METHOD FOR MANUFACTURED LITHIUM ION BATTERIES, PARTICULARLY HIGH-POWER BATTERIES, AND BATTERY OBTAINED BY THIS METHOD

Abstract

New high-power battery architecture including unique anodic and cathodic conductive means which gives it an improved lifespan. Figure for the abstract: [Fig. 17].

Description

Title of the invention: METHOD FOR MANUFACTURED LITHIUM ION BATTERIES, PARTICULARLY HIGH-POWER BATTERIES, AND BATTERY OBTAINED BY THIS METHOD Technical field of the invention

[0001] The present invention relates to the manufacture of lithium-ion batteries. The invention concerns a new method for manufacturing batteries, and in particular high-power lithium-ion batteries. It also relates to the batteries obtained by this method, which have a new architecture that gives them an improved lifespan. State of the art

[0002] In order to increase the production yield of rechargeable batteries with high energy density and high power density, such as all-solid-state batteries or batteries impregnated with a liquid electrolyte, the simultaneous manufacture of several batteries can be achieved from a superposition of alternating anode and cathode sheets previously coated with a layer of electrolyte.

[0003] WO 2016 / 001584 (LTEN) describes sheets comprising a conductive substrate successively covered with an electrode layer covered with an electrolyte layer; these sheets are cut, before or after deposition, according to patterns, notably U-shaped. These sheets are stacked alternately to form a stack of several elementary cells. The cutting patterns of the anodes and cathodes are arranged in a head-to-tail configuration so that the stacking of the cathode and anode layers is laterally offset. After the stacking step, it is known from this document to deposit a thick-film encapsulation system, approximately ten microns thick and conformal, typically a polymeric layer, onto the stack and into the available cavities within the stack.This ensures, on the one hand, the rigidity of the structure at the cutting planes and, on the other hand, the protection of the battery cell from the atmosphere. Once the stack is assembled and encapsulated in a rigid structure, it is cut along cutting planes to obtain individual batteries, exposing the cathodic and anodic connections of the batteries on each cutting plane. It turns out that during these cuts, the encapsulation system can be torn off, resulting in a discontinuity in the battery's seal. It is also known to add terminations (i.e., electrical contacts) where these cathodic and anodic connections are exposed.

[0004] This prior art is explained here in greater detail with reference to [Fig. 12] which illustrates a lithium-ion battery structure described in WO 2016 / 001584. The battery 200 comprises several anodes 230 and several cathodes 210, which are arranged alternately one below the other. Each anode and each cathode includes a layer of an active material, respectively, called the anode layer and the cathode layer. Furthermore, a layer of electrolyte material, not shown in [Fig. 12], is interposed between the anode and the cathode, such that this electrolyte material separates two opposing active layers. The thickness of the individual layers does not normally exceed 15 µm and is often between 2 µm and 8 µm. The battery has, on a first lateral edge 201, anodic connections 230' arranged one below the other. Furthermore, on the opposite lateral edge 202, cathode connections 210' are provided, located one below the other.The stacking of the anodes 230 and cathodes 210 is laterally offset. The cathode connections 210' are located in projection, relative to the free face 230" of the anode. Similarly, on the opposite edge 201, the free face 210" of the cathode is located inset relative to the free face of the anode on which the anodic connections 230' are subsequently deposited.

[0005] This known solution, however, has certain drawbacks. Indeed, depending on the electrode positioning, particularly the proximity of the electrode edges for multilayer batteries and the cleanliness of the cuts, a leakage current can appear at the ends, typically in the form of a creeping short circuit. This reduces battery performance, even with the use of an encapsulation system around the battery and near the cathode and anodic connections. Furthermore, unsatisfactory deposition of the encapsulation system on the battery is sometimes observed, particularly on the battery edges in the spaces created by the lateral offsets of the electrodes at the battery edges.

[0006] Furthermore, since the anode and cathode terminations are located behind the adjacent cathode and anode layers, respectively, a large cutout is necessary. This cutout must then be filled with an insulating material. Due to its large size, this cutout leads to a substantial loss of usable material for the actual battery construction. Moreover, it requires depositing thick layers of insulation in the available cavities within the stack. Thick insulation risks weakening the entire battery encapsulation system because, during the cutting process, the encapsulation system deposited in a thick layer tends to delaminate. The prior art design therefore presents both technical and economic disadvantages.

[0007] Finally, for many applications, it is important to reduce battery resistance, which leads to power loss. For very high-power batteries according to the prior art, the resistance of the connecting elements contributes significantly to the battery resistance: a battery architecture that increases the resistance of the connecting elements would not be acceptable, even if it could solve some of the other problems mentioned above. As such, the connection between the connecting elements and the conductive surfaces of the battery intended to come into contact with said connecting elements presents a contact resistance, which must be minimized. This connection can be made simply by gluing. To illustrate this, see [Fig.

[12] As mentioned above, a metal foil can be glued to the edges of the anodes 230' and cathodes 210', after encapsulating the battery and making a lateral cut that exposes these edges. A good connection exhibits low electrical resistance, which should not degrade over the battery's lifetime.

[0008] However, conductive adhesives, which are often used to bond metal sheets at terminations, generally exhibit high contact resistance, especially adhesives containing graphite. In contrast, excellent electrical conductivity is known to be achieved with inks containing metallic nanoparticles or carbide or nitride nanoparticles. However, this low resistance is only obtained when these inks undergo heat treatment at a temperature sufficient to induce sintering of the conductive nanoparticles. Typically, a temperature of around 400 °C leads to sintering, which remains incomplete, but such a temperature is far too high for batteries containing a liquid electrolyte.

[0009] Furthermore, the density of sintered inks is not high enough to make them impermeable to water vapor (this permeability is expressed by the Water Vapor Transmission Rate, abbreviated WVTR, and hereafter referred to as the WVTR coefficient); this is the case, for example, with the Métalon®-Nano Copper ink from Novacentrix®. There is therefore a real need to improve the quality of the electrical contact between the battery conductive surfaces and the connecting elements, both to reduce contact resistance and to improve the durability of this electrical contact.

[0010] The present invention aims to remedy at least in part some of the drawbacks of the prior art mentioned above.

[0011] It aims in particular to increase the production efficiency of rechargeable batteries with high energy density and high power density and to achieve more efficient encapsulations at a lower cost.

[0012] It aims in particular to propose a method that reduces the risk of short circuits, and which allows for the manufacture of a battery with low self-discharge.

[0013] It aims in particular to propose a process which makes it possible to manufacture in a simple, reliable and rapid manner a battery with a very long lifespan.

[0014] It also aims to propose such a process, which uses a cutting step of better quality than in the prior art.

[0015] It also aims to propose such a process, which makes it possible to improve the encapsulation phases and the encapsulation itself, taking place during the production of the final battery.

[0016] It also aims to propose a battery manufacturing process that generates less material loss.

[0017] In any event, the solution to these problems must not increase the resistance of the battery, and must, if possible, reduce it. Objects of the invention

[0018] At least one of the above objectives is achieved through at least one of the objects according to the invention as described below. The present invention proposes as a first object a battery 100 comprising at least one anode 3 and at least one cathode 1, arranged alternately one above the other, said battery 100 comprising lateral edges 101, 102 comprising at least one anodic connection zone and at least one cathodic connection zone, laterally opposite the anodic connection zone, and longitudinal edges 103, 104, in which the anode 3 comprises: - a current-collecting substrate, - at least one anode layer, and - optionally a layer of an electrolyte material or of a separator impregnated with an electrolyte,

[0019] and cathode 1 comprises: - a current-collecting substrate, - at least one cathode layer, and - optionally a layer of electrolyte material or a separator impregnated with an electrolyte,

[0020] so that the battery successively comprises at least one anode layer, at least one layer of an electrolyte material or of a separator impregnated with an electrolyte, and at least one cathode layer,

[0021] so that: - each anode and each cathode comprises a respective principal body 111,131, separated from a respective secondary body 112,132, by a free space 113,133 of any electrode material, electrolyte and current-collecting substrate, said free space connecting the opposite longitudinal edges 103,104 of the battery, - each anode and each cathode comprises, in top view, at least one first through hole 51, 53 made in the main body and a second through hole 52, 54 made in the secondary body,

[0022] it being understood that each first through hole 51 made in the main body of the cathode extends in line with each second through hole 54 made in the secondary body of the anode, so that these holes 51, 54, extending one in line with the other, form a first through passage 61 which crosses the battery from one side to the other,

[0023] and that each first through hole 53 made in the main body of the anode extends in line with each second through hole 52 made in the secondary body of the cathode, so that these holes 52, 53, extending one in line with the other, form a second through passage 63 which passes through the battery, - the battery further comprises at least one cathodic conductive means 71, 71', 71" received in said first through passage 61 and at least one anodic conductive means 73, 73', 73" received in said second through passage 63, the anodic conductive means 73, 73', 73" being capable of collecting at least a portion of the battery current towards at least one anodic connection zone and the cathodic conductive means 71, 71', 71" being capable of collecting at least one part of the battery current towards at least one cathode connection area.

[0024] Advantageously, in top view, the free spaces of the cathodes 113 are superimposed.

[0025] Advantageously, in top view, the free spaces of the anodes 133 are superimposed.

[0026] Advantageously, in top view, the free spaces of the cathodes 113 and the free spaces of the anodes 133 are not confused.

