Method for producing electrochemical cell for polymer matrix battery

Abstract

The invention relates to a method for manufacturing an electrochemical cell (60) for a polymer matrix battery, the method comprising:-covering an anode current collector film (81) with an anode mixture (82) comprising an anode active material dispersed in a first crosslinkable liquid electrolyte comprising a first crosslinkable composition to form an anode electrode (83); covering the cathode current collector film (91) with a cathode mixture (92) comprising a cathode active material dispersed in a second crosslinkable liquid electrolyte comprising a second crosslinkable composition to form a cathode electrode (93); -stacking an anode electrode and a cathode electrode, in which a porous, electrically insulating separation membrane (71) impregnated with a third crosslinkable liquid or semi-liquid electrolyte is positioned between the anode electrode and the cathode electrode, thereby forming a stack (6); and-exposing the stack to at least one electron beam such that the first crosslinkable liquid electrolyte and the second crosslinkable liquid electrolyte cure as a whole, thereby forming the electrochemical cell.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing an electrochemical cell for a battery, and a related apparatus for manufacturing an electrochemical cell for a battery.

[0002] The present invention finds a preferred application for manufacturing an electrochemical cell of a polymer matrix battery, which can be used in various fields, not limited to portable electrical devices such as tools and communication devices, electric vehicles, whether rolling, flying or floating electric vehicles, or stationary electrical energy storage devices. Background Art

[0003] In a known manner, an electrochemical cell of a battery includes an anode electrode and a cathode electrode, the anode electrode and the cathode electrode are separated by an electrically insulating separator membrane, and are respectively provided with an anode current collector and a cathode current collector.

[0004] To manufacture such an electrochemical cell, and in particular an electrochemical cell with a liquid electrolyte, it is known to use a hermetic enclosure to contain the liquid electrolyte, which ensures ionic conduction between the anode electrode and the cathode electrode and within each of these two electrodes. The main drawbacks lie in the manufacture and sealing of the enclosure, as well as the filling of the enclosure with the liquid electrolyte and the subsequent risk of leakage, which can lead to accidents such as combustion, explosion and environmental pollution.

[0005] Therefore, there is a need for a reliable, industrializable and economical manufacturing method.

[0006] Therefore, document WO2022 / 013741 proposes a manufacturing method, which realizes the manufacture of an anode half-cell by curing a paste cathode layer containing a first electrolyte mixture crosslinkable under irradiation, and then realizes the manufacture of a cathode half-cell by curing a paste anode layer containing a second electrolyte mixture crosslinkable under irradiation. After each of the two half-cells is pre-irradiated at least once to initiate their crosslinking, while interposing a separator layer, and before the completion of their crosslinking, the assembly of the two half-cells is performed, and then the curing of the cell is ensured.

[0007] Although the half-cells and the separator layer are assembled before complete curing, the method does not provide an optimized surface adhesion between the separator layer and each of the two half-cells, mainly because of the surface effect of the crosslinkable electrolyte mixture that has started to cure / crosslink in a non-uniform manner between the separator layer and each of the two half-cells, which affects the ionic conductivity of the cell. The uniformity of crosslinking is highlighted by the characteristics of the layer to be crosslinked (thickness, density of the components, color, presence of a bulk that is opaque to irradiation), making the method unsuitable for very thick electrochemical cells and requiring several stages of thin layer deposition followed by exposure to irradiation to properly initiate the crosslinking of the thin layers. Summary of the Invention

[0008] An object of the present invention is to provide a method for manufacturing an electrochemical cell of a battery, which is both economical and can be used on an industrial scale, and provides improved results in terms of ionic conductivity and electron conduction, and is suitable for cells of large thickness.

[0009] For this purpose, the present invention provides a method for manufacturing an electrochemical cell of a battery having a polymer matrix, the method comprising the following steps:

[0010] - A first covering step, during which an anode current collector film is covered or impregnated with the following anode mixture: the anode mixture is in a paste or semi-liquid state and contains at least one anode active material dispersed in a first crosslinkable liquid electrolyte containing a first crosslinkable composition, so as to form an anode electrode;

[0011] - A second covering step, in which a cathode current collector film is covered or impregnated with the following cathode mixture: the cathode mixture is in a paste or semi-liquid state and contains at least one cathode active material dispersed in a second crosslinkable liquid electrolyte containing a second crosslinkable composition, so as to form a cathode electrode;

[0012] - A third impregnation step, during which a porous electrically insulating separator film is impregnated with a third crosslinkable liquid or semi-liquid electrolyte containing a third crosslinkable composition, so as to form a pre-impregnated separator film;

[0013] - A stacking step, during which the anode electrode and the cathode electrode are stacked on top of each other by interposing the pre-impregnated separator film between the anode electrode and the cathode electrode, so as to form a stack;

[0014] - A curing step, which is carried out after the stacking step, during which the stack is exposed to at least one electron beam, so that the first crosslinkable liquid electrolyte, the second crosslinkable liquid electrolyte, and the third crosslinkable liquid or semi-liquid electrolyte are cured integrally in the anode electrode, the cathode electrode, and the separator film, thereby forming a polymer matrix electrochemical cell.

[0015] Accordingly, the present invention proposes to fabricate two polymer matrix half-units, each formed respectively by the anode electrode obtained at the end of the first covering step and the cathode electrode obtained at the end of the second covering step, and then to assemble them by interposing a separating membrane that electrically insulates the two half-units, which will make it possible to obtain an optimal surface bonding force between the separating membrane and each of the two half-units. In fact, since the anode mixture and the cathode mixture are still in a paste or semi-liquid state and the crosslinking of the first crosslinkable liquid electrolyte and the second crosslinkable liquid electrolyte has not yet started (in other words, the curing of the anode mixture and the cathode mixture has not yet started), these first crosslinkable liquid electrolytes and second crosslinkable liquid electrolytes will be able to tightly insert themselves into the pores / holes of the separating membrane impregnated with the third crosslinkable liquid or semi-liquid electrolyte during the stacking step, and, where appropriate, into the pores / holes of the current collector membrane before curing (sometimes also called gelation) which will only start after the stacking step, and will then form a continuous polymer matrix throughout the stack at the end of the curing step.

[0016] In other words, the stacking step before the curing step promotes the mutual penetration of both the first crosslinkable liquid electrolyte and the second crosslinkable liquid electrolyte in the separating membrane and, where appropriate, in the current collector membrane to obtain a polymer matrix throughout the stack after crosslinking, promoting on the one hand the ionic conductivity between the two electrodes and on the other hand the electronic conductivity between each electrode and its respective current collector, thus enabling subsequent charge and discharge cycles of the final cell.

[0017] It is very clear that the size of the pores / holes of the separating membrane is such that the active material and the electronic conduction filler cannot be inserted inside these pores / holes of the separating membrane; the separating membrane must remain an insulating layer while enabling ionic conduction through these pores / holes.

[0018] In addition, the third impregnation step is conducive to increasing the mutual penetration and surface adhesion between the separating membrane and each of the two half-units before curing. In the case where the anode mixture and the cathode mixture contain an electronic conduction filler (as described below), this also makes it possible to enhance the electrical insulation at the separating membrane by preventing the electronic conduction filler of the anode mixture (and thus ultimately the anode electrode) from contacting the electronic conduction filler of the cathode mixture (and thus ultimately the cathode electrode).

[0019] And finally, the curing step exposed to at least one electron beam will achieve overall uniform curing by constructing a polymer matrix across the entire thickness of the stack to form a polymer matrix electrochemical cell, which will surely be solid, but the polymer matrix electrochemical cell will have properties equivalent to or at least close to those of a liquid electrolyte cell. In fact, the method will allow the production of a polymer matrix stack that includes nano- or micro-sized interconnected liquid domains or islands therein, which are strong ion exchangers between the anode electrode and the cathode electrode, and allows, where appropriate, the inclusion of an electron-conducting filler enclosed within the polymer matrix to ensure electron conduction in the electrodes towards their respective current collectors.

[0020] Using this method, the cell obtained at the end (or the final electrochemical cell) can be divided into desired sizes, thus enabling the obtaining of multiple electrochemical cells, which can be assembled in series, in parallel, or in series / parallel, for example, by simply superposing the conducting outer faces of the current collector films, to form a multi-cell battery.

[0021] According to a variant, the anode mixture and the cathode mixture are paste or semi-liquid mixtures, and each of the anode mixture and the cathode mixture has a viscosity, for example, included between 10,000 cps and 30,000 cps (centipoise).

[0022] According to one possibility, the first crosslinkable liquid electrolyte and the second crosslinkable liquid electrolyte do not contain any electron-conducting filler.

[0023] According to a feature, the first crosslinkable composition, the second crosslinkable composition, and the third crosslinkable composition are similar.

[0024] It is indeed advantageous to use similar (and, for example, the same) crosslinkable compositions for the two half-cells and the separator membrane to facilitate ion conduction in the interfacial region with the separator membrane.

[0025] According to one possibility, the first crosslinkable composition, the second crosslinkable composition, and the third crosslinkable composition respectively contain a first monomer or prepolymer mixture, a second monomer or prepolymer mixture, and a third monomer or prepolymer mixture. The first monomer or prepolymer mixture, the second monomer or prepolymer mixture, and the third monomer or prepolymer mixture each contain a monomer or prepolymer or a combination of a monomer and a prepolymer, wherein the monomer or prepolymer contains crosslinking functional groups for curing the anode mixture, the cathode mixture, and the third crosslinkable liquid or semi-liquid electrolyte when exposed to at least one electron beam.

[0026] Advantageously, the first crosslinkable composition and the second crosslinkable composition each do not have a crosslinking initiator additive.

