wherein: The exposure (224a) of the cathode layer (16a) and the exposure (224b) of the anode layer (16b) are performed by passing the first strip and the second strip in front of at least one first radiation source (124a) and at least one second radiation source (124b), respectively.

8. The method according to any one of claims 3 to 7, wherein the exposure (234a) of the first separating layer (18a) and the exposure (234b) of the second separating layer (18b) are performed by passing the first strip and the second strip in front of the third radiation source (134a) and the fourth radiation source (134b), respectively.

9. The method of claim 2, wherein the first carrier and the second carrier are respectively a first carrier strip and a second carrier strip, and wherein: The dimensional determination of the cathode layer (16a) thickness (226a) and the dimensional determination of the anode layer (16b) are respectively performed by passing the first carrier strip with the cathode layer and the second carrier strip with the anode layer through the first pair of dimensional determination rollers (126a) and the second pair of dimensional determination rollers (126b).

10. The method according to any one of claims 2 and 9, wherein The thickness of the first separator layer (18a) and the thickness of the second separator layer (18b) are fixed (236a) and 236b respectively by passing the first half-cell (10a) and the second half-cell (10b) through the third pair of fixed-size rollers (136a) and the fourth pair of fixed-size rollers (136b).

11. The method according to any one of the preceding claims, comprising carrying out steps a4) and b4) and including placing an electrically insulating grid diaphragm (20) between the separator layers (18a, 18b) during the assembly of the first half-cell (10a) and the second half-cell (10b).

12. The method according to any one of the preceding claims, comprising, after half-cell assembly, an operation of formatting the battery (250), comprising cutting the battery pack cells into formatted cells (1010, 1011, 1012, 1013, 1014, 1105).

13. The method of claim 12, comprising providing a protective coating (1024) of an electrically insulating material on at least one side of a formatted battery pack cell (1010).

14. The method according to any one of the preceding claims, wherein the first liquid electrolyte mixture of the cathode layer (16a), the second liquid electrolyte mixture of the anode layer (16b), the first liquid electrolyte mixture of the first separator layer (18a), the second liquid electrolyte mixture of the second separator layer (18b), and the third liquid electrolyte mixture of the third separator layer (18c) are the same.

15. A method of manufacturing a battery pack, comprising manufacturing a plurality of battery pack cells (1011, 1012, 1013, 1014, 1015) and a stack (1000) forming the battery pack cells according to any one of claims 11 and 12, wherein forming the stack includes contacting a free conductive surface of a first carrier (14a) of a formatted battery pack cell (1011) with a free conductive surface of a second carrier (14b) of a subsequently formatted battery pack cell (1012) of the stack (1000).

16. An apparatus for manufacturing a battery pack according to any one of claims 1 to 13, comprising: - First manufacturing line (110a) for manufacturing the first half-cell (10a); - A second manufacturing line (110b) for manufacturing the second half-cell (10b); - A pair of assembly rollers (142) for assembling the first half-cell (10a) formed on the first manufacturing line (110a) and the second half-cell (10b) formed on the second manufacturing line (110b); - A battery pack winding roller (150) is positioned downstream of the pair of assembly rollers (142); At least one of the first manufacturing line (110a) and the second manufacturing line (110b) includes: - Unwinding rollers (112a, 112b) for unwinding carrier strips (14a, 14b); and sequentially comprising between the unwinding rollers and the pair of assembly rollers (142): - First coating modules (320a, 320b) for forming the cathode layer and anode layer respectively; - First rolling module (326a, 326b); - Second coating modules (330a, 330b) for forming the separating layers (18a, 18b); and -Second rolling mill module (336a, 336b), The first and second rolling modules each include a pair of fixed-size rolls (126a, 126b, 136a, 136b) and thickness sensors (128a, 128b, 138a, 138b) associated with the pair of fixed-size rolls, and The first coating module and the second coating module respectively include a deposition head (120a, 120b, 130a, 130b) and at least one radiation source (124a, 124b, 134a, 134b) associated with the deposition head.

17. The apparatus of claim 16, wherein the take-up roller (150) is a drive roller.

18. The apparatus of claim 16, wherein the unwinding rollers (112a, 112b) are brake rollers.

19. The apparatus of claim 16, wherein the deposition head (120a) of the first coating module (320a) is a cathode deposition head (120a), and the deposition head (120b) of the second coating module (320b) is an anode deposition head; at least one radiation source (124a) is associated with the cathode deposition head (120a), and at least one radiation source (124b) is associated with the anode deposition head (120b).

20. The apparatus according to any one of claims 16 to 19, comprising a drive unit (101) for at least one of the take-up roller (150), the first coating module (320a, 320b), the second coating module (330a, 330b), the first rolling module (326a, 326b) and the second rolling module (336a, 336b).

Images