[0027] Advantageously, in top view, the first opening passage 61 and the second opening passage 63 are not confused.

[0028] Advantageously, free faces of the secondary bodies respectively of the cathodes 112' and of the anodes 132', which are opposite to the free space, are flush with the free faces of the main body respectively of the anodes 131' and of the cathodes 111'.

[0029] Advantageously, the smallest distance D59 / D56 separating the first opening passage 61 from the free face 111', 132' opposite the free space 133 is between 0.04 mm and 1.95 mm.

[0030] Advantageously, the battery comprises an encapsulation system covering four of the six faces of said battery, and partially covering the other two faces, these two other faces being opposite and substantially perpendicular to the first and second open passages 61, 63 of the battery comprising at least one anodic connection zone and at least one cathodic connection zone.

[0031] Advantageously, the encapsulation system comprises: - at least one first coating layer, preferably chosen from parylene, type F parylene, polyimide, epoxy resins, silicone, polyamide, sol-gel silica, organic silica and / or a mixture thereof, deposited on the battery, - at least one second cover layer composed of an electrically insulating material, deposited by atomic layer deposition or PECVD, HDPCVD or ICPCVD on said at least first cover layer,

[0032] it being understood that this sequence of at least one first cover layer and at least one second cover layer can be repeated z times with z > 1.

[0033] Advantageously and alternatively, the encapsulation system may comprise: - at least one first coating layer having a very low WVTR coefficient, preferably a WVTR coefficient of less than 105 g / m2 .d, deposited on the outer periphery of the stack of anodic and cathodic foils,

[0034] it being understood that this first covering layer can be repeated z' times with z' > 1.

[0035] Advantageously, the first at least coating layer comprises a ceramic material and / or a low-melting-point glass, preferably a glass with a melting point below 600°C. Advantageously, the ceramic material and / or glass is selected from:

[0036] - a low melting point glass (typically < 600°C), preferably SiO2-B2O3; Bi2 O3-B2O3, ZnO-Bi2O3-B2O3, TeO2-V2O5, PbO-SiO2,

[0037] - oxides, nitrides, oxynitrides, SixNy, SiO2, SiON of Silicon amorphous or SiC.

[0038] Advantageously, the battery includes a termination system covering at least the anode connection area 75, 75' and at least the cathode connection area 76, 76'.

[0039] Advantageously, the transverse dimension, or width, of the free space Ln3 is between 0.01 mm and 0.5 mm.

[0040] Advantageously, the transverse dimension, or width, of the secondary bodies Ln2 is between 0.05 mm and 2 mm.

[0041] Advantageously, the anodic and cathodic conducting means are chosen, in- differently from each other, among: - a bar made of an electrically conductive material, the two opposite ends of which preferably define fastening heads, - a tight-fitting metal rod, the two opposite ends of which preferably define fastening heads, - a metal rod surrounded by an electrically conductive sheath material, the two opposite ends of which preferably define fixing heads.

[0042] The present invention proposes as a second object a method for manufacturing a battery, said battery comprising at least one anode 3 and at least one cathode 1, arranged one above the other in an alternating manner, said battery 100 comprising longitudinal edges 103,104 and lateral edges 101,102,

[0043] wherein the anode 3 comprises: - a current-collecting substrate, - at least one anode layer, and - possibly a layer of electrolyte material or a separator impregnated with an electrolyte,

[0044] and cathode 1 comprises: - a current-collecting substrate, - at least one cathode layer, and - possibly a layer of electrolyte material or a separator impregnated with an electrolyte

[0045] so that the battery successively comprises at least one anode layer, at least one layer of an electrolyte material or of a separator impregnated with an electrolyte, and at least one cathode layer,

[0046] each anode 3 comprising an anodic connection zone, located in the vicinity of a first lateral edge of the battery, while each cathode 1 comprises a cathodic connection zone, located on a second lateral edge of the battery, opposite said first edge,

[0047] said manufacturing process comprising:

[0048] a) supplying a stack I of alternating sheets, this stack comprising first sheets or anode sheets, each intended to form an anode layer of several batteries, and second sheets or cathode sheets, each intended to form a cathode layer of several batteries,

[0049] each anode foil comprising at least one anode slot 34 and each cathode foil comprising at least one cathode slot 14, said anode and cathode slots respectively comprising at least two longitudinal portions 16, 36 in superimposed parts, intended to delimit the longitudinal edges 103,104 of the battery, as well as a lateral part 18, 38 connecting said two longitudinal parts, the lateral part of the anode slot 38 and the lateral part of the cathode slot 18 being mutually offset, it being understood that each lateral part of the slots delimits a space free of any electrode material, electrolyte and current-collecting substrate, said free space separating, for each anode and each cathode, a primary body from a secondary body,

[0050] b) carrying out a heat treatment and / or mechanical compression of the stack of alternating sheets previously supplied,

[0051] c) for each anode and each cathode, the making of at least one first through hole 51, 53 in the main body and the making of at least one second through hole 52, 54 in the secondary body, - said first through hole 51, made in the main body of the cathode, extending in the continuation of the second through hole 54 made in the secondary body of the anode, so that these holes 51, 54, extending one in the continuation of the other, form a first through passage 61 which crosses the battery from one side to the other, - and said first through hole 53, made in the main body of the anode, extending in line with the second through hole 52, made in the secondary body of the cathode, so that these holes 52, 53, extending one in line with the other, form a second through passage 63 which goes all the way through the battery, it being understood that step c) can be carried out before step a) on the anode and cathode sheets or after step b),

[0052] d) the introduction of a cathodic conducting means 71, 71', 71" in the first open passage 61 and of an anodic conducting means 73, 73', 73" in the second open passage 63, each of these conducting means being capable of collecting at least a part of the battery current, and each of these conducting means protruding from the faces substantially perpendicular to the first and second open passages 61, 63 of the battery,

[0053] e) the making of two cuts Dn, D'n extending at least partially inside said slots, the first cut extending between the lateral part of the anode slot and the end opposite the longitudinal parts, while the second cut extends between the lateral part of the cathode slot and the end opposite the longitudinal parts.

[0054] Advantageously, the process comprises, after step b) or after step e) of producing the diced stack, a step f) of impregnating the diced stack with a lithium ion carrier phase such as liquid electrolytes or an ionic liquid containing lithium salts.

[0055] Advantageously, the process comprises, after step e) or after step f), encapsulating the diced stack by depositing: - at least one first coating layer, preferably chosen from parylene, type F parylene, polyimide, epoxy resins, silicone, polyamide, sol-gel silica, organic silica and / or a mixture thereof, on the battery, and then - at least one second cover layer composed of an electrically insulating material, deposited by atomic layer deposition or PECVD, HDPCVD or ICPCVD on said at least first cover layer,

[0056] it being understood that the sequence of at least one first cover layer and at least one second cover layer can be repeated z times with z > 1.

[0057] Advantageously, the two cuts Dn, D'n are made through at least a majority of the anodes and cathodes, in particular through all the anodes and cathodes.

[0058] Advantageously, the distances between each cutout and the ends opposite the longitudinal portions are identical. Advantageously, these distances are between 0.05 mm and 2 mm.

[0059] Advantageously, each slot has an overall H shape, the longitudinal parts forming the main vertical recesses of the H, while the lateral part forms the channel of the H.

[0060] Advantageously, each lateral part of the slots delimits a space free of any electrode material, electrolyte and / or current collector substrate connecting the opposite longitudinal edges of the battery, said free space separating, for each anode and each cathode, a primary body from a secondary body.

[0061] Advantageously, the width of the lateral part is between 0.05 mm and 2 mm.

[0062] Advantageously, each sheet belonging to said stack comprises several rows of slots arranged side by side. Advantageously, the two cuts are made through all the slots of the same row.

[0063] Advantageously, each sheet comprises several rows of slots arranged one below the other.

[0064] Advantageously, the distance separating adjacent cutouts, made in neighboring lines, is between 0.05 mm and 5 mm.

[0065] Advantageously, the number of lines is between 10 and 500, while the number of rows is between 10 and 500.

[0066] Advantageously, each cut is made by a sawing process, by guillotine, or by laser. Figures

[0067] The accompanying figures, given by way of non-limiting examples, represent different aspects and embodiments of the invention. [Fig. 12] represents a battery according to the prior art.

[0068] [Fig.1] is a perspective view of the anode and cathode sheets intended to form a stack according to the battery manufacturing process according to the invention.

[0069] [Fig.2] is a front view, illustrating one of the leaves of [Fig.1].

[0070] [Fig.3] is a larger-scale front view illustrating H-shaped slots passes made in adjacent leaves as well as first and second passes made in adjacent leaves.

[0071] [Fig.4] is a perspective view, also on a large scale, illustrating these slots in H-shaped cuts made in adjacent leaves, as well as these first and second cuts made in adjacent leaves.

[0072] [Fig. 5] is a top view, illustrating a cutting step carried out on different slots made in the stacking of the previous figures.

[0073] [Fig.6] is a top view, illustrating on a larger scale the cutouts made on an H-shaped slot.

[0074] [Fig.7] is a cross-sectional view, along line VILVII indicated on [Fig.6].

[0075] [Fig.8] is a cross-sectional view, along line VIII-VIII indicated on [Fig.6].