[0027] There is no such additive that enables the limitation of the presence of inactive materials and thus increases the mass energy density of the cell.

[0028] According to another possibility, the crosslinkable functional groups are selected from acrylate, methacrylate, vinyl, styrene, isocyanate, acrylamide, and methacrylamide functional groups.

[0029] Of course, the present invention cannot be limited to such functional groups, but they have effective advantages.

[0030] According to another possibility, the first crosslinkable composition has a mass percentage in the anode mixture that is included between 2% and 20%, and for example between 3% and 7%, and the second crosslinkable composition has a mass percentage in the cathode mixture that is included between 2% and 20%, and for example between 3% and 7%.

[0031] In a specific embodiment, the first covering step realizes the roll-to-roll deposition or impregnation of the anode mixture onto the anode current collector film such that the anode electrode forms a first continuous strip, the second covering step realizes the roll-to-roll deposition or impregnation of the cathode mixture onto the cathode current collector film such that the cathode electrode forms a second continuous strip, and the third impregnation step realizes the continuous impregnation of the separator membrane with a third crosslinkable liquid or semi-liquid electrolyte such that the pre-impregnated separator membrane forms a third continuous strip that is interposed between the first continuous strip and the second continuous strip during the stacking step.

[0032] The roll-to-roll deposition or impregnation technique is particularly advantageous for industrial-scale implementation because the roll-to-roll deposition or impregnation technique is both economical and fast, which will also enable the continuous stacking of the three strips.

[0033] Furthermore, it is stipulated that the third crosslinkable liquid or semi-liquid electrolyte does not contain any electron-conducting fillers.

[0034] According to one possibility, the third crosslinkable composition does not have a crosslinking initiator additive.

[0035] Advantageously, the third crosslinkable composition is the same as the first crosslinkable composition and the second crosslinkable composition.

[0036] Therefore, it is sufficient to prepare only one crosslinkable composition that will be used in the first crosslinkable liquid electrolyte, the second crosslinkable liquid electrolyte, and the third crosslinkable liquid electrolyte.

[0037] Advantageously, in the third impregnation step, the third crosslinkable liquid or semi-liquid electrolyte is impregnated throughout the entire volume of the separator membrane to facilitate the bonding with the anode electrode and the cathode electrode plated on the two opposite surfaces of the separator membrane.

[0038] According to another possibility, the separator membrane is continuously unwound from a third web and continuously impregnated with a third crosslinkable liquid or semi-liquid electrolyte to form a third continuous strip.

[0039] In a variant not covered by the claims, the separator membrane may not be pre-impregnated with such a third crosslinkable liquid or semi-liquid electrolyte and may be sandwiched directly and as such between two half-cells (in other words, between the anode electrode and the cathode electrode); in this case, the separator membrane may be in the form of a fine mesh fabric made of an electrically insulating polymer, for example.

[0040] In an advantageous embodiment, the stacking step compresses the stack before the stack is exposed to at least one electron beam.

[0041] Compression of the stack promotes tight surface contact between the layers, namely the anode electrode, the separator membrane and the cathode electrode in turn, and also promotes control of the thickness of the stack.

[0042] Such compression of the stack can be carried out, for example, by continuous rolling or by a press, such as a hydraulic press or a mechanical press.

[0043] Advantageously, compression of the stack is carried out by continuously compressing the first continuous strip, the third continuous strip and the second continuous strip between two rolling rollers.

[0044] In fact, such compression by continuous rolling promotes productivity while allowing precise control of the thickness of the stack before curing.

[0045] According to a particular embodiment, the method includes a final compression step during which, after having been exposed to at least one electron beam, the stack is compressed, for example, by continuous rolling or by a press.

[0046] According to a feature, the anode active material includes anode active material particles having a maximum size included between 0.5 micrometers and 200 micrometers, and for example between 1 micrometer and 20 micrometers, and the cathode active material includes cathode active material particles having a maximum size included between 0.5 micrometers and 200 micrometers, and for example between 1 micrometer and 20 micrometers.

[0047] According to another feature, the anode active material particles and the cathode active material particles are spherical or substantially spherical in shape.

[0048] Such a spherical or substantially spherical shape is advantageous for having a homogeneous anode mixture and cathode mixture and thus allows good distribution of the active particles before overall crosslinking, which is advantageous for ion conduction.

[0049] In a particular embodiment, the anode mixture comprises a first electronically conductive filler dispersed in a first crosslinkable liquid electrolyte, and the cathode mixture comprises a second electronically conductive filler dispersed in a second crosslinkable liquid electrolyte.

[0050] According to one possibility, the first and second electronically conductive fillers are fillers having at least one nano-size included between 1 nanometer and 200 nanometers.

[0051] According to another possibility, the first and second electronically conductive fillers are:

[0052] - carbonaceous fillers selected from carbon black, carbon nanofibers, carbon nanofibers coated with titanium nitride, carbon nanotubes, graphene powder, and graphene oxide powder;

[0053] - non-carbonaceous fillers selected from metal fibers, metal powders, such as carbon fluoride powder, aluminum or nickel powder, conductive metal oxides, conductive polymers, and conductive ceramic powders.

[0054] According to a variant, the first and second electronically conductive fillers have a mass percentage included between 0.1% and 10%, and for example between 0.5% and 5%, in the respective anode and cathode mixtures.

[0055] According to a variant, each of the first and second crosslinkable liquid electrolytes comprises at least one lithium salt or sodium salt dissolved in at least one liquid solvent.

[0056] Similarly, the third crosslinkable liquid electrolyte may comprise at least one lithium salt or sodium salt dissolved in at least one liquid solvent.

[0057] Advantageously, each of the first and second crosslinkable liquid electrolytes comprises at least one surfactant having a mass percentage included between 1% and 5%, and for example between 2% and 4%.

[0058] Such a surfactant promotes the encapsulation of the electronically conductive filler by the crosslinking monomer or prepolymer, which is beneficial for improving safety and preventing the formation of dendrites.

[0059] Similarly, the third crosslinkable liquid electrolyte may comprise at least one surfactant having a mass percentage included between 1% and 5%, and for example between 2% and 4%.

[0060] According to a feature, the first covering step achieves: unwinding the anode current collector film previously wound on the first reel; and covering or impregnating the anode current collector film with the anode mixture when the anode current collector film is unwound.

[0061] According to another feature, the second covering step consists in: unwinding the cathode current collector film previously wound on the second web; and covering or impregnating the cathode current collector film with the cathode mixture while unwinding the cathode current collector film.

[0062] In an advantageous embodiment, the first covering step comprises a first thickness calibration step, which includes mechanically adjusting the thickness of the anode electrode before the stacking step, this thickness being referred to as the first thickness.

[0063] In this way, this first thickness is controlled, which promotes the control of the thickness of the final unit. Furthermore, this calibration makes it possible to discharge any excess anode mixture (or excess first crosslinkable liquid electrolyte) deposited, which excess anode mixture will be discharged at least in part, for example, through the lateral parts of the anode electrode and / or, where appropriate, through the pores / holes of the anode current collector film.

[0064] Advantageously, the first thickness is adjusted to a value included between 10 μm and 1000 μm, and for example between 30 μm and 500 μm.

[0065] In a particular embodiment, the first thickness calibration step is achieved by compressing the anode electrode before the stacking step.

[0066] According to one possibility, the anode electrode is compressed by continuous rolling between two rolling rollers including a first input roller and a first output roller.

[0067] According to another possibility, the anode current collector film is continuously fed into the first input roller, and the anode mixture is deposited at this first input roller to cover or impregnate said anode current collector film, thereby forming an anode electrode, which anode electrode is continuously fed between the first input roller and the first output roller to be compressed and then is fed out of the first output roller.

[0068] In an advantageous embodiment, the second covering step comprises a second thickness calibration step, which includes mechanically adjusting the thickness of the cathode electrode, this thickness being referred to as the second thickness.

[0069] In this way, this second thickness is controlled, which promotes the control of the thickness of the final unit. Furthermore, this calibration makes it possible to discharge any excess cathode mixture (or excess second crosslinkable liquid electrolyte) deposited, which excess cathode mixture will be discharged at least in part, for example, through the lateral parts of the cathode electrode and / or, where appropriate, through the pores / holes of the cathode current collector film.

[0070] Advantageously, the second thickness is adjusted to a value included between 10 μm and 1000 μm, and for example between 30 μm and 500 μm.

[0071] In a particular embodiment, a second thickness calibration step is achieved by compressing the cathode electrode before the stacking step.

[0072] According to one possibility, the cathode electrode is compressed by continuous rolling between two rolling rollers including a second input roller and a second output roller.

[0073] According to another possibility, the cathode current collector film is continuously fed into the second input roller, and the cathode mixture is deposited at the second input roller to cover or impregnate the cathode current collector film, thereby forming a cathode electrode, which is continuously fed between the second input roller and the second output roller to be compressed, and then is fed out of the second output roller.

[0074] According to a variant, during the curing step, the stack is exposed to at least one electron beam, the at least one electron beam including:

[0075] - a single electron beam facing one of the anode electrode or the cathode electrode; or

[0076] - two electron beams respectively facing the anode electrode and the cathode electrode.

[0077] To achieve complete curing of the stack of the formed electrochemical cells, the number of beams will depend on the thickness and mass density of each constituent strip in the constituent strips of the stack, the irradiation dose emitted by each of the beams, and the rolling speed of the stack in front of the electron beam.

[0078] According to a feature, the at least one electron beam has an irradiation dose characteristic including between 10 kGy and 100 kGy, and for example between 50 kGy and 80 kGy.

[0079] According to another feature, the at least one electron beam has an accelerating voltage characteristic including between 100 keV and 1 MeV.

[0080] According to yet another feature, the rolling speed of the stack has a speed characteristic including between 1 m / min and 500 m / min, and for example between 1 m / min and 30 m / min.

[0081] According to a variant, at least one of the anode current collector film and the cathode current collector film is selected from:

[0082] - a metal laminated film, which is made of, for example, copper or aluminum and is provided with perforations;

[0083] - a polymer and metal fiber-based metal composite porous film, and the polymer and metal fiber-based metal composite porous film are combined to form a nonwoven fabric;

[0084] - A polymer and carbon fiber-based carbon composite porous membrane, where the polymer and carbon fiber-based carbon composite porous membranes are combined to form a non-woven fabric, and the carbon fibers are optionally (and thus not necessarily) subjected to pretreatment to improve their electrical conductivity and thermal conductivity;

[0085] - A carbon fiber-based porous membrane, where the carbon fiber-based porous membranes are combined to form a non-woven fabric, and the carbon fibers are optionally (and thus not necessarily) subjected to pretreatment to improve their electrical conductivity and thermal conductivity.

[0086] It should be noted that when the anode current collector membrane is a metal laminated membrane, the first covering step achieves covering the metal laminated membrane with the anode mixture. Similarly, when the cathode current collector membrane is a metal laminated membrane, the second covering step achieves covering the metal laminated membrane with the cathode mixture.

[0087] When the anode current collector membrane is a porous membrane, the first covering step achieves impregnating the porous membrane with the anode mixture. Similarly, when the cathode current collector membrane is a porous membrane, the second covering step achieves impregnating the porous membrane with the cathode mixture.

[0088] According to one possibility, the perforations of the metal laminated membrane have a maximum size included between 0.5 mm and 2 mm and are distributed with a density included between 2 perforations per square centimeter and 10 perforations per square centimeter.

[0089] According to another possibility, the pretreatment includes depositing a pretreatment layer based on titanium nitride or titanium carbide or a combination of titanium nitride and carbide on the carbon fibers, and the pretreatment layer has a thickness included between 100 nm and 1000 nm.

[0090] In an embodiment, the anode current collector membrane includes an internal anode face and an external anode face opposite to the internal anode face. During the first covering step, the anode mixture is deposited or impregnated on the internal anode face, and the external anode face is pre-covered or impregnated with a leak-proof and conductive conductive varnish layer;

[0091] And the cathode current collector membrane includes an internal cathode face and an external cathode face opposite to the internal cathode face. During the second covering step, the cathode mixture is deposited or impregnated on the internal cathode face, and the external cathode face is pre-covered or impregnated with another leak-proof and conductive conductive varnish layer.

[0092] These two conductive varnish layers will at least partially ensure the sealing of the unit; the technical purpose of such a seal is to prevent moisture and air from entering the electrochemical unit and to prevent the solvent from evaporating from the liquid electrolyte. These two conductive varnish layers can be hardened, for example, when exposed to at least one electron beam during the curing step (of the electrochemical unit), or hardened before the covering step.

[0093] According to the characteristics, the conductive varnish layer and another conductive varnish layer each have a thickness less than or equal to 30 micrometers, for example, included between 5 micrometers and 30 micrometers.

[0094] Advantageously, the first covering step and the second covering step are carried out in parallel.

[0095] In an advantageous embodiment, the stack has two opposite longitudinal edges, and the manufacturing method includes the following steps: applying an electrically insulating varnish after the stacking step and before the curing step, during the step of applying the electrically insulating varnish, two electrically insulating varnish layers that are leak-proof and electrically insulating are respectively deposited on the two opposite longitudinal edges of the stack.

[0096] These two electrically insulating varnish layers will contribute to the sealing of the cell.

[0097] Advantageously, the two electrically insulating varnish layers are hardened when exposed to at least one electron beam during the curing step.

[0098] Therefore, the electrically insulating varnish contains monomers or prepolymers or a combination of monomers and prepolymers, wherein the monomers or prepolymers contain crosslinking functional groups for curing when exposed to at least one electron beam.

[0099] Advantageously, the anode current collector film has two opposite longitudinal edges, the width of the anode current collector film is defined between the two opposite longitudinal edges, and during the first covering step, an anode mixture is deposited to cover or impregnate the anode current collector film to form a strip having a width smaller than the width of the anode current collector film, so that the two longitudinal edges of the anode current collector film are not covered and impregnated by the anode mixture.

[0100] The cathode current collector film has two opposite longitudinal edges, the width of the cathode current collector film is defined between the two opposite longitudinal edges, and during the second covering step, a cathode mixture is deposited to cover or impregnate the cathode current collector film to form a strip having a width smaller than the width of the cathode current collector film, so that the two longitudinal edges of the cathode current collector film are not covered and impregnated by the cathode mixture.

[0101] So that before the step of applying the electrically insulating varnish, the two opposite longitudinal edges of the stack do not have the anode mixture and the cathode mixture.

[0102] According to a variant, the active anode material is selected from anode materials used alone or in combination, and the anode materials are based on:

[0103] - carbon, such as graphite;

[0104] - silicon;

[0105] - carbonaceous silicon or lithiated silicon;

[0106] - A transition metal or an alloy of transition metals;

[0107] - A composite material combining a transition metal and carbon;

[0108] - Lithium metal;

[0109] - Sodium metal;

[0110] - Lithium titanate;

[0111] - Aluminum, or magnesium, or tin, or zinc.

[0112] According to another variant, the cathode active material is selected from cathode materials used alone or in combination, the cathode materials being based on:

[0113] - Lithiated nickel manganese cobalt;

[0114] - Lithiated nickel cobalt aluminum;

[0115] - Lithium iron phosphate;

[0116] - Lithiated lithium cobaltate;

[0117] - Lithiated manganese oxide;

[0118] - A sulfur-carbon composite material in the presence of a lithiated anode material;

[0119] - Lithium sulfide;

[0120] - A sodium alloy, such as for example Na3V2(PO4)2F3.

[0121] In an embodiment, the first covering step, the second covering step, the stacking step and the curing step are carried out in an anhydrous environment and for example in an environment of argon or carbon dioxide.

[0122] Such an environment is favorable for the safety of the method.

[0123] The present invention also relates to a device for manufacturing an electrochemical cell of a polymer matrix battery, the device comprising the following stations:

[0124] - A first covering station, the first covering station comprising: a first dispenser for an anode current collector film; a first reservoir that houses an anode mixture that is in a paste or semi-liquid state and contains at least one anode active material dispersed in a first crosslinkable liquid electrolyte containing a first crosslinkable composition; and a first covering unit for covering or impregnating the anode current collector film with the anode mixture in order to form an anode electrode;

[0125] - A second covering station, which includes: a second dispenser for the cathode current collector film; a second reservoir that houses a cathode mixture in a paste or semi-liquid state and contains at least one cathode active material dispersed in a second crosslinkable liquid electrolyte containing a second crosslinkable composition, and a second covering unit that is used to cover or impregnate the cathode current collector film with the cathode mixture so as to form a cathode electrode;

[0126] - A third impregnation station, which includes a third dispenser for an electrically insulating and porous separator film and an impregnation unit that is used to impregnate the separator film with a third crosslinkable liquid or semi-liquid electrolyte so as to form a pre-impregnated separator film;

[0127] - A stacking station that is used to stack the anode electrode and the cathode electrode, wherein the pre-impregnated separator film is interposed between the anode electrode and the cathode electrode to form a stack;

[0128] - A curing station that is located at the outlet of the stacking station, and the curing station includes at least one electron beam generator that is used to expose the stack to at least one electron beam, so that the first crosslinkable liquid electrolyte, the second crosslinkable liquid electrolyte, and the third crosslinkable liquid or semi-liquid electrolyte are integrally cured in the anode electrode, the cathode electrode, and the separator film, thereby forming a polymer matrix electrochemical cell.

[0129] The device may also have all or some of the features associated with the above method. Description of the Drawings

[0130] Other features and advantages of the present invention will become apparent upon reading the following detailed description of non-limiting exemplary implementations with reference to the accompanying drawings, in which:

[0131] Figure 1 is a schematic diagram of a manufacturing device according to an exemplary embodiment of the present invention, and the manufacturing device is suitable for implementing a method for manufacturing an electrochemical cell of a polymer matrix battery according to the present invention;

[0132] Figure 2 is Figure 1 a schematic diagram of the first covering unit of the device, and the first covering unit is used to cover or impregnate the anode current collector film with the anode mixture and form an anode electrode;

[0133] Figure 3 is Figure 1 a schematic diagram of the second covering unit of the device, and the second covering unit is used to cover or impregnate the cathode current collector film with the cathode mixture and form a cathode electrode;

[0134] Figure 4 is​​​​Figure 1 Schematic view of the impregnation unit of the third impregnation station of the device and the stacking station for stacking the anode electrode and the cathode electrode, with a pre-impregnated separator membrane interposed between the anode electrode and the cathode electrode;

[0135] Figure 5 is a schematic top view of the anode current collector film partially covered with the anode mixture in the first covering unit;

[0136] Figure 6 is a schematic top view of the cathode current collector film partially covered with the cathode mixture in the second covering unit;

[0137] Figure 7 is a schematic cross-sectional view of the electrochemical unit of the polymer matrix battery obtained at the outlet of the device;

[0138] Figure 8 is a schematic cross-sectional view of a variant of the electrochemical unit of the polymer matrix battery;

[0139] Figure 9 is a schematic view of a coil winding machine that forms a unit coil after the Figure 1 device. Detailed Description

[0140] Figure 1 Illustrated is the device 9 for manufacturing the electrochemical unit of the polymer matrix battery 60 and its various stations described below.