[0076] [Fig.9] is a top view illustrating a battery according to the invention, which is likely to be obtained in particular by means of the process shown in the preceding figures.

[0077] [Fig. 10] is a cross-sectional view, along line XX indicated on [Fig. 6] illustrating a battery according to the invention, which can be obtained in particular according to the process of the preceding figures.

[0078] [Fig. 11] is a perspective view, illustrating a battery according to the invention, which can be obtained in particular according to the process of the preceding figures.

[0079] [Fig. 12] is a perspective view illustrating a battery according to the prior art.

[0080] [Fig. 13] is a top view, illustrating a cutting step carried out on different H-shaped slots formed on an anode or cathode sheet according to a second variant of the invention and having the first and second passages formed on this anode or cathode sheet according to the second variant of the invention.

[0081] [Fig. 14] is a top view, illustrating on a larger scale the cutouts made on H-shaped slots according to the second variant of the invention.

[0082] [Fig. 15] is a perspective view, illustrating a battery according to the invention, which is likely to be obtained in particular according to the second variant of the invention.

[0083] [Fig. 16] comprises Figures 16A, 16B and 16C. These Figures 16A, 16B and 16C are cross-sectional views, along line XVI-XVI indicated on [Fig. 15] illustrating a battery according to the invention, which can be obtained in particular according to the process of the preceding figures and whose first and second passages provided on this battery are filled by conductive means intended to make the electrical connection between the cells of the battery.

[0084] [Fig. 17] is a cross-sectional view illustrating a battery according to the invention, which can be obtained in particular according to the process of the preceding figures, this battery comprising the conductive means intended to make the electrical connection between the battery cells and an encapsulation system.

[0085] The following reference numerals are used in these figures and in the description that follows:

[0086] I: stack of anode and cathode sheets

[0087] 1: cathode leaf

[0088] 2: Perforations present at the four ends of the anode and cathode sheets

[0089] 3: anode foil

[0090] 10: perforated central area of ​​the cathode sheet

[0091] 12: peripheral frame of the cathode sheet

[0092] XX: longitudinal or horizontal direction of the stack

[0093] YY: vertical or transverse direction of the stack

[0094] L: line of slots

[0095] R: row of slots

[0096] 20 / 1020: bridges of matter between two lines

[0097] H20 / H1020: Bridge heights

[0098] 22: strips of material between two rows

[0099] L22: band width

[0100] 14 / 1014: H-shaped slits in the cathode leaves

[0101] 16 / 1016: main vertical recesses of 14

[0102] 18 / 1018: horizontal channel of 14

[0103] Hm: total height of the slot

[0104] Lm: total width of the slot

[0105] Li6: width of each main recess 16

[0106] Hi8: height of each channel 18

[0107] Di8: distance between the vertex of 16 and 18

[0108] 34 / 1034 / 1014: H-shaped slots in the anode foils, analogous to slots 14

[0109] 36 / 1036: main vertical recesses of 34

[0110] 1101 / 1102: lateral edges of 1100 [YES] 38 / 1038: horizontal channel of 34

[0112] Dio2o: distance between the cut Dn and the face opposite the channel 1018

[0113] 51: First through hole made in the main body of the cathode

[0114] 52: Second through hole made in the secondary body of the cathode

[0115] 53: First through hole made in the main body of the anode

[0116] 54: Second through hole made in the secondary body of the anode

[0117] 61: First through passage

[0118] 63: Second passage leading out

[0119] 71, 71', 71”: cathode conductor

[0120] 73, 73', 73”: anodic conductor

[0121] 80: encapsulation system

[0122] 90: termination

[0123] 91: First conductive polymer layer of the terminations

[0124] XH / XH': horizontal median axis of slots 14 and 34, respectively of slots 1014 and 1034

[0125] D, D', Dn, D'n, Dn+i, D'n+i: Cut

[0126] 100 / 1100: Battery according to the invention

[0127] 40 / 1040: material falls

[0128] 41: cathode material falls

[0129] 43: anode material falls

[0130] X 100, Y 100: median longitudinal and lateral axes of 100

[0131] 101 / 102: lateral edges of 100

[0132] 103 / 104: longitudinal edges of 100

[0133] 110 / 1110: cathode layers

[0134] 130 / 1130: anode layers

[0135] 111, 131 / 1111, 1131: main body of 110, respectively of 130 / body main of 1110, respectively of 1130

[0136] 112, 132 / 1112, 1132: secondary body of 110, respectively of 130 / body se secondary of 1110, respectively of 1130

[0137] 113 / 1113: free space between 111 and 112, respectively between 1111 and 1112, of all electrode material, electrolyte and / or current collector substrate

[0138] 133 / 1133: free space between 131 and 132, respectively between 1131 and 1132, of all electrode material, electrolyte and / or current collector substrate

[0139] Lj13 / Li113: width of the free space between 111 and 112, respectively between 1111 and 1112

[0140] L!12 / Lu 12: width of the secondary body 112, respectively 1112

[0141] 111', 112', 131', 132': free faces respectively of 111, 112, 131, 132

[0142] 200: batteries of the prior art see [Fig. 12]

[0143] 210 / 230: cathode / anode

[0144] 201 / 202: lateral edges

[0145] 210' / 230': free faces of the cathode / anode also called respectively anodic / cathode connections

[0146] 210” / 230”: free faces of the cathode / anode located inset

[0147] D20: distance between the cut Dn and the face opposite the channel 18

[0148] D40: distance between the cut D'n and the face opposite the channel 38

[0149] D38: distance between the vertex of 36 and 38

[0150] 56: Strip of cathodic material separating the hole 51 from the free lateral edge of the battery

[0151] 57: Strip of cathode material separating the hole 52 from the free lateral edge of the battery

[0152] 58: Strip of anodic material separating hole 53 from the free lateral edge of the battery

[0153] 59: Strip of anodic material separating hole 54 from the free lateral edge of the battery

[0154] D56: distance separating hole 51 from the free lateral edge of the battery

[0155] D57: distance separating hole 52 from the free lateral edge of the battery

[0156] D58: distance separating hole 53 from the free lateral edge of the battery

[0157] D59: distance separating hole 54 from the free lateral edge of the battery

[0158] 75, 75': Anodic connection zone

[0159] 76, 76': Cathode ray connection zone

[0160] 92: second nickel layer of the terminations

[0161] 93: third tin layer of the terminations Description of the invention

[0162] The method according to the invention first comprises a step in which an alternating stack I of sheets is made, these sheets being referred to hereafter as "anode sheets" and "cathode sheets," as appropriate. As will be seen in more detail, each anode sheet is intended to form the anode of several batteries, and each cathode sheet is intended to form the cathode of several batteries. In the example illustrated in [Fig. 1], five cathode sheets 1 and five anode sheets 3 are shown. In practice, this stack is formed by a larger number of sheets, typically between ten and one thousand.In an advantageous embodiment, all these sheets have perforations 2 at their four ends such that when these perforations 2 are stacked, all the cathodes and anodes of these sheets are arranged specifically, as will be explained in greater detail below (see Figures 1 and 2). These perforations 2 at the four ends of the sheets are positioning guides allowing the sheets to be aligned during stacking.

[0163] These perforations 2 at the four ends of the sheets can be made by any suitable means, in particular on anode and cathode sheets after manufacture or on anode and / or cathode sheets coated with a layer of electrolyte or coated with a separator so that this electrolyte layer or separator is intercalated between two sheets of opposite polarity, i.e. between the anode sheet and the cathode sheet.

[0164] The physicochemical structure of each anode or cathode foil, which may be of a known type, is not part of the invention and will be described only briefly. Each anode foil 3 comprises an anodic current-collecting substrate coated with an active layer of an anode material, hereinafter referred to as the anode layer. Each cathode foil 1 comprises a cathodic current-collecting substrate coated with an active layer of a cathode material, hereinafter referred to as the cathode layer. Each of these active layers may be solid, and more particularly of a dense or porous nature. Furthermore, in order to prevent any electrical contact between two adjacent foils, namely, between two active layers of opposite polarities, an electrolyte layer or a separator impregnated with a liquid electrolyte (not shown in Fig. 1) is used.(l) is disposed on at least one of these two sheets, namely, on the active layer of at least one of these current-collecting substrates previously coated with the active layer, in contact with the active layer of the opposite sheet. The electrolyte layer or the separator impregnated with a liquid electrolyte, not shown in the figures describing the present invention, is intercalated between two sheets of opposite polarity, i.e., between the anode sheet and the cathode sheet. More precisely, the electrolyte layer or the separator may be disposed on the anode layer and / or on the cathode layer; the electrolyte layer or the separator is an integral part of the anode sheet 3 and / or the cathode sheet 1 or comprises it.

[0165] An elementary battery cell comprises successively at least one anodic current-collecting substrate, at least one anode layer, at least one layer of an electrolyte material or of a separator impregnated with an electrolyte, at least one cathode layer, and at least one cathodic current-collecting substrate. The current-collecting substrates may be metallic strips.

[0166] Advantageously, the two faces of the anodic and cathodic current-collecting substrate can be coated with an anode layer and a cathode layer, respectively, and optionally with an electrolyte or separator layer, disposed on the anode layer and the cathode layer, respectively. In this case, the anodic and cathodic current-collecting substrate will serve as a current collector for two adjacent elementary cells. The use of these substrates in batteries makes it possible to increase the production efficiency of rechargeable batteries with high energy density and high power density.