[0141] The device 9 includes a first covering station 1, and the first covering station 1 includes a first dispenser 10 for dispensing the anode current collector film 81. The first dispenser 10 is in the form of a coil unwinder or a dispenser, and the anode current collector film 81 is in the form of a first coil 810 unwound continuously from the first dispenser 10.

[0142] The anode current collector film 81 is selected from:

[0143] - A metal laminated film, which is made of, for example, copper or aluminum and is provided with perforations, the maximum size of the perforations being, for example, included between 0.5 mm and 2 mm, and the perforations being distributed at a density of, for example, between 2 perforations per square centimeter and 10 perforations per square centimeter;

[0144] - A polymer and metal fiber-based metal composite porous membrane, which is combined to form a non-woven fabric;

[0145] - A polymer and carbon fiber-based carbon composite porous membrane, which is combined to form a non-woven fabric, and the carbon fiber is optionally subjected to pretreatment to improve its electrical conductivity and thermal conductivity; ​​​​​

[0146] - A carbon fiber-based porous membrane, and the carbon fiber-based porous membranes are combined to form a non-woven fabric. The carbon fibers are optionally subjected to a pretreatment to improve their electrical conductivity and thermal conductivity.

[0147] This pretreatment of the carbon fibers includes, for example, depositing a pretreatment layer based on titanium nitride or titanium carbide, or a combination of titanium nitride and carbide, on the carbon fibers. The pretreatment layer has a thickness, for example, included between 100 nanometers and 1000 nanometers.

[0148] The anode current collector membrane 81 has an inner face and an opposite outer face. According to one possibility, the outer face of the anode current collector membrane 81 is pre-covered or impregnated with a conductive varnish layer 66 (see Figure 8 ). The conductive varnish layer 66 is leak-proof and conductive. The conductive varnish layer 66 has a thickness, for example, less than or equal to 30 micrometers, for example, included between 5 micrometers and 30 micrometers.

[0149] The first covering station 1 further includes a first reservoir 11 for accommodating the anode mixture 82. The anode mixture 82 is in a paste or semi-liquid state (for example, its viscosity is included between 10000 cps and 30000 cps), and the anode mixture 82 contains at least one active anode material and a first electron-conducting filler dispersed in a first crosslinkable liquid electrolyte containing a first crosslinkable composition.

[0150] The first reservoir 11 is a sealed reservoir and is in an anhydrous environment and, for example, in an environment of an inert gas, such as argon or carbon dioxide. The first reservoir 11 is advantageously equipped with a mechanical mixer or stirrer 110 to homogenize the anode mixture 82.

[0151] According to one possibility, the first crosslinkable composition has a mass percentage included between 2% and 20% in the anode mixture 82, and, for example, between 3% and 7%. The first crosslinkable composition contains a first monomer or prepolymer mixture, and the first monomer or prepolymer mixture contains monomers or prepolymers, or a combination of monomers and prepolymers. Among them, the monomers or prepolymers contain crosslinking functional groups for crosslinking the first crosslinkable liquid electrolyte (and thus curing the anode mixture 82) when exposed to an electron beam. These crosslinking functional groups are, for example, selected from acrylate, methacrylate, vinyl, styrene, isocyanate, acrylamide, and methacrylamide functional groups.

[0152] According to one possibility, the first electron-conducting filler has a mass percentage included between 0.1% and 10% in the anode mixture 82, and, for example, between 0.5% and 5%. These first electron-conducting fillers are advantageously at least one filler with a nano-size included between 1 nanometer and 200 nanometers, and these first electron-conducting fillers are:

[0153] - Any carbon filler selected from carbon black, carbon nanofibers, carbon nanofibers coated with titanium nitride, carbon nanotubes, graphene powder, and graphene oxide powder;

[0154] - Or non-carbonaceous fillers selected from metal fibers, metal powders, such as carbon fluoride powder, aluminum or nickel powder, conductive metal oxides, conductive polymers, and conductive ceramic powders.

[0155] According to another possibility, the first crosslinkable liquid electrolyte comprises at least one lithium salt or sodium salt dissolved in at least one liquid solvent. It is conceivable that the first crosslinkable liquid electrolyte comprises a surfactant in a mass percentage included between 1% and 5%, and for example between 2% and 4%.

[0156] According to another possibility, the anode active material comprises anode active material particles with a maximum size included between 0.5 micrometers and 200 micrometers, and for example between 1 micrometer and 20 micrometers. These anode active material particles are advantageously spherical or substantially spherical in shape. The anode active material is selected from anode materials used alone or in combination, the anode materials being based on:

[0157] - Carbon, such as for example graphite;

[0158] - Silicon;

[0159] - Carbonaceous silicon or lithiated silicon;

[0160] - Transition metals or alloys of transition metals;

[0161] - Composite materials combining transition metals and carbon;

[0162] - Lithium metal;

[0163] - Sodium metal;

[0164] - Lithium titanate;

[0165] - Aluminum, or magnesium, or tin, or zinc.

[0166] The first covering station 1 further comprises a first covering unit 12 for covering or impregnating the anode current collector film 81, and more specifically the inner face of the anode current collector film 81, with the anode mixture 82 in order to form an anode electrode 83, the anode electrode 83 comprising the anode current collector film 81 at least partially impregnated with the first crosslinkable liquid electrolyte and a layer of anode mixture 82.

[0167] Thus, the first covering station 1 achieves:

[0168] - Unwinding the anode current collector film 81 from the first coil 810 previously wound on the first dispenser 10; and

[0169] - When the anode current collector film 81 is unwound, the anode mixture 82 is fed from the first reservoir 11 via the conduit 111, and the anode current collector film 81 is covered or impregnated with the anode mixture 82 at the first covering unit 12.

[0170] The first covering unit 12 realizes the roll-to-roll deposition or impregnation of the anode mixture 82 on the anode current collector film 81, such that the anode electrode 83 forms a first continuous strip, and the first covering unit 12 also realizes the compression of the anode electrode 83 by continuous rolling between two rolling rollers 13, 14 including a first input roller 13 and a first output roller 14. In addition, the first covering unit 12 includes these two rolling rollers 13, 14.

[0171] Thus, the anode current collector film 81 is continuously conveyed into the input portion on the first input roller 13, and the anode mixture 82 is deposited or impregnated on the inner surface of the anode current collector film 81 at the level of the first input roller to form the anode electrode 83. Thus, the first covering unit 12 includes a deposition nozzle 15 fluidly connected to the first reservoir 11 by means of the conduit 111, and the deposition nozzle 15 is arranged adjacent to the first input roller 13 to deposit or impregnate the anode mixture 82 on the inner surface of the anode current collector film 81.

[0172] Referring to Figure 5 , the anode current collector film 81 has two opposite longitudinal edges 811, and the width L81 of the anode current collector film 81 is defined between the two opposite longitudinal edges 811 (the Figure 5 arrow in which illustrates the advancing or conveying direction in the device 9), and according to an alternative possibility, the anode mixture 82 is deposited or impregnated on the anode current collector film 81 in the first covering unit 12 to form a strip having a width L82 smaller than the width L81 of the anode current collector film 81, so that the two longitudinal edges 811 of the anode current collector film 81 are not covered and impregnated with the anode mixture 82. In other words, the anode current collector film 81 has two edge strips 812 along these two corresponding longitudinal edges 811, and the two edge strips 812 are not covered and impregnated with the anode mixture 82.

[0173] The width L82 of the strip is preferably greater than or equal to 90% of the width L81 of the anode current collector film 81, so that approximately 5% of the uncovered portion remains on each of the two edge strips 812 of the anode current collector film 81. Alternatively, the anode mixture 82 is deposited or impregnated over the entire width L81 of the anode current collector film 81.

[0174] The first covering unit 12 further includes a doctor blade 16 which is arranged adjacent to the first input roller 13 and after the deposition nozzle 15 for scraping off the excessive anode mixture 82 deposited on the anode current collector film 81.

[0175] After the deposition through the deposition nozzle 15 and the scraping through the doctor blade 16, the anode electrode 83 is continuously conveyed between the first input roller 13 (which is a fixed roller) and the first output roller 14 (which is a movable roller with a compression spring) to be compressed, and then is conveyed out of the first output roller 14. Thus, the anode electrode 83 is compressed by continuously rolling between these two rolling rollers 13, 14.

[0176] Therefore, this compression by rolling allows for thickness calibration, which includes mechanically adjusting the thickness of the anode electrode 83, which thickness is referred to as the first thickness E1. The first thickness E1 is advantageously adjusted to a value included between 10 micrometers and 1000 micrometers, and for example between 30 micrometers and 500 micrometers. The first covering unit 12 may include a first thickness sensor 17 which is disposed on the path of the anode electrode 83 to measure the first thickness E1, and thus for controlling the compression operation.

[0177] This rolling compression also promotes the impregnation of the first crosslinkable liquid electrolyte in the thickness of the anode current collector film 81. This rolling compression also makes it possible to extract any excess first crosslinkable liquid electrolyte, any excess first crosslinkable liquid electrolyte which will be discharged through the pores in the anode active material and / or the holes in the anode current collector film 81; the excess first crosslinkable liquid electrolyte can be recovered in the recovery reservoir 18.

[0178] The device 9 includes a second covering station 2 which includes a second dispenser 20 for dispensing the cathode current collector film 91. The second dispenser 20 is in the form of a roll unwinder or dispenser, and the cathode current collector film 91 is in the form of a second roll 910 which is continuously unwound from the second dispenser 20.

[0179] The cathode current collector film 91 is selected from:

[0180] - a metal laminated film, which metal laminated film is made of, for example, copper or aluminum and is provided with perforations, the maximum size of the perforations including, for example, between 0.5 millimeters and 2 millimeters, and the perforations being distributed at a density included between, for example, 2 perforations per square centimeter and 10 perforations per square centimeter;

[0181] - a polymer and metal fiber-based metal composite porous film, the polymer and metal fiber-based metal composite porous film being combined to form a nonwoven fabric;

[0182] - A polymer and carbon fiber-based carbon composite porous membrane, the polymer and carbon fiber-based carbon composite porous membrane being combined to form a non-woven fabric, and the carbon fibers being optionally subjected to a pretreatment to improve their electrical conductivity and thermal conductivity;

[0183] - A carbon fiber-based porous membrane, the carbon fiber-based porous membrane being combined to form a non-woven fabric, and the carbon fibers being optionally subjected to a pretreatment to improve their electrical conductivity and thermal conductivity.

[0184] Such a pretreatment of the carbon fibers includes, for example, depositing a pretreatment layer based on titanium nitride or titanium carbide or a combination of titanium nitride and carbide on the carbon fibers, the pretreatment layer having a thickness, for example, included between 100 nanometers and 1000 nanometers.

[0185] The cathode current collector membrane 91 has an inner face and an opposite outer face. According to one possibility, the outer face of the cathode current collector membrane 91 is pre-covered or impregnated with another conductive varnish layer 67 (see Figure 8 ), the conductive varnish layer 67 being leak-proof and conductive. The another conductive varnish layer 67 has a thickness, for example, less than or equal to 30 microns, for example included between 5 microns and 30 microns.

[0186] The second covering station 2 further includes a second reservoir 21 for accommodating the cathode mixture 92, the cathode mixture 92 being in a paste or semi-liquid state (for example, its viscosity is included between 10000 cps and 30000 cps), and the cathode mixture 92 containing at least one active cathode material and a second electronic conduction filler dispersed in a second crosslinkable liquid electrolyte containing a second crosslinkable composition.

[0187] The second reservoir 21 is a sealed reservoir and is in an anhydrous environment and, for example, in an environment of an inert gas, such as, for example, argon or carbon dioxide. The second reservoir 21 is advantageously equipped with a mechanical mixer or stirrer 210 to homogenize the cathode mixture 92.

[0188] According to one possibility, the second crosslinkable composition has a mass percentage included between 2% and 20% in the cathode mixture 92, and, for example, between 3% and 7%. The first crosslinkable composition contains a second monomer or prepolymer mixture, the second monomer or prepolymer mixture containing a monomer or prepolymer or a combination of a monomer and a prepolymer, wherein the monomer or prepolymer contains crosslinking functional groups for curing the second crosslinkable liquid electrolyte when exposed to an electron beam. These crosslinking functional groups are, for example, selected from acrylate, methacrylate, vinyl, styrene, isocyanate, acrylamide, and methacrylamide functional groups.

[0189] Advantageously, the first crosslinkable composition and the second crosslinkable composition are similar and, for example, they are the same.

[0190] According to one possibility, the second electronic conduction filler in the cathode mixture 92 has a mass percentage included between 0.1% and 10%, and for example between 0.5% and 5%. These first electronic conduction fillers are advantageously at least one filler of nanometric size having a size included between 1 nanometer and 200 nanometers, and these second electronic conduction fillers are:

[0191] - Any carbon filler selected from carbon black, carbon nanofibers, carbon nanofibers coated with titanium nitride, carbon nanotubes, graphene powder, and graphene oxide powder;

[0192] - Or non-carbonaceous fillers selected from metal fibers, metal powders, such as carbon fluoride powder, aluminum or nickel powder, conductive metal oxides, conductive polymers, and conductive ceramic powders.

[0193] According to another possibility, the second crosslinkable liquid electrolyte contains at least one lithium salt or sodium salt dissolved in at least one liquid solvent. It is conceivable that the second crosslinkable liquid electrolyte contains a surfactant having a mass percentage included between 1% and 5%, and for example between 2% and 4%.

[0194] According to another possibility, the cathode active material includes cathode active material particles having a maximum size included between 0.5 micrometers and 200 micrometers, and for example between 1 micrometer and 20 micrometers. These cathode active material particles are advantageously particles of spherical shape or substantially spherical shape. The cathode active material is selected from cathode materials used alone or in combination, the cathode material being based on:

[0195] - Lithiated nickel manganese cobalt;

[0196] - Lithiated nickel cobalt aluminum;

[0197] - Lithium iron phosphate;

[0198] - Lithiated lithium cobaltate;

[0199] - Lithiated manganese oxide;

[0200] - Sulfur-carbon composite material in the presence of a lithiated anode material;

[0201] - Lithium sulfide;

[0202] - Sodium alloy, such as for example Na3V2(PO4)2F3.

[0203] The second covering station 2 further includes a second covering unit 22 for covering or impregnating the cathode current collector film 91, and more specifically the inner face of the cathode current collector film 91, with the cathode mixture 92 in order to form a cathode electrode 93, the cathode electrode 93 including a cathode current collector film 91 at least partially impregnated with the second crosslinkable liquid electrolyte and a layer of cathode mixture 92.

[0204] Therefore, the second covering station 2 implements:

[0205] - Unwinding the cathode current collector film 91 previously wound on the second web 910 of the second dispenser 20; and

[0206] - When the cathode current collector film 91 is unwound, feeding the cathode mixture 92 from the second reservoir 21 via the conduit 211 and covering or impregnating the cathode current collector film 91 with the cathode mixture 92 at the second covering unit 22.

[0207] The second covering unit 22 implements roll-to-roll deposition or impregnation of the cathode mixture 92 on the cathode current collector film 91 such that the cathode electrode 93 forms a second continuous strip, and the second covering unit 22 also implements compression of the cathode electrode 93 by continuous rolling between two rolling rollers 23, 24 including a second input roller 23 and a second output roller 24. In addition, the second covering unit 22 includes these two rolling rollers 23, 24.

[0208] Therefore, the cathode current collector film 91 is continuously conveyed into the input section on the second input roller 23, and the cathode mixture 92 is deposited or impregnated on the inner surface of the cathode current collector film 91 at the level of the second input roller 23 to form the cathode electrode 93. Therefore, the second covering unit 22 includes a deposition nozzle 25 fluidly connected to the second reservoir 21 by means of the conduit 211, and the deposition nozzle 25 is arranged adjacent to the second input roller 23 to deposit or impregnate the cathode mixture 92 on the inner surface of the cathode current collector film 91.

[0209] Referring to Figure 6 , the cathode current collector film 91 has two opposite longitudinal edges 911, and the width L91 of the cathode current collector film 91 is defined between the two opposite longitudinal edges 911 (the Figure 6 arrow in shows the forward or conveying direction in the device 9), and according to an optional possibility, the cathode mixture 92 is deposited or impregnated on the cathode current collector film 91 in the second covering unit 22 to form a strip having a width L92 smaller than the width L91 of the cathode current collector film 91, so that the two longitudinal edges 911 of the cathode current collector film 91 are not covered and impregnated with the cathode mixture 92. In other words, the cathode current collector film 91 has two edge strips 912 along these two corresponding longitudinal edges 911, and the two edge strips 912 are not covered and impregnated with the cathode mixture 91.

[0210] The width L92 of the strip is preferably greater than or equal to 90% of the width L91 of the cathode current collector film 91, so that approximately 5% of the uncovered portion is left on each of the two edge strips 912 of the cathode current collector film 91. Alternatively, the cathode mixture 92 is deposited or impregnated over the entire width L91 of the cathode current collector film 91.

[0211] The second covering unit 22 further includes a doctor blade 26 which is arranged adjacent to the second input roller 23 and after the deposition nozzle 25 for scraping off the excess cathode mixture 92 deposited on the cathode current collector film 91.

[0212] After the deposition through the deposition nozzle 26 and the scraping through the doctor blade 26, the cathode electrode 93 is continuously conveyed between the second input roller 23 (which is a fixed roller) and the second output roller 24 (which is a movable roller with a compression spring) to be compressed, and then conveyed out of the second output roller 24. Thus, the cathode electrode 93 is compressed by continuously rolling between these two rolling rollers 23, 24.

[0213] Therefore, this compression by rolling allows thickness calibration which includes mechanically adjusting the thickness of the cathode electrode 93, which thickness is referred to as the second thickness E2. The second thickness E2 is advantageously adjusted to a value included between 10 microns and 1000 microns, and for example between 30 microns and 500 microns. The second covering unit 22 may include a second thickness sensor 27 which is placed in the path of the cathode electrode 93 to measure this second thickness E2 and thus for controlling the compression operation.

[0214] This compression by rolling also promotes the impregnation of the second crosslinkable liquid electrolyte in the thickness of the cathode current collector film 91. This compression by rolling also makes it possible to extract any excess second crosslinkable liquid electrolyte, which excess second crosslinkable liquid electrolyte will be discharged through the pores in the cathode active material and / or the holes in the cathode current collector film 91; this excess second crosslinkable liquid electrolyte can be recovered in the recovery tank 28.

[0215] The device 9 includes a third impregnation station 3 which includes a third dispenser 30 for dispensing the porous and electrically insulating separator film 71. The third dispenser 30 is in the form of a coil unwind or dispenser, and the separator film 71 is in the form of a third coil 710 which is continuously unwound from the third dispenser 30. The separator film 71 has an inner face and an outer face which are opposite to each other.

[0216] The third impregnation station 3 includes an impregnation unit 32 for impregnating the separator membrane 71 with a third crosslinkable liquid or semi-liquid electrolyte 72; the third crosslinkable liquid or semi-liquid electrolyte 72 contains a third crosslinkable composition for curing the third crosslinkable liquid or semi-liquid electrolyte upon exposure to an electron beam.