[0167] We will now describe the mechanical structure of one of the cathode leaves 1, It is understood that the other cathode leaves have an identical structure. Furthermore, as will be seen below, the anode leaves 3 have a structure very similar to that of the cathode leaves 1.

[0168] As can be seen in [Fig. 2], the cathode sheet 1 has a quadrilateral shape, essentially square. It delimits a central area 10, referred to as a perforated area, in which H-shaped slots are formed, which will be described below. With reference to the positioning of these H-shaped slots, a vertical direction YY of the sheet is defined, corresponding to the vertical direction of these H-shaped slots, as well as a horizontal direction XX of the sheet, perpendicular to the YY direction. The central area 10 is bordered by a peripheral frame 12, which is solid, i.e., without slots. The function of this frame is, in particular, to ensure easy handling of each sheet.

[0169] The H-shaped slots are distributed along lines Lx to Ly, arranged one below the other, as well as along rows Ri to Rx arranged side by side. By way of non-limiting example, in the manufacture of surface-mount component (SMD) microbatteries, the anode and cathode sheets used can be 100 mm x 100 mm plates. Typically, the number of lines on these sheets is between 10 and 500, while the number of rows is also between 10 and 500. Depending on the desired battery capacity, its dimensions can vary, and the number of lines and rows per anode and cathode sheet can be adjusted accordingly. The dimensions of the anode and cathode sheets used can be modulated as required. As shown in [Fig.[2] Two adjacent rows are separated by material bridges 20, whose height is denoted H20, and which is between 0.05 mm and 5 mm. Two adjacent rows are separated by material strips 22, whose width is denoted L22, and which is between 0.05 mm and 5 mm. These bridges and material strips of the anode and cathode sheets give them sufficient mechanical rigidity so that they can be easily handled.

[0170] The slots 14 are through slots, meaning that they open onto the upper and lower faces of the sheet, respectively. The slots 14 can be formed in a manner known per se, directly on the substrate, before any deposition of anode or cathode materials, by chemical etching, electroforming, laser cutting, micro-perforation, or stamping. These slots can also be formed on substrates coated with anode or cathode materials, or on anode or cathode sheets coated with an electrolyte layer or a separator, in a manner known per se, for example, by laser cutting, femtosecond laser cutting, micro-perforation, or stamping. The slots 14, formed in all the cathodes, are superimposed, as shown in particular in [Fig. 3].

[0171] We will now describe one of the H-shaped slots 14, it being understood that all the cutouts in the cathode sheet are identical. The slot 14 is formed by two main vertical and parallel recesses 16, which are connected in their upper part by a horizontal channel 18, preferably perpendicular to the two main vertical recesses 16. We note: H14 the height of the entire slot, which is typically between 0.25 mm and 10 mm; • Li4 its width, which is typically between 0.25 mm and 10 mm; • Li6 the width of each main recess, which is typically included between 0.02 mm and 5 mm; • Hi8 the height of each channel, which is typically between 0.01 mm and 0.5 mm; • Di8 the difference in heights between the top of the main recesses and the top of the channel, which is typically between 0.05 mm and 2 mm.

[0172] Moreover, as shown in particular in [Fig.10], at least one first through hole 51 is made in the main body and a second through hole 52 is made in the secondary body.

[0173] The through holes 51 / 52 / 53 / 54 are also referred to as through holes, meaning that they open onto the upper and lower faces of the sheet, respectively. These through holes can be made in a method known per se, directly on the anode and / or cathode sheets before or after stacking alternating sheets comprising first sheets or anode sheets, each intended to form an anode layer of several batteries, and second sheets or cathode sheets, each intended to form a cathode layer of several batteries. The through holes can be made by chemical etching, electroforming, laser cutting, micro-perforation, or stamping.

[0174] The first 51 and second 52 through holes, made in all the cathodes, are superimposed as shown in particular in [Fig. 3]. The through holes 53 and 54 are visible in [Fig. 10].

[0175] Each anode is also provided with different rows and lines of slots 34, provided in the same number as the slots 14. As shown in particular in [Fig. 4], the structure of each slot 34 is substantially similar to that of each slot 14, namely that this slot 34 comprises two main vertical recesses 36, connected by a channel 38. The dimensions of the main vertical recesses 36 are identical to those of the main vertical recesses 16 and, similarly, the dimensions of the channels 38 are similar to those of the channels 18.

[0176] In top view, the main vertical recesses 36 are superimposed with those 16. The only difference between slots 14 and 34 is that channels 38 are located in the lower part. As shown in particular in [Fig. 3], channels 18 and 38 are mutually symmetrical in top view, with respect to the median axis of the H, which is denoted XH.

[0177] Moreover, as shown in particular in [Fig.3], at least one first through hole 53 is made in the main body and a second through hole 54 is made in the secondary body.

[0178] Advantageously, the first through hole 51 made in the main body of the cathode extends in line with the second through hole 54 made in the secondary body of the anode, so that these holes 51 / 54 extend in line with each other and form a first through passage 61 which passes completely through the battery. Furthermore, the first through hole 53 made in the main body of the anode extends in line with the second through hole 52 made in the secondary body of the cathode, so that these holes 53 / 52 extend in line with each other and form a second through passage 63 which passes completely through the battery.

[0179] Advantageously, the second through holes 52 / 54 are made at a certain distance from the channels 18 and 38 of the slots in order to avoid any risk of short circuit while maintaining the mechanical strength of the stack. This distance is advantageously chosen according to the nature of the anode and cathode foils, in particular the nature of the current-collecting substrate used, its thickness, and its rigidity. The presence of these through holes within the stack must not degrade the mechanical strength of the stack. The dimensions of the through holes can be adjusted according to requirements.

[0180] Advantageously, the first and second through holes 53 / 52 / 51 / 54 are made at a certain distance from the lateral edges 101 and 102 of the battery, delimiting a ribbon of material 56 / 57 / 58 / 59 as will be detailed below. Advantageously, the second through holes 52 / 54 are made in the respective secondary bodies 112 / 132 at a certain distance from the respective free spaces 113 / 133 of the battery, delimiting a second ribbon of material not shown in the figures. It is assumed that the stack, described above, is subjected to steps aimed at ensuring its overall mechanical stability. These steps, of a type known per se, include in particular the heat pressing of the different layers. As will be seen below, this stack allows the formation of individual batteries, the number of which is equal to the product of the number of lines Y and the number of rows X.

[0181] To this end, with reference to [Fig. 5], three lines Ln.i to Ln+i, and three rows Rn.i to Rn+i, are illustrated. In accordance with the invention, two cuts Dn and D'n are made per line of slots. Each cut, which is made through, to Knowing that it extends over the entire height of the stack is achieved in a way that is known in itself. Non-exhaustive examples include sawing, particularly dicing, guillotine cutting, and laser cutting.

[0182] As shown in particular in [Fig. 6], which is a larger-scale view of one of the slots in [Fig. 5], each cut is made between a respective channel and the end opposite the H. The thickness of said cut is assumed to be negligible. Under these conditions, with reference to [Fig. 6], by way of non-limiting examples, we note: • the distance D20 between the cut Dn and the face opposite the horizontal channel 18 is between 0.05 mm and 2 mm, it being understood that this distance D20 is less than or equal to Di8; • the distance D4o between the cut D'n and the face opposite the horizontal channel 38, between 0.05 mm and 2 mm, it being understood that this distance D40 is less than or equal to D38.

[0183] With further reference to [Fig. 5], each final battery is delimited, at the top and bottom, by the two cutouts and, on the right and left, by the inner faces of the main vertical recesses of the H. In [Fig. 5], the batteries 100, once cut by the cutting lines Dn and D'n, are hatched. The areas 40 of the stack's sheets, which do not form the batteries, are shown with dots, while the volume of the slots is left white. Furthermore, [Fig. 5] illustrates the first and second passages 61 / 63 that pass completely through the battery; these passages will subsequently be filled by conductive means protruding from both the upper and lower surfaces of the battery. These first and second passages 61 / 63 are preferably substantially perpendicular to the cathode and anode sheets constituting the stack.

[0184] Figures 7 and 8 are cross-sectional views, taken along parallel cutting lines. Section VII-VII extends through the main vertical recesses of the H, while section VIII-VIII passes through the material. In [Fig.7], the zones 40, also illustrated in [Fig.5], have been referenced, which correspond to material offcuts, in particular offcuts of anode material 43 and cathode material 41. In [Fig.8] it is noted that the cuts are made both through the anodes and the cathodes, namely at a distance D20 from the channels of the H-shaped slots so as to have for each cathode 1, respectively each anode 3 of the battery 100 a main body 111, respectively 131, separated from a secondary body 112, respectively 132, by a space free of any electrode material, electrolyte and / or current collector substrate 113, respectively 133.This is a particularly advantageous feature of the invention, since it allows for improved quality. of the cut in relation to the prior art and to avoid the presence of short circuits at the lateral edges of the battery.