[0217] The third impregnation station 3 further includes a third reservoir 31 that houses the third crosslinkable liquid or semi-liquid electrolyte 72 containing the third crosslinkable composition. The third reservoir 31 is a sealed reservoir and is in an anhydrous environment, and for example, in an environment of an inert gas, such as argon or carbon dioxide. The third reservoir 31 is advantageously equipped with a mechanical mixer or stirrer 310 to homogenize the third crosslinkable liquid or semi-liquid electrolyte 72.

[0218] According to one possibility, the third crosslinkable composition contains a third monomer or prepolymer mixture that includes monomers or prepolymers or a combination of monomers and prepolymers, where the monomers or prepolymers contain crosslinking functional groups for curing the third crosslinkable liquid or semi-liquid electrolyte during exposure to an electron beam. These crosslinking functional groups are, for example, selected from acrylate, methacrylate, vinyl, styrene, isocyanate, acrylamide, and methacrylamide functional groups.

[0219] Advantageously, the third crosslinkable composition is similar to and, for example, the same as the first crosslinkable composition and the second crosslinkable composition.

[0220] According to another possibility, the third crosslinkable liquid or semi-liquid electrolyte contains at least one lithium salt or sodium salt dissolved in at least one liquid solvent. It is conceivable that the third crosslinkable liquid or semi-liquid electrolyte contains a surfactant with a mass percentage included between 1% and 5%, and for example, between 2% and 4%.

[0221] Advantageously, the third crosslinkable liquid or semi-liquid electrolyte is similar to and, for example, the same as the first crosslinkable liquid electrolyte and / or the second crosslinkable liquid electrolyte.

[0222] The impregnation unit 32 is configured to impregnate the third crosslinkable liquid or semi - liquid electrolyte 72 on two opposite faces (inner face and outer face) of the separator membrane 71, so as to impregnate the separator membrane 71 with the third crosslinkable liquid or semi - liquid electrolyte 72 throughout the volume of the separator membrane 71. Thus, the separator membrane 71 is continuously conveyed to the inlet of the impregnation unit 32, and the third crosslinkable liquid or semi - liquid electrolyte 72 is impregnated on two opposite faces of the separator membrane 71 throughout its volume to form a pre - impregnated separator membrane 73 in the form of a third continuous strip. In other words, the separator membrane 71 is continuously unwound from the third roll 710 and continuously impregnated with the third crosslinkable liquid or semi - liquid electrolyte 72 to form a pre - impregnated separator membrane 73 in the form of a third continuous strip 73.

[0223] The impregnation unit 32 includes two deposition nozzles 35 fluidly connected to the third reservoir 31 by means of a conduit 311, and the two deposition nozzles 35 are arranged to face the inner face and the outer face of the separator membrane 71 respectively, so as to deposit the third crosslinkable liquid or semi - liquid electrolyte 72 on the inner face and the outer face of the separator membrane 71. The impregnation unit 32 further includes two scrapers 36 arranged after the two corresponding deposition nozzles 35 to scrape off the excess third crosslinkable liquid or semi - liquid electrolyte 72 impregnated on two opposite faces of the separator membrane 71.

[0224] The first covering station 1, the second covering station 2 and the third impregnation station 3 operate continuously and in parallel.

[0225] The apparatus 9 includes a stacking station 4 for stacking the anode electrode 83 (which forms a first continuous strip at the outlet of the first covering station 1) and the cathode electrode 93 (which forms a second continuous strip at the outlet of the second covering station 2), wherein the pre - impregnated separator membrane 73 (which forms a third continuous strip 73 at the outlet of the third impregnation station 3) is interposed between the anode electrode 83 and the cathode electrode 93. Thus, at the stacking station 4, the third continuous strip (or pre - impregnated separator membrane 73) is sandwiched or interposed between the first continuous strip (or anode electrode 83) and the second continuous strip (or cathode electrode 93).

[0226] Therefore, the stacking station 4 enables a stack 6 to be obtained and continuously obtained at the outlet, and the stack 6 sequentially includes an anode current collector film 81 (partially impregnated with the first crosslinkable liquid electrolyte), an anode mixture 82, a separator membrane 71 impregnated with the third crosslinkable liquid or semi - liquid electrolyte 72, a cathode mixture 92, and a cathode current collector film 91 (partially impregnated with the second crosslinkable liquid electrolyte).

[0227] Before exposing the stack 6 to at least one electron beam, the stacking station 4 compresses the stack 6, for example, by continuous rolling or using a press. This compression allows the first crosslinkable liquid electrolyte and the second crosslinkable liquid electrolyte to penetrate into the separator membrane 71, and thus combines the first crosslinkable liquid electrolyte and the second crosslinkable liquid electrolyte with the third crosslinkable liquid or semi-liquid electrolyte of the third continuous strip (or pre-impregnated separator membrane 73).

[0228] In Figure 4 the example illustrated in, the stacking station 4 includes a continuous rolling machine having two rolling rollers 41 (for example, a fixed roller and a movable roller with a compression spring) to perform continuous compression of the stack 6.

[0229] The device 9 includes a curing station 5 located at the outlet of the stacking station 4. The curing station 5 includes at least one electron beam generator 50 to expose the stack 6 to at least one electron beam, such that the first crosslinkable liquid electrolyte, the second crosslinkable liquid electrolyte, and the third crosslinkable liquid or semi-liquid electrolyte are simultaneously crosslinked or cured in the anode current collector film 81, the anode mixture 82, the cathode mixture 92, the cathode current collector film 91, and the separator membrane 71, thereby forming a polymer matrix electrochemical cell 60.

[0230] Under the action of the electron beam, the crosslinking functional groups of the first crosslinkable composition, the second crosslinkable composition, and the third crosslinkable composition will cause the overall curing of the first crosslinkable liquid electrolyte, the second crosslinkable liquid electrolyte, and the third crosslinkable liquid or semi-liquid electrolyte, thereby forming a polymer matrix for the electrochemical cell 60. The polymer matrix is produced by the device 9 and thus by the method implemented in this device 9.

[0231] In Figure 1 the example illustrated in, the curing station 5 includes two electron beam generators 50. The two electron beam generators 50 face the anode electrode 83 and the cathode electrode 93 respectively. In other words, the electron beam generators 50 are on both sides of the stack 6 at the outlet of the stacking station 4.

[0232] As a variant, and depending on whether the target thickness and mass density of the constituent strips of the polymer matrix electrochemical cell 60 allow, the curing station 5 may include a single electron beam generator 50 facing either the anode electrode 83 or the cathode electrode 93.

[0233] The electron beam generator 50 or each electron beam generator 50 has:

[0234] - An irradiation dose characteristic including between 10 kGy and 100 kGy, and for example, between 50 kGy and 80 kGy;

[0235] - An acceleration voltage characteristic between 100 keV and 1 MeV.

[0236] According to one possibility, at the curing station 5, the winding speed of the stack 6 has a speed characteristic included between 1 m / min and 500 m / min, and for example between 1 m / min and 30 m / min; this winding speed is ensured by ensuring speed synchronization in the previous stations, and in particular in the first covering station 1, the second covering station 2 and the third impregnation station 3 in continuous operation.

[0237] Optionally, the device 9 includes a station for applying an electrically insulating varnish located between the stacking station 4 and the curing station 5 to deposit two electrically insulating varnish layers 68 that are leak-proof and electrically insulating on two opposite longitudinal edges of the stack 6 (see Figure 8 ); wherein, the electrically insulating varnish contains monomers or prepolymers, and the monomers or prepolymers contain crosslinking functional groups for curing the electrically insulating varnish when exposed to at least one electron beam. Thus, the two electrically insulating varnish layers 68 harden in the curing station 5 during exposure to the electron beam 50.

[0238] The use of these electrically insulating varnish layers 68 is suitable in the above (and illustrated in Figure 5 and Figure 6 ) cases, where the two longitudinal edges 810 of the anode current collector film 81 are not covered and impregnated with the anode mixture 82, and where the two longitudinal edges 910 of the cathode current collector film 91 are not covered and impregnated with the cathode mixture 92, such that in this case, before applying the electrically insulating varnish, the two opposite longitudinal edges of the stack 6 are free of the anode mixture 82 and the cathode mixture 92.

[0239] The device 9 includes a final compression station 55 located at the outlet of the curing station 5, and the final compression station 55 is used to compress the stack 6, for example by continuous rolling or a press after exposure to the electron beam, in other words, to compress the polymer matrix electrochemical unit 60.

[0240] In the illustrated example, the final compression station 55 includes a continuous rolling machine having two rolling rollers 56 (for example, a fixed roller and a movable roller with a compression spring) to perform continuous compression of the polymer matrix electrochemical unit 60.

[0241] Then, the polymer matrix electrochemical unit 60 is in the form of a continuous strip, and this continuous strip can be wound around a coil winder 62 in the form of a unit coil 61, as illustrated in Figure 9 .

[0242] Advantageously, the first covering unit 12, the second covering unit 22, the impregnation unit 32, the stacking station 4, the curing station 5 and the final compression station 55 are arranged in an enclosure 57 in an anhydrous environment and, for example, in an environment of argon or carbon dioxide. The first dispenser 10, the second dispenser 20 and the third dispenser 30 may be located outside the enclosure 57.

[0243] Figure 7 Schematically illustrates a cross-section of a polymer matrix electrochemical cell 60 obtained at the outlet of the device 9, in which the polymer matrix electrochemical cell is superposed with:

[0244] - an anode current collector film 81, in which a first electrolyte is cured inside the anode current collector film 81, in particular at the interface with the anode mixture 82;

[0245] - an anode mixture 82, in which a first electrolyte is cured inside the anode mixture 82, the anode mixture 82 as a whole comprising a first electronically conductive filler (nanosized first electronically conductive filler) and anode active material particles (microsized anode active material particles);

[0246] - a separator membrane 71, in which a third electrolyte and a first electrolyte at the interface with the anode mixture 82 and a second electrolyte at the interface with the cathode mixture 92 are cured inside the separator membrane 71;

[0247] - a cathode mixture 92, in which a second electrolyte is cured inside the cathode mixture 92, the cathode mixture 92 as a whole comprising a second electronically conductive filler (nanosized second electronically conductive filler) and cathode active material particles (microsized cathode active material particles);

[0248] - a cathode current collector film 91, in which a second electrolyte is cured inside the cathode current collector film 91, in particular at the interface with the cathode mixture 92.

[0249] In the anode mixture 82 of the electrochemical cell 60, the anode active material particles are coated with a first cured electrolyte, and in the cathode mixture 92 of the electrochemical cell 60, the cathode active material particles are coated with a second cured electrolyte.

[0250] The term "cured electrolyte" is used here in a simplified way to denote the fact that it is the crosslinking of a crosslinkable composition initially contained in the corresponding liquid electrolyte, the electrolyte remaining in the liquid state and forming domains or islands within the polymer matrix, where there is the possibility of ion exchange between different domains or islands, and coating the active material and the electronically conductive filler.

[0251] Figure 8 Illustrates a variant of the electrochemical cell 60, which still includes the same superposition, but is additionally sealed with:

[0252] - A conductive varnish layer 66, the conductive varnish layer 66 being leak - proof and conductive and located on the outer face of the anode current collector film 81;

[0253] - Another conductive varnish layer 67, the other conductive varnish layer 67 being leak - proof and conductive and located on the outer face of the cathode current collector film 82; and

[0254] - Two electrically insulating varnish layers 68, the two electrically insulating varnish layers 68 being leak - proof and conductive and located on two opposite longitudinal edges of the electrochemical cell 60 (the two electrically insulating varnish layers 68 are initially deposited on the stack 6 and hardened during exposure to the electron beam 50).

Claims

1. A method for manufacturing an electrochemical cell (60) for a polymer matrix battery, the method comprising the following steps: - A first covering step, in which an anode current collector film (81) is covered or impregnated with the following anode mixture (82): the anode mixture is in a paste or semi-liquid state and contains at least one anode active material dispersed in a first crosslinkable liquid electrolyte containing a first crosslinkable composition, so as to form an anode electrode (83); - A second covering step, in which a cathode current collector film (91) is covered or impregnated with the following cathode mixture (92): the cathode mixture is in a paste or semi-liquid state and contains at least one cathode active material dispersed in a second crosslinkable liquid electrolyte containing a second crosslinkable composition, so as to form a cathode electrode (93); - A third impregnation step, during which an electrically insulating and porous separator membrane (71) is impregnated with a third crosslinkable liquid or semi-liquid electrolyte (72) containing a third crosslinkable composition, so as to form a pre-impregnated separator membrane (73); - A stacking step, during which the anode electrode (83) and the cathode electrode (93) are stacked on each other by interposing the pre-impregnated separator membrane (73) between the anode electrode (83) and the cathode electrode (93), so as to form a stack (6); - A curing step, which is after the stacking step, during which the stack (6) is exposed to at least one electron beam, such that the first crosslinkable liquid electrolyte, the second crosslinkable liquid electrolyte, and the third crosslinkable liquid or semi-liquid electrolyte (72) are cured integrally in the anode electrode (83), the cathode electrode (93), and the separator membrane (71), thereby forming the polymer matrix electrochemical cell (60).

2. The manufacturing method according to claim 1, wherein, the first crosslinkable composition, the second crosslinkable composition, and the third crosslinkable composition are similar.

3. The manufacturing method according to claim 1 or 2, wherein, the first crosslinkable composition, the second crosslinkable composition, and the third crosslinkable composition respectively comprise a first monomer or prepolymer mixture, a second monomer or prepolymer mixture, and a third monomer or prepolymer mixture, and the first monomer or prepolymer mixture, the second monomer or prepolymer mixture, and the third monomer or prepolymer mixture each comprise a monomer or prepolymer or a combination of a monomer and a prepolymer, wherein the monomer or prepolymer contains a crosslinking functional group for curing the anode mixture (82), the cathode mixture (92), and the third crosslinkable liquid or semi-liquid electrolyte (72) when exposed to the at least one electron beam.

4. The manufacturing method according to claim 3, wherein, the crosslinking functional group is selected from acrylate, methacrylate, vinyl, styrene, isocyanate, acrylamide, and methacrylamide functional groups.

5. The manufacturing method according to any one of the preceding claims, wherein, the first crosslinkable composition has a mass percentage in the anode mixture (82) that includes between 2% and 20%, and for example between 3% and 7%, and the second crosslinkable composition has a mass percentage in the cathode mixture (92) that includes between 2% and 20%, and for example between 3% and 7%.

6. The manufacturing method according to any one of the preceding claims, wherein, the first covering step realizes the roll-to-roll deposition or impregnation of the anode mixture (82) onto the anode current collector film (81) such that the anode electrode (83) forms a first continuous strip, the second covering step realizes the roll-to-roll deposition or impregnation of the cathode mixture (92) onto the cathode current collector film (91) such that the cathode electrode (93) forms a second continuous strip, and the third impregnation step realizes the continuous impregnation of the separator membrane (71) with the third crosslinkable liquid or semi-liquid electrolyte (72) such that the pre-impregnated separator membrane (73) forms a third continuous strip, and the third continuous strip is interposed between the first continuous strip and the second continuous strip during the stacking step.

7. The manufacturing method according to claim 6, wherein, the separator membrane (71) is continuously unwound from a third roll stock (710) and continuously impregnated with the third crosslinkable liquid or semi-liquid electrolyte (72) to form the third continuous strip.

8. The manufacturing method according to any one of the preceding claims, wherein, in the third impregnation step, the third crosslinkable liquid or semi-liquid electrolyte (72) is impregnated throughout the entire volume of the separator membrane (71).

9. The manufacturing method according to any one of the preceding claims, wherein, before exposing the stack (6) to the at least one electron beam, the stacking step is realized by continuously rolling or by a press to compress the stack (6).

10. The manufacturing method according to claims 6 and 9, wherein, the compression of the stack (6) is performed by continuously compressing the first continuous strip, the third continuous strip, and the second continuous strip between two rolling rollers (41).

11. The manufacturing method according to any one of the preceding claims includes a final compression step, during which, after having been exposed to the at least one electron beam, the stack (6) is compressed, for example, by continuously rolling or by a press.

12. The manufacturing method according to any one of the preceding claims, wherein, the anode active material includes anode active material particles having a maximum size that includes between 0.5 microns and 200 microns, and for example between 1 micron and 20 microns, and the cathode active material includes cathode active material particles having a maximum size that includes between 0.5 microns and 200 microns, and for example between 1 micron and 20 microns.

13. The manufacturing method according to claim 12, wherein, The anode active material particles and the cathode active material particles are spherical or substantially spherical particles.

14. The manufacturing method according to any one of the preceding claims, wherein, the anode mixture (82) contains a first electron-conducting filler dispersed in the first crosslinkable liquid electrolyte, and the cathode mixture (92) contains a second electron-conducting filler dispersed in the second crosslinkable liquid electrolyte.

15. The manufacturing method according to claim 14, wherein, the first electron-conducting filler and the second electron-conducting filler are fillers having at least one nano-size between 1 nanometer and 200 nanometers.

16. The manufacturing method according to claim 14 or 15, wherein, the first electron-conducting filler and the second electron-conducting filler are: - carbonaceous fillers selected from carbon black, carbon nanofibers, carbon nanofibers coated with titanium nitride, carbon nanotubes, graphene powder, and graphene oxide powder; or - non-carbonaceous fillers selected from metal fibers, metal powders, such as carbon fluoride powder, aluminum or nickel powder, conductive metal oxides, conductive polymers, and conductive ceramic powders.

17. The manufacturing method according to any one of claims 14 to 16, wherein, the first electron-conducting filler and the second electron-conducting filler have a mass percentage in the anode mixture (82) and the cathode mixture (92) respectively, which is included between 0.1% and 10%, and for example between 0.5% and 5%.

18. The manufacturing method according to any one of the preceding claims, wherein, the first crosslinkable liquid electrolyte and the second crosslinkable liquid electrolyte each contain at least one lithium salt or sodium salt dissolved in at least one liquid solvent.

19. The manufacturing method according to any one of the preceding claims, wherein, the first crosslinkable liquid electrolyte and the second crosslinkable liquid electrolyte each contain at least one surfactant with a mass percentage included between 1% and 5%, and for example between 2% and 4%.

20. The manufacturing method according to any one of the preceding claims, wherein, the first covering step achieves: - unwinding the anode current collector film (81) previously wound on the first roll stock (810); and - covering or impregnating the anode current collector film (81) with the anode mixture (82) when the anode current collector film (81) is unwound.

21. The manufacturing method according to any one of the preceding claims, wherein, the second covering step achieves: - unwinding the cathode current collector film (91) previously wound on the second roll stock (910); and - covering or impregnating the cathode current collector film (91) with the cathode mixture (92) when the cathode current collector film (91) is unwound.

22. The manufacturing method according to any one of the preceding claims, wherein, The first covering step includes a first thickness calibration step, and the first thickness calibration step includes mechanically adjusting the thickness of the anode electrode (83) before the stacking step, and the thickness is referred to as the first thickness (E1).

23. The manufacturing method according to claim 22, wherein, the first thickness (E1) is adjusted to a value included between 10 micrometers and 1000 micrometers, and for example between 30 micrometers and 500 micrometers.