[0185] Application WO 2016 / 001584 describes stacks of several elementary cells, consisting of anode and cathode sheets stacked alternately and laterally offset (see [Fig. 12]), encapsulated in an encapsulation system to protect the battery cell from the atmosphere. Cutting these encapsulated stacks to obtain unit batteries, with exposed anode and cathode connections, is carried out along a cutting plane that passes through an alternating succession of electrodes and encapsulation systems. Due to the difference in density between the electrode and the encapsulation system of the prior art battery, cutting along this plane creates a risk of the encapsulation system being torn away near the cutting plane, thus creating short circuits.In the prior art, during encapsulation, the encapsulation layer fills the gaps in the stack of sheets bearing U-shaped cutouts. This encapsulation layer, introduced at these gaps, is thick and does not adhere very well to the stack, leading to a risk of the encapsulation system being torn away during subsequent cutting.

[0186] According to the present invention, this risk is eliminated by using sheets with H-shaped cutouts, because the thermo-pressed H-shaped mechanical structure is extremely rigid near the cutout due to the alternating overlap of cathode and anode sheets. The use of such a rigid structure, with sheets bearing H-shaped cutouts, reduces the number of defects during cutting, increases the cutting speed, and thus improves battery production efficiency.

[0187] According to the invention, the D'n and Dn cuts are made through anodes and cathodes of comparable density, resulting in a cleaner, higher-quality cut. Furthermore, the presence of a space free of any electrode material, electrolyte, and / or current-collecting substrate prevents any risk of short circuit.

[0188] With reference now to Figures 9 to 11, one of the 100 batteries according to the invention is illustrated. X100 and Y100 denote the longitudinal and lateral median axes of this battery, respectively. 101 and 102 denote the lateral edges, and 103 and 104 the longitudinal edges of this battery. Each cathode is denoted 110, and each anode 130. The number of these cathodes, which is identical to the number of these anodes, corresponds to the number of cathode and anode sheets in the stack shown above.

[0189] As shown in [Fig. 9], namely in top view, the free spaces of the cathodes are superimposed. Moreover, according to this same top view, the free spaces of the anodes are superimposed. Finally, according to this same top view, the free spaces cathodes and anodes are not confused, i.e., not mutually superimposed. This is notably represented, as an example, in [Fig.10].

[0190] The free space 113 connects the opposite longitudinal edges of the battery, which are represented as upper and lower in [Fig.9]. This free space extends between the opposite longitudinal edges of the battery, separating, for each anode and each cathode, a primary body from a secondary body.

[0191] Each cathode 110 comprises a main body 111, a secondary body 112 located on a first lateral edge 101, and a space 113 free of any electrode material, electrolyte, and / or current-collecting substrate. The latter, whose width corresponds to that of the channel 18 of the slot 14 described above, extends between the longitudinal edges 103 and 104. Similarly, each anode 130 comprises a main body 131 and a secondary body 132 located on the lateral edge 102 opposite to that of 101. The main body 131 and the secondary body 132 are separated by a space 133 free of any electrode material, electrolyte, and / or current-collecting substrate, connecting the edges 103 and 104, i.e., extending between the longitudinal edges 103 and 104. The 2 free spaces 113 and 133 are mutually symmetric, with respect to the median axis Y100.

[0192] The width Ln3 of each free space 113 corresponds to the width of the channel 18, belonging to the slot described in the preceding figures. Furthermore, the width Ln2 of each secondary body 112 corresponds to the distance D2o, as described with reference to [Fig. 6] or [Fig. 8].

[0193] Figure 13 illustrates a further variant of the invention. In this Figure 13, the mechanical elements analogous to those in Figures 1 to 11 illustrating the first embodiment are assigned the same reference numbers plus the number 1000.

[0194] This second embodiment differs from the first embodiment essentially in that the H-shaped slots 1014 are distributed along lines Lx to Ly, arranged one below the other, as well as along rows Ri to Rx provided one next to the other. Thus, at least one of the main vertical recesses 1016 of the slot positioned in row Rn coincides with at least one of the main vertical recesses 1016 of the adjacent slot positioned in row Rn and / or Rn+1. In this case, the two adjacent rows are not separated by material bands. As shown in [Fig. 13], two adjacent rows are separated by material bridges 1020, whose height is denoted H1020, and which is between 0.05 mm and 5 mm. These material bridges give the anode and cathode sheets sufficient mechanical rigidity for them to be easily handled.

[0195] In this second embodiment of the invention, the H-shaped slots 1014 can preferably be the same as in the first variant. The slot 1014 is preferably formed by two main vertical and parallel recesses 1016, which are connected in their upper part by a horizontal channel 1018, preferably perpendicular to the two main vertical recesses 1016.

[0196] Each cathode is provided with different rows and lines of slots 1014. Each anode is also provided with different rows and lines of slots 1034, provided in the same number as the slots 1014.

[0197] The structure of each slot 1034 is substantially analogous to that of each slot 1014, namely that this slot 1034 comprises two main vertical recesses 1036, connected by a channel 1038. The dimensions of the main vertical recesses 1036 are identical to those of the main vertical recesses 1016 and, similarly, the dimensions of the channels 1038 are analogous to those of the channels 1018.

[0198] In top view, the main vertical recesses 1036 are superimposed with the main vertical recesses 1016. The only difference between the slots 1014 and 1034 is that the channels 1038 are provided in the lower part. As shown in particular in [Fig. 14], the channels 1018 and 1038 are mutually symmetrical in top view with respect to the median axis of the H, which is denoted XH'.

[0199] It is assumed that the stacking of the anode and cathode sheets, described above, is subjected to steps aimed at ensuring its overall mechanical stability. These steps, of a type known per se, include in particular the heat pressing of the different layers. As will be seen below, this stacking allows the formation of individual batteries, the number of which is equal to the product of the number of lines Y and the number of rows X.

[0200] To this end, with reference to [Fig. 14], three lines Ln.i to Ln+i, and three rows Rn.i to Rn+i, are illustrated. According to the invention, two cuts Dn and D'n are made per line of slots. Each cut, which is made through the entire stack, i.e., it extends over the whole height of the stack, is made in a manner known per se. By way of non-limiting examples, sawing, in particular dicing, guillotine cutting, or laser cutting may be cited.

[0201] Each cut is made between a respective channel and the end opposite the H. The thickness of said cut is assumed to be negligible. The cuts are made both through the anodes and the cathodes, namely at a distance Dio2o from the channels of the H-shaped slots so as to have, for each cathode 1110, respectively each anode 1130 of the battery 1100, a main body 1111, respectively 1131, separated from a secondary body 1112, respectively 1132, by a space free of any electrode material, electrolyte and / or current collector substrate 1113, respectively 1133, as illustrated in [Fig. 15]. This is a characteristic The invention is particularly advantageous because it improves the quality of the cutting compared to the prior art and prevents short circuits at the lateral edges of the battery. Each final battery 1100 is delimited, at the top and bottom, by the two cutouts and, on the right and left, by the inner faces of the main vertical recesses of the H. In [Fig. 13], the batteries 1100 are hatched once cut by the cutting lines Dn and D'n; the areas 1040 of the stacking sheets, which do not form the batteries, are illustrated with dots, while the volume of the slots is left white.

[0202] According to the invention, the D'n and Dn cuts are made through anodes and cathodes of comparable density, resulting in a clean, high-quality cut. Furthermore, the presence of a space free of any electrode material, electrolyte, and / or current-collecting substrate prevents any risk of short circuit.

[0203] As shown in [Fig. 15], each cathode 1110 comprises a main body 1111, a secondary body 1112 located on a first lateral edge 1101, and a space 1113 free of any electrode material, electrolyte, and / or current-collecting substrate. The latter, whose width corresponds to that of the channel 1018 of the slot 1014 described above, extends between the longitudinal edges. Similarly, each anode 1130 comprises a main body 1131, as well as a secondary body 1132 located on the lateral edge 1102, opposite to that 1101. The main body 1131 and the secondary body 1132 are separated by a free space 1133 from any electrode material, electrolyte and / or current-collecting substrate, connecting the longitudinal edges, i.e. extending between the longitudinal edges 1103 and 1104. The two free spaces 1113 and 1133 are mutually symmetrical, with respect to the median axis Y100.

[0204] The width Lm3 of each free space 1113 corresponds to the width of the channel 1018, belonging to the slot described in the preceding figures. Furthermore, the width Lm2 of each secondary body 1112 corresponds to the distance Dio2o, as described previously.

[0205] The battery 1100 obtained according to the second variant of the invention is in every respect identical to that obtained according to the first variant of the invention even though the arrangement of the slots 1014 is different.

[0206] In a third embodiment of the invention, which is not shown in the figures, the H-shaped slots 14 / 1014 can be distributed along lines Lx to Ly, arranged one below the other, as well as along rows Ri to Rx arranged side by side. Thus, on the same anode and / or cathode sheet, the H-shaped slots 14 / 1014 are arranged according to the first and second embodiments of the invention, on the anode and / or cathode sheets, so as to maintain sufficient mechanical rigidity for these sheets to be ma easily assembled and so that the stacking can advantageously define a maximum of unit batteries.

[0207] The 1100 battery obtained according to the third variant of the invention is in every respect identical to that obtained according to the first and / or second variants according to the invention even though the arrangement of the slots 14 / 1014 on the anode and / or cathode sheets is different.