24. The manufacturing method according to claim 22 or 23, wherein, before the stacking step, the first thickness calibration step is achieved by compressing the anode electrode (83).

25. The manufacturing method according to claim 24, wherein, the anode electrode (83) is compressed by continuous rolling between two rolling rollers including a first input roller (13) and a first output roller (14).

26. The manufacturing method according to claim 25, wherein, the anode current collector film (81) is continuously conveyed into the first input roller (13), and the anode mixture (82) is deposited or impregnated on the anode current collector film (81) at the first input roller (13) to form the anode electrode (83), and the anode electrode (83) is continuously conveyed between the first input roller (13) and the first output roller (14) to be compressed, and then is conveyed out of the first output roller (14).

27. The manufacturing method according to any one of the preceding claims, wherein, the second covering step includes a second thickness calibration step, and the second thickness calibration step includes mechanically adjusting the thickness of the cathode electrode (93), and the thickness is referred to as the second thickness (E2).

28. The manufacturing method according to claim 27, wherein, the second thickness (E2) is adjusted to a value included between 10 micrometers and 1000 micrometers, and for example between 30 micrometers and 500 micrometers.

29. The manufacturing method according to claim 27 or 28, wherein, before the stacking step, the second thickness calibration step is achieved by compressing the cathode electrode (93).

30. The manufacturing method according to claim 29, wherein, the cathode electrode (93) is compressed by continuous rolling between two rolling rollers including a second input roller (23) and a second output roller (24).

31. The manufacturing method according to claim 30, wherein, the cathode current collector film (91) is continuously conveyed into the second input roller (23), and the cathode mixture (92) is deposited or impregnated on the cathode current collector film (91) at the second input roller (23) to form the cathode electrode (93), and the cathode electrode (93) is continuously conveyed between the second input roller (23) and the second output roller (24) to be compressed, and then is conveyed out of the second output roller (24).

32. The manufacturing method according to any one of the preceding claims, wherein, During the curing step, the stack (6) is exposed to the at least one electron beam, the at least one electron beam comprising: - a single electron beam facing one of the anode electrode (83) or the cathode electrode (93); or - two electron beams facing the anode electrode (83) and the cathode electrode (93) respectively.

33. The manufacturing method according to any one of the preceding claims, wherein, the at least one electron beam has an irradiation dose characteristic including between 10 kGy and 100 kGy, and for example between 50 kGy and 80 kGy.

34. The manufacturing method according to any one of the preceding claims, wherein, the at least one electron beam has an accelerating voltage characteristic including between 100 keV and 1 MeV.

35. The manufacturing method according to any one of the preceding claims, wherein, the winding speed of the stack (6) has a speed characteristic including between 1 m / min and 500 m / min, and for example between 1 m / min and 30 m / min.

36. The manufacturing method according to any one of the preceding claims, wherein, at least one of the anode current collector film (81) and the cathode current collector film (91) is selected from: - a metal laminated film, the metal laminated film being made of, for example, copper or aluminum and provided with perforations; - a polymer and metal fiber-based metal composite porous film, the polymer and metal fiber-based metal composite porous film being combined to form a non-woven fabric; - a polymer and carbon fiber-based porous carbon composite film, the polymer and carbon fiber-based porous carbon composite film being combined to form a non-woven fabric, and the carbon fiber being optionally subjected to a pretreatment to improve the electrical conductivity and thermal conductivity of the carbon fiber; - a carbon fiber-based porous film, the carbon fiber-based porous film being combined to form a non-woven fabric, and the carbon fiber being optionally subjected to a pretreatment to improve the electrical conductivity and thermal conductivity of the carbon fiber.

37. The manufacturing method according to claim 36, wherein, the perforations of the metal laminated film have a maximum size including between 0.5 mm and 2 mm and are distributed at a density including between 2 perforations per square centimeter and 10 perforations per square centimeter.

38. The manufacturing method according to claim 36, wherein, the pretreatment includes depositing a pretreatment layer based on titanium nitride or titanium carbide or a combination of titanium nitride and carbide on the carbon fiber, the pretreatment layer having a thickness including between 100 nm and 1000 nm.

39. The manufacturing method according to any one of the preceding claims, wherein, the anode current collector film (81) includes an internal anode surface and an external anode surface opposite to the internal anode surface. During the first covering step, the anode mixture (82) is deposited or impregnated on the internal anode surface, wherein the external anode surface is pre-covered or impregnated with a leak-proof and conductive conductive varnish layer (66); And the cathode current collector film (91) includes an inner cathode surface and an outer cathode surface opposite to the inner cathode surface. During the second covering step, the cathode mixture (92) is deposited or impregnated on the inner cathode surface, wherein the outer cathode surface is pre-covered or impregnated with another electrically conductive varnish layer (67) that is leak-proof and conductive.

40. The manufacturing method according to claim 39, wherein, each of the electrically conductive varnish layer (66) and the other electrically conductive varnish layer (67) has a thickness less than or equal to 30 microns, for example, included between 5 microns and 30 microns.

41. The manufacturing method according to any one of the preceding claims, wherein, the first covering step and the second covering step are performed in parallel.

42. The manufacturing method according to any one of the preceding claims, wherein, the stack (6) has two opposite longitudinal edges, and the manufacturing method includes the following steps: applying an electrically insulating varnish after the stacking step and before the curing step. During the step of applying the electrically insulating varnish, two electrically insulating and leak-proof electrically insulating varnish layers (68) are correspondingly deposited on the two opposite longitudinal edges of the stack (6).

43. The manufacturing method according to claim 42, wherein, the two electrically insulating varnish layers (68) are hardened when exposed to the at least one electron beam during the curing step.

44. The manufacturing method according to claim 42 or 43, wherein, the anode current collector film (81) has two opposite longitudinal edges (811), the width (L81) of the anode current collector film (81) is defined between the two opposite longitudinal edges (811), and during the first covering step, the anode mixture (82) is deposited or impregnated on the anode current collector film (81) to form a strip having a width (L82) smaller than the width (L81) of the anode current collector film (81), so that the two longitudinal edges (811) of the anode current collector film (81) are not covered and impregnated by the anode mixture (82), the cathode current collector film (91) has two opposite longitudinal edges (911), the width (L91) of the cathode current collector film (91) is defined between the two opposite longitudinal edges (911), and during the second covering step, the cathode mixture (92) is deposited or impregnated on the cathode current collector film (91) to form a strip having a width (L92) smaller than the width (L91) of the cathode current collector film (91), so that the two longitudinal edges (911) of the cathode current collector film (91) are not covered and impregnated by the cathode mixture (92), such that before the step of applying the electrically insulating varnish, the two opposite longitudinal edges of the stack (6) are free of the anode mixture (82) and the cathode mixture (92).

45. The manufacturing method according to any one of the preceding claims, wherein, The active anode material is selected from anode materials used alone or in combination, and the anode materials are based on: - carbon, such as graphite for example; - silicon; - carbonaceous silicon or lithiated silicon; - transition metals or alloys of transition metals; - composite materials combining transition metals and carbon; - lithium metal; - sodium metal; - lithium titanate; - aluminum, or magnesium, or tin, or zinc.

46. The manufacturing method according to any one of the preceding claims, wherein, The active cathode material is selected from cathode materials used alone or in combination, and the cathode materials are based on: - lithiated nickel manganese cobalt; - lithiated nickel cobalt aluminum; - lithium iron phosphate; - lithiated lithium cobaltate; - lithiated manganese oxide; - sulfur-carbon composite materials in the presence of lithiated anode materials; - lithium sulfide; - sodium alloys, such as Na3V2(PO4)2F3 for example.

47. The manufacturing method according to any one of the preceding claims, wherein, The first covering step, the second covering step, the stacking step and the curing step are carried out in an anhydrous environment and for example in an environment of argon or carbon dioxide.

48. A device for manufacturing an electrochemical cell (60) of a polymer matrix battery, the device comprising the following stations: - A first covering station (1), the first covering station (1) comprising: a first dispenser (10) for an anode current collector film (81); a first reservoir (11) that houses an anode mixture (82) which is in a paste or semi-liquid state and contains at least one anode active material dispersed in a first crosslinkable liquid electrolyte containing a first crosslinkable composition; and a first covering unit (12) for covering or impregnating the anode current collector film with the anode mixture (82) to form an anode electrode (83); - A second covering station (2), the second covering station (2) comprising: a second dispenser (20) for a cathode current collector film (91); a second reservoir (21) that houses a cathode mixture (92) which is in a paste or semi-liquid state and contains at least one cathode active material dispersed in a second crosslinkable liquid electrolyte containing a second crosslinkable composition; and a second covering unit (22) for covering or impregnating the cathode current collector film (91) with the cathode mixture (92) to form a cathode electrode (93); - A third impregnation station (3), the third impregnation station (3) comprising a third dispenser (30) for an electrically insulating and porous separator membrane (71) and an impregnation unit (32) for impregnating the separator membrane (71) with a third crosslinkable liquid or semi-liquid electrolyte (72) to form a pre-impregnated separator membrane (73); - Stacking station (4) for stacking the anode electrode (83) and the cathode electrode (93), wherein the pre-impregnated separator membrane (73) is interposed between the anode electrode (83) and the cathode electrode (93) to form a stack (6); - Curing station (5) located at the outlet of the stacking station (4), the curing station (5) comprising at least one electron beam generator (50) for exposing the stack (6) to at least one electron beam such that the first crosslinkable liquid electrolyte, the second crosslinkable liquid electrolyte and the third crosslinkable liquid or semi-liquid electrolyte (72) are cured integrally in the anode electrode (83), the cathode electrode (93) and the separator membrane (71) to form the polymer matrix electrochemical cell (60).

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