[0208] A comparison between Figures 11 and 12 highlights some advantages of the invention. In fact, substantially the entire overall volume of the battery is occupied by useful material, i.e., material that contributes to the electrochemical operation of the battery 100. Indeed, only the two very small free spaces 133 / 1133 cannot be considered useful material. In this regard, with reference to [Fig. 10], it is noted that the free faces 112' of the secondary cathode bodies are flush with the free faces 131' of the main anode body, while the free faces 132' of the secondary anode bodies are flush with the free faces 111' of the main cathode body. In other words, the opposite lateral edges of the battery according to the invention, comprising electrode materials, are substantially continuous, compared with those of the prior art illustrated in [Fig. 10]. 12], which are discontinuous due to the presence of withdrawals.

[0209] The "free face of the secondary body" corresponds to the face belonging to the secondary body that is opposite the principal body. The "free face of the principal body" corresponds to the face belonging to the principal body that is opposite the secondary body.

[0210] With reference to [Fig. 10], it is noted that: - the first through hole 51 made in the main body of the cathode extends in line with the second through hole 54 made in the secondary body of the anode, so that these holes 51 / 54 extend one in line with the other, and form a first through passage 61 which crosses the battery completely, and that - the first through hole 53 made in the main body of the anode, extends in the continuation of the second through hole 52 made in the secondary body of the cathode, so that these holes 53 / 52 extend one another in the continuation of the other, and form a second through passage 63 which crosses the battery from one side to the other.

[0211] Advantageously, the second through hole 52 is made in the secondary body of the cathode, at a certain distance D57 from the free space 113 (corresponding to the channel 18 of the slot 14) in order to avoid any risk of short circuit. Similarly, the second through hole 54 is made in the secondary body of the anode, at a certain distance D59 from the free space 133 (corresponding to the channel 38 of the slot 34). to avoid any risk of short circuit.

[0212] Advantageously the first and second through holes 53 / 52 / 51 / 54 are made at a certain distance from the lateral edges 101 and 102 of the battery, delimiting a band of material 56 / 57 / 58 / 59.

[0213] Note:

[0214] • D56, the width of the material ribbon 56, which corresponds to the distance between the face free 111' of battery 100 according to the invention and the face opposite the first through hole 51 made in the main body of the cathode; this distance D56 is between 0.04 mm and 1.95 mm, it being understood that this distance D56 is substantially equal to the distance D59, and is less than the width of the secondary anodic body;

[0215] • D57, the width of the material ribbon 57, which corresponds to the distance between the face free 112' of battery 100 according to the invention and the face opposite the second through hole 52 made in the secondary body of the cathode, this distance D57 is between 0.04 mm and 1.95 mm, it being understood that this distance D57 is substantially equal to the distance D58, and is less than the width of the secondary cathode body,

[0216] • D58, the width of the material ribbon 58, which corresponds to the distance between the face free 131' of battery 100 according to the invention and the face opposite the first through hole 53 made in the main body of the anode, this distance D58 is between 0.04 mm and 1.95 mm, it being understood that this distance D58 is substantially equal to the distance D57,

[0217] • D59, the width of the material ribbon 59, which corresponds to the distance between the face free 132' of battery 100 according to the invention and the face opposite the second through hole 52 made in the secondary body of the anode, this distance D59 is between 0.04 mm and 1.95 mm, it being understood that this distance D59 is substantially equal to the distance D56.

[0218] The first and second passages 61 / 63 provided on the battery according to the invention are filled by conductive means intended to make the electrical connection between the cells of the battery as shown in figures 16A, 16B and 16C. These conductive means protrude at the upper and lower surfaces of the battery.

[0219] The conductive means can be obtained from electrically conductive materials. Advantageously, the WVTR coefficient of these conductive means is extremely low; these conductive means are sealed. They are in intimate contact with the electrical connection areas of the stack.

[0220] By way of example, conductive means may be: - a bar made of an electrically conductive material, such as conductive glass or a metal introduced in a molten state or by any suitable means into the passage. Upon solidification, this material forms the aforementioned bar, the two opposite ends of which preferably define fixing heads as shown in Figure 16A. - a tight-fitting metal rod, the two opposite ends of which preferably define fastening heads, as shown in Figure 16B, - a metal rod surrounded by an electrically conductive sheath material, the sheath being obtainable from glass or metal introduced in a molten state or by any suitable means into the passage. Upon solidification, this material forms the aforementioned metal rod surrounded by an electrically conductive sheath material, the two opposite ends of which preferably define fastening heads as shown in Figure 16C.

[0221] The apex of each of these fastening heads or each of the opposite ends of the conductive means may define an electrical connection zone, namely an anodic connection zone 75 / 75' or cathodic connection zone 76 / 76' of the battery according to the invention, such that the battery comprises at least one anodic connection zone 75 / 75' and at least one cathodic connection zone 76 / 76'.

[0222] The conductivity of conductive glass can be obtained by adding particles of gold, nickel, chromium, nickel-chromium alloy, tungsten, molybdenum, graphite, carbides or nitrides to the glass.

[0223] These electrical connections are watertight and have a low water vapor transmission rate (also called water vapor permeance, and in English Water Vapor Transmission Rate, abbreviated WVTR). This rate depends in particular on the materials used and their manufacturing process. The measurement of water vapor permeability or permeance can be carried out using a method that is the subject of US 7,624,621 and is also described in the publication "Structural properties of ultraviolet cured polysilazane gas barrier lions on polymer substrates" by A. Mortier et al., published in the journal Thin Solid Films 6+550 (2014) 85-89. The lower the WVTR coefficient, the more watertight the encapsulation system.

[0224] The “free face of the secondary body” corresponds to the face belonging to the secondary body which is opposite to the principal body.

[0225] The “free face of the principal body” corresponds to the face belonging to the principal body which is opposite the secondary body.

[0226] Furthermore, the presence of free spaces on each anode and cathode layer of the battery eliminates the need for any encapsulation system, i.e., any insulating material such as parylene within the battery, as these free spaces act as electrical insulators. This simplifies the final stages of battery manufacturing, such as encapsulation. It is no longer necessary, As in the prior art and illustrated in [Fig. 12], the recessed regions 210”, 230” within the battery are isolated, i.e., the gaps in the prior art structure are filled with an encapsulation system, and the space in the U-shaped cutouts, positioned head-to-tail and offset, is filled with an encapsulation system to prevent short circuits. The use of a rigid structure according to the invention, employing sheets with H-shaped cutouts, facilitates encapsulation and reduces encapsulation thicknesses compared to the prior art. Multilayer encapsulation systems with thinner and more rigid layers than those of the prior art can be considered.

[0227] Advantageously, after the step of stacking the anode and cathode sheets, the resulting stack is assembled by heat treatment and / or mechanical compression.

[0228] Advantageously, after the stacking step of the anode and cathode sheets, the heat treatment of the stack, enabling the assembly of the battery, is carried out at a temperature between 50°C and 500°C, preferably at a temperature below 350°C, and / or the mechanical compression of the stack of anode and cathode sheets to be assembled is carried out at a pressure between 10 and 100 MPa, preferably between 20 and 50 MPa. In a particular embodiment, it is advantageous, after the stacking and heat treatment step of the latter, to carry out the first open passage 61 and the second open passage 63 as indicated previously, then to introduce a cathodic conducting means 71, 71', 71" into the first open passage 61 and an anodic conducting means 73, 73', 73" into the second open passage 63, each of these conducting means being capable of collecting at least a part of the battery current.

[0229] In all cases, these anodic and cathodic conducting means protrude from the opposite surfaces of the structure of the stacked anode and cathode sheets; these conducting means thus protrude from the overall volume of the stack as shown in Figures 16A, 16B and 16C.

[0230] The stack of anode and cathode sheets, comprising anodic and cathodic conductive means, is then cut by any suitable means along the cutting lines D'n and Dn so as to obtain unit batteries.

[0231] In the case of batteries impregnated with a liquid electrolyte, the impregnation of the battery with a liquid electrolyte is advantageously carried out, after the ionic conductive means have been developed, by means of a lithium ion carrier phase such as an ionic liquid and / or a mixture of ionic liquids with or without solvent and containing a lithium salt; this lithium ion carrier phase penetrates the battery by capillary action. The impregnation can be carried out by techniques known as such.

[0232] After the formation of the conductive means, or in the case of batteries impregnated with a liquid electrolyte, after the battery has been impregnated with a lithium ion carrier phase, it is advantageous to encapsulate the stack by depositing an encapsulation system to protect the battery cell from the atmosphere. The encapsulation system must be chemically stable, resistant to high temperatures, and impermeable to the atmosphere to perform its function as a barrier layer. Advantageously, the stack of anode and cathode foils according to the invention can be covered with a sequence, preferably z sequences, of an encapsulation system comprising: - a first coating layer, preferably chosen from parylene, type F parylene, polyimide, epoxy resins, silicone, polyamide and / or a mixture thereof, deposited on the stack of anode and cathode sheets,

[0233] a second covering layer composed of an electrically insulating material, deposited by atomic layer deposition (ALD) or plasma-enhanced chemical vapor deposition (PECVD) or by HDPCVD (High Density Plasma Chemical Vapor Deposition) or ICP CVD (Inductively Coupled Plasma Chemical Vapor Deposition) on said first covering layer.

[0234] This sequence can be repeated z times with z > 1. This multilayer sequence has a barrier effect. The more the encapsulation system sequence is repeated, the greater this barrier effect will be. It will be even greater the more thin layers are deposited.

[0235] Typically, the first coating layer is made of a polymer, for example, silicone, epoxy resin, polyimide, polyamide, or poly-para-xylylene (more commonly known as parylene). This first coating layer protects the sensitive components of the battery from the environment. It also seals the surface pores of the stack and creates a uniform bonding layer for the subsequent layers of the encapsulation system. Advantageously, this layer covers all six sides of the battery and completely seals it. The thickness of this first coating layer is preferably between 0.5 µm and 50 µm.

[0236] Advantageously, the first coating layer may be made of type C parylene, type D parylene, type N parylene (CAS 1633-22-3), type F parylene, or a mixture of type C, D, N, and / or F parylene. Parylene (also called poly-paraxylylene or poly(p-xylylene)) is a transparent, semi-crystalline, dielectric material that exhibits high thermodynamic stability and excellent resistance parylene exhibits resistance to solvents and very low permeability. It also possesses barrier properties that protect the battery from its external environment. Battery protection is further enhanced when this first coating layer is made from type F parylene. This first coating layer is advantageously obtained by the condensation of gaseous monomers deposited by chemical vapor deposition (CVD) onto the surfaces, resulting in a conformal, thin, and uniform coating of all accessible surfaces of the stack. This first coating layer is advantageously rigid; it cannot be considered a flexible surface.Since this first covering layer is not sufficiently waterproof (in terms of water vapor permeance), it is necessary to apply at least a second covering layer made of an electrically insulating material, preferably with low water vapor permeance.

[0237] The second coating layer is composed of an electrically insulating material, preferably inorganic. It is advantageously deposited by atomic layer deposition (ALD), so as to obtain conformal coverage of all accessible surfaces of the stack previously coated with the first coating layer. The layers deposited by ALD are very mechanically brittle and require a rigid support surface to ensure their protective role. Depositing a brittle layer on a flexible surface would lead to the formation of cracks, resulting in a loss of integrity of this protective layer. Furthermore, the growth of the layer deposited by ALD is influenced by the nature of the substrate. A layer deposited by ALD on a substrate with areas of different chemical compositions will have inhomogeneous growth, which could lead to a loss of integrity of this protective layer.

[0238] ALD deposition techniques are particularly well suited for coating highly rough surfaces in a completely airtight and conformal manner. They allow for the creation of conformal, defect-free layers, such as pinhole-free layers, and provide excellent barriers. Their WVTR coefficient is extremely low. The second coating layer can advantageously be deposited by plasma-enhanced chemical vapor deposition (PECVD) or by HDPCVD or ICP CVD. This second coating layer preferably has a thickness between 10 nm and 10 pm. The thickness of this second layer is advantageously chosen according to the desired level of gas tightness, i.e., the desired WVTR coefficient, and depends on the deposition technique used, in particular ALD, PECVD, HDPCVD, and ICPCVD.The second coating layer can be made of ceramic material, vitreous material or other material. glass-ceramic, for example in the form of oxide, of type A12O3, Ta2O5, nitride, phosphates, oxynitride, or siloxane.

[0239] This second coating layer, deposited by ALD, PECVD, HDPCVD, or ICP CVD on the first coating layer, serves two purposes: first, to ensure the structure is watertight, i.e., to prevent water migration into the object; and second, to protect the first coating layer, preferably of type F parylene, from the atmosphere, particularly air and humidity, and from thermal exposure, thus preventing its degradation. This second coating layer improves the lifespan of the encapsulated battery.

[0240] Encapsulating the stack of anode and cathode foils in this sequence of the encapsulation system, preferably in z sequences, allows the WVTR coefficient of the encapsulation system to be reduced to a minimum, i.e. increasing the sealing of the stack and the final battery.

[0241] The stack of anode and cathode foils thus encapsulated in this sequence of the encapsulation system, preferably in z sequences, can then be coated with a final covering layer so as to mechanically protect the encapsulated stack and optionally give it an aesthetic appearance. This final covering layer protects and improves the battery's lifespan. Advantageously, this final covering layer is also chosen to withstand high temperatures and has sufficient mechanical strength to protect the battery during its subsequent use. Advantageously, the thickness of this final covering layer is between 1 µm and 50 µm. Ideally, the thickness of this final covering layer is about 10–15 µm; such a thickness range protects the battery against mechanical damage.

[0242] This final coating layer is preferably based on epoxy resin, polyethylene naphthalate (PEN), polyimide, polyamide, polyurethane, silicone, silica sol-gel, or organic silica. Advantageously, this final coating layer is applied by dipping.

[0243] Alternatively, the encapsulation system, which protects the battery cell, or the stack of anode and cathode foils according to the invention, from the atmosphere, may consist of a sequence, preferably z' sequences, comprising a first alternative coating layer having a very low WVTR coefficient, preferably less than 105 g / m².d. This sequence can be repeated z' times with z > 1. It exhibits a barrier effect, which is all the more significant as the value of z' increases. Encapsulating the stack of anode and cathode foils in this sequence of the encapsulation system, preferably in z' sequences, allows for to minimize the WVTR coefficient of the encapsulation system, i.e. to increase the sealing of the encapsulation, to increase the sealing of the stack and ultimately to increase the sealing of the battery.

[0244] The thickness of said first alternative covering layer is preferably between 0.5 pm and 50 pm.

[0245] This alternative coating layer may be composed of a ceramic material and / or a low-melting-point glass, preferably a glass with a melting point below 600°C, deposited on the outer periphery of the stack of anodic and cathodic foils. The ceramic material and / or glass used in this layer is advantageously selected from:

[0246] - a low melting point glass (typically < 600°C), preferably SiO2-B2O3; Bi2 O3-B2O3, ZnO-Bi2O3-B2O3, TeO2-V2O5, PbO-SiO2,

[0247] - oxides, nitrides, oxynitrides, SixNy, SiO2, SiON of Silicon amorphous or SiC.

[0248] These lenses can be deposited by molding or by dip-coating.

[0249] Ceramic materials are advantageously deposited by PECVD or preferably by HDPCVD or by ICP CVD at low temperature; these processes allow the deposition of a layer having good sealing properties.

[0250] Advantageously, the alternative encapsulation system may comprise z' alternative covering layers of different natures in order to reduce the WVTR coefficient of the encapsulation, i.e., to increase the sealing of the stack. By way of example, the encapsulation system may comprise a first layer composed of a ceramic material, a second layer composed of a low-melting-point glass disposed on the first layer, and vice versa.

[0251] Encapsulation in a glass film can be achieved by depositing an ink comprising oxides, phosphates, borates and / or precursors of a low melting point glass, followed by sintering.

[0252] This results in a rigid and sealed encapsulation, which in particular prevents the passage of water vapor at the interface between the encapsulation system and the contact parts.

[0253] After ensuring the battery cell is sealed by encapsulation, the electrical connections are exposed at the ends of the battery's conductive means by any means, including polishing.

[0254] Terminations (electrical contacts) are added at the point where the cathodic and anodic connections are exposed (not coated with insulating electrolyte). These contact areas are preferably located on opposite sides of the battery stack to collect current. The connections are metallized using techniques known to those skilled in the art, preferably by immersion in a conductive epoxy resin and / or a bath of molten tin.

[0255] The terminations can be made of a single metallic layer, for example tin, or be multilayered. Preferably, the terminations consist, in the vicinity of the cathodic and anodic connections, of a first stack of layers comprising successively a first layer of conductive polymer, such as a silver-filled resin, a second layer of nickel deposited on the first layer, and a third layer of tin deposited on the second layer. The nickel and tin layers can be deposited by electrodeposition techniques.

[0256] In this three-layer complex, the nickel layer protects the polymer layer during the soldering assembly steps, and the tin layer ensures the solderability of the battery interface.

[0257] The terminations allow for the reconnection of positive and negative electrical connections on the upper and lower faces of the battery. These terminations allow for parallel electrical connections between the different battery cells. The cathode connections preferably exit on one side of the battery, and the anodic connections are preferably available on the other side.

[0258] According to the invention, the battery can comprise any technically compatible combination of the encapsulation systems as described, the anodic and cathodic conductive means and the terminations.

[0259] The battery according to the invention may be a lithium-ion microbattery, a lithium-ion minibattery, or a high-power lithium-ion battery. In particular, it may be designed and sized to have a capacity less than or equal to about 1 mA h (commonly called a "microbattery"), to have a power greater than about 1 mA h up to about 1 Ah (commonly called a "minibattery"), or to have a capacity greater than about 1 Ah (commonly called a "power battery"). Typically, microbatteries are designed to be compatible with microelectronic manufacturing processes.

[0260] Batteries in each of these three power ranges can be made: - either with "all-solid" type layers, i.e., without impregnated liquid or paste phases (said liquid or paste phases being a lithium ion-conducting medium capable of acting as an electrolyte), - or with mesoporous "all-solid" type layers, impregnated by a liquid or paste phase, typically a lithium ion-conducting medium, which spontaneously enters the interior of the layer and does not exit. of this layer, so that this layer can be considered quasi-solid, either with impregnated porous layers (i.e. layers with a network of open pores that can be impregnated with a liquid or paste phase, and which gives these layers wet properties).

Claims

1. Demands Battery (100) comprising at least one anode (3) and at least one cathode (1), arranged alternately one above the other, said battery (100) comprising lateral edges (101, 102) comprising at least one anodic connection zone and at least one cathodic connection zone, laterally opposite the anodic connection zone, and longitudinal edges (103, 104), in which the anode (3) comprises: - a current-collecting substrate, - at least one anode layer, and - optionally a layer of electrolyte material or a separator impregnated with an electrolyte, and the cathode (1) comprises: - a current-collecting substrate, - at least one cathode layer, and - optionally a layer of electrolyte material or a separator impregnated with an electrolyte, so that the battery successively comprises at least one anode layer, at least one layer of an electrolyte material or of a separator impregnated with an electrolyte, and at least one cathode layer, characterized in that - each anode and each cathode comprises a respective main body (111, 131), separated from a respective secondary body (112, 132), by a free space (113, 133) of any electrode material and current-collecting substrate, said free space connecting the opposite longitudinal edges (103, 104) of the battery, - each anode and each cathode comprises, in top view, at least one first through hole (51, 53) made in the main body and a second through hole (52, 54) made in the secondary body, it being understood that each first through hole (51) made in the the main body of the cathode, extends in the continuation of each second through hole (54) made in the secondary body of the anode, so that these holes (51, 54), extending one in the continuation of the other, form a first through passage (61) which passes through the battery, and that each first through hole (53) made in the main body of the anode, extends in the continuation of each second through hole (52) made in the secondary body of the cathode, so that these holes (52, 53), extending one in the continuation of the other, form a second through passage (63) which passes through the battery, - the battery further comprises at least one cathodic conductive means (71, 71', 71”) received in said first through passage (61) and at least one anodic conductive means (73, 73', 73”) received in the said second opening passage (63), the anodic conductor means (73, 73',73”) being capable of collecting at least a portion of the battery current towards at least one anodic connection area and the cathodic conductive means (71, 71', 71”) being capable of collecting at least a portion of the battery current towards at least one cathodic connection area.

2. Battery according to any one of the preceding claims, characterized in that free faces of the secondary bodies respectively of the cathodes (112') and of the anodes (132'), which are opposite the free space, are flush with the free faces of the main body respectively of the anodes (131') and of the cathodes (111').

3. Battery according to the preceding claim, characterized in that the smallest distance (D59 / D56) separating the first open passage (61) from the free face (111', 132') opposite the free space (133) is between 0.04 mm and 1.95 mm.

4. Battery according to any one of the preceding claims, characterized in that it comprises an encapsulation system covering four of the six faces of said battery, and partially covering the other two faces, these other two faces being opposite and substantially perpendicular to the first and second through-holes (61, 63) of the battery comprising at least one anodic connection zone and to the minus a cathode connection zone.

5. Battery according to claim 4, characterized in that the encapsulation system comprises: - at least one first coating layer, preferably selected from parylene, type F parylene, polyimide, epoxy resins, silicone, polyamide, sol-gel silica, organic silica and / or a mixture thereof, deposited on the battery, - at least one second coating layer composed of an electrically insulating material, deposited by atomic layer deposition or PECVD, HDPCVD or ICPCVD on said at least first coating layer, it being understood that this sequence of at least one first coating layer and at least one second coating layer can be repeated z times with z > 1.

6. Battery according to claim 4, characterized in that the encapsulation system comprises: - at least one first coating layer having a very low WVTR coefficient, preferably a WVTR coefficient less than 105 g / m2.d, deposited on the outer periphery of the stack of anodic and cathodic foils, it being understood that this first coating layer can be repeated z' times with z' > 1.

7. Battery according to claim 6, characterized in that the at least first coating layer comprises: - a ceramic material, preferably selected from oxides, nitrides, oxynitrides, SixNy, SiO2, SiON, amorphous silicon or SiC, and / or - a low melting point glass, preferably a glass having a melting point below 600°C, more preferably a low melting point glass selected from SiO2-B2O3; Bi2O3-B2O3, ZnO-Bi2O3-B2O3, TeO2-V2O5 and PbO-SiO2.

8. Battery according to any one of the preceding claims, ca- characterized in that it includes a termination system covering at least the anodic connection area (75, 75') and at least the cathodic connection area (76, 76').

9. Battery according to the preceding claim, characterized in that the termination system comprises successively: - a first layer of conductive polymer, preferably a silver-filled resin, - a second layer of nickel disposed on the first layer of the termination system, and - a third layer of tin, disposed on the second layer of the termination system.

10. Battery according to any one of the preceding claims, characterized in that the transverse dimension, or width, of the free space (Ln3) is between 0.01 mm and 0.5 mm.

11. Battery according to any one of the preceding claims, characterized in that the transverse dimension, or width, of the secondary bodies (Ln2) is between 0.05 mm and 2 mm.

12. Battery according to any one of the preceding claims, characterized in that the anodic and cathodic conductive means are chosen, indifferently from each other, from: - a bar formed of an electrically conductive material, the two opposite ends of which define, preferably, fixing heads, - a metal rod with a tight fit, the two opposite ends of which define, preferably, fixing heads, - a metal rod surrounded by an electrically conductive sheath material, the two opposite ends of which define, preferably, fixing heads.

13. A method for manufacturing a battery, said battery comprising at least one anode (3) and at least one cathode (1), arranged alternately one above the other, said battery (100) comprising longitudinal edges (103, 104) and lateral edges (101, 102), wherein the anode (3) comprises: - a current-collecting substrate, - at least one anode layer, and - optionally a layer of electrolyte material or a separator impregnated with an electrolyte, and the cathode (1) comprises: - a current-collecting substrate, - at least one cathode layer, and - optionally a layer of electrolyte material or a separator impregnated with an electrolyte such that the battery successively comprises at least one anode layer, at least one layer of an electrolyte material or of a separator impregnated with an electrolyte, and at least one cathode layer, each anode (3) comprising an anodic connection zone, located in the vicinity of a first lateral edge of the battery, while each cathode (1) comprises a cathodic connection zone, located on a second lateral edge of the battery, opposite said first edge, said manufacturing process comprising: (a) the supply of a stack (I) of alternating sheets, this stack comprising first sheets or anode sheets, each intended to form an anode layer of several batteries, and second sheets or cathode sheets, each intended to form a cathode layer of several batteries, each anode sheet comprising at least one anode slot (34) and each cathode sheet comprising at least one cathode slot (14), said anode and cathode slots respectively comprising at least two longitudinal parts (16, 36) partially overlapping, intended to delimit the longitudinal edges (103, 104) of the battery, and a lateral part (18, 38) connecting said two longitudinal parts, the lateral part of the anode slot (38) and the lateral part of the cathode slot (18) being mutually offset,it being understood that each lateral part of the slots delimits a space free of any electrode material and current-collecting substrate, said free space separating, for each anode and each cathode, a primary body from a secondary body, b) the execution of a heat treatment and / or mechanical compression of the stack of alternating sheets previously supplied, (c) for each anode and each cathode, the production of at least one first through hole (51, 53) in the main body and the production of at least one second through hole (52, 54) in the secondary body, - said first through hole (51), made in the main body of the cathode, extending in line with the second through hole (54) made in the secondary body of the anode, so that these holes (51, 54), extending one in line with the other, form a first through passage (61) which crosses the battery from one side to the other, - and said first through hole (53), made in the main body of the anode, extending in line with the second through hole (52), made in the secondary body of the cathode, so that these holes (52, 53), extending one in line with the other, form a second through passage (63) which goes through the battery, it being understood that step c) can be carried out before step a) on the anode and cathode sheets or after step b), d) the introduction of a cathodic conducting means (71, 71', 71”) in the first open passage (61) and an anodic conducting means (73, 73', 73”) in the second open passage (63), each of these conducting means being capable of collecting at least a portion of the battery current, and each of these conducting means projecting from the faces substantially perpendicular to the first and second open passages (61, 63) of the battery, e) the making of two cuts (Dn, D'n) extending at least partially inside said slots, the first cut extending between the lateral part of the anode slot and the end opposite the longitudinal parts, while the second cut extends between the lateral part of the cathode slot and the end opposite the longitudinal parts.

14. The method according to claim 13, characterized in that it comprises, after step b) or after step e) of making the diced stack, a step f) of impregnating the diced stack, by a lithium ion carrier phase such as liquid electrolytes or an ionic liquid containing lithium salts.

15. A method according to claim 13 or claim 14, characterized in that it comprises, after step e) or after step f), encapsulating the diced stack, by depositing: - at least one first coating layer, preferably selected from parylene, type F parylene, polyimide, epoxy resins, silicone, polyamide, sol-gel silica, organic silica and / or a mixture thereof, on the battery, and then - at least one second coating layer composed of an electrically insulating material, deposited by atomic layer deposition or PECVD, HDPCVD or ICPCVD on said at least first coating layer, it being understood that the sequence of at least one first coating layer and at least one second coating layer can be repeated z times with z > 1.

16. A method according to any one of claims 13 to 15, characterized in that the two cuts (Dn, D'n) are made through at least a majority of the anodes and cathodes, in particular through all the anodes and cathodes.

17. A method according to any one of claims 13 to 16, characterized in that each slot has an overall H shape, the longitudinal parts forming the main vertical recesses of the H, while the lateral part forms the channel of the H.

18. A method according to any one of claims 13 to 17, characterized in that each lateral part of the slots delimits a space free of any electrode material and current collector substrate connecting the opposite longitudinal edges of the battery, said free space separating, for each anode and each cathode, a primary body from a secondary body.

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