METHOD FOR MANUFACTURING A BATTERY, AND BATTERY OBTAINED BY THIS METHOD

Abstract

This method for manufacturing a battery includes a step of supplying a stack of electrode sheets, the stack having at least one pair of longitudinal slots (70), substantially parallel to each other, intended to define the lateral edges of a battery. The method also includes a first punching of the stack so as to form, for each pair of longitudinal slots (70), two orifices (102, 104) interposed between said longitudinal slots (70) and spaced longitudinally apart from each other, each of the orifices (102, 104) being at a distance from each longitudinal slot (70). It also includes a second punching of the stack so as to form, for each hole (102, 104) formed during the first punching, a cutout (132, 134) passing through said hole (102, 104), said cutout (132, 134) connecting the longitudinal slots (70) to each other. Figure for the abbreviation: Fig. 19

Description

Title of the invention: METHOD FOR MANUFACTURING A BATTERY, AND BATTERY OBTAINED BY THIS METHOD Field of the invention

[0001] The present invention relates to the manufacture of batteries. It can be applied in particular to lithium-ion, sodium-ion, or potassium-ion batteries. It also relates to batteries obtained by this process. Technological background

[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 2020 / 136313 Al is known a method for manufacturing batteries from electrode sheets comprising a conductive substrate successively coated with an active layer and then with a layer of electrolyte or a porous separator. These sheets are cut, before or after deposition, into H-shaped patterns. These sheets are stacked alternately to form a stack of several elementary cells. The cut patterns of the anodes and cathodes are arranged in a "head-to-tail" configuration so as to form longitudinal through-slits through the stack. Once the stack is formed, it is cut along transverse cutting planes to obtain individual batteries. This cutting is notably carried out by sawing. The individual batteries thus obtained are then impregnated with a liquid electrolyte.

[0004] However, this process is not entirely satisfactory. It has been observed that sawing the stack induces a folding of the conductive substrate layers of the electrode sheets, preventing the active layers and the electrolyte or porous separator layers from being impregnated by the liquid electrolyte. It is therefore necessary to polish the battery terminations to allow effective impregnation of the active layers and the electrolyte or porous separator layers, which is essential for the battery to achieve the desired performance. However, such polishing is tedious and costly, as the batteries must be polished individually. Furthermore, this polishing leads to several problems, including inconsistent battery dimensions and delamination of battery layers.

[0005] To solve this problem, it was considered to cut the stack by punching, using punches of a dimension equal to the width of the H. However, This solution proved equally unsatisfactory, as this punching caused the tearing away of the battery end portions located between the H bar and the punching end. Description of the invention

[0006] One objective of the invention is to reduce the manufacturing costs of solid-state or quasi-solid-state batteries, in particular micro-batteries, obtained by cutting from a stack of electrode sheets. Another objective is to enable such batteries to be cut in such a way as to preserve their physical and mechanical integrity while facilitating their impregnation with a liquid electrolyte.

[0007] To this end, the invention relates, according to a first aspect, to a method for manufacturing a battery, comprising the following steps: - supply of a stack of electrode sheets, each electrode sheet comprising: • a current-collecting substrate, and • on at least one face of the current-collecting substrate, an active layer,

[0008] at least a portion of the electrode sheets further comprising, on at least one of its faces, a separation layer, intended to form an electrolytic layer, covering the active layer, the electrode sheets being arranged within the stack so that each active layer is opposite another active layer while being separated from it by at least one separation layer,

[0009] the stack also having at least one pair of longitudinal slots, substantially parallel to each other, intended to delimit the lateral edges of a battery, - performing heat treatment and / or mechanical compression of the stack, - first punching of the stack so as to form, for each pair of longitudinal slots, two orifices interposed between said longitudinal slots and spaced longitudinally apart from each other, each of the orifices being at a distance from each longitudinal slot, and - second punching of the stack so as to form, for each hole formed during the first punching, a cut through said hole, said cut connecting the longitudinal slots to each other.

[0010] According to particular embodiments of the invention, the manufacturing process also has one or more of the following characteristics, taken individually or in any technically possible combination(s): each orifice has a transverse dimension less than or equal to 60%, preferably less than 55%, for example less than or equal to 51%, of the transverse edge-to-edge distance between the longitudinal slots of the pair; each orifice has a transverse dimension greater than or equal to 40%, preferably greater than 45%, for example greater than or equal to 49%, of the transverse edge-to-edge distance between the longitudinal slots of the pair; each orifice has a transverse dimension approximately equal to half the edge-to-edge transverse distance between the longitudinal slits of the pair; each orifice has a transverse dimension less than or equal to 1.375 mm, preferably less than or equal to 1.275 mm; each orifice has a transverse dimension greater than or equal to 1.125 mm, preferably greater than or equal to 1.225 mm; each orifice is approximately centered between the longitudinal slits of the pair; each orifice has an inner edge close to the other orifice formed for the same pair of longitudinal slots and an outer edge opposite said inner edge, the second punching being carried out at a distance from said inner edge; the manufacturing process includes, between the first punching and the second punching, the impregnation of the stack by a cation-carrying phase; the cation-carrying phase comprises at least one liquid electrolyte and / or at least one ionic liquid; the liquid electrolyte and / or ionic liquid includes cationic salts, such as lithium, sodium or potassium salts; the electrode sheets comprise anode sheets and cathode sheets, said anode and cathode sheets being alternated within the stack, each anode sheet having, for each pair of longitudinal slots, an anodic transverse slot connecting the longitudinal slots to each other and each cathode sheet having, for each pair of longitudinal slots, a cathodic transverse slot connecting the longitudinal slots to each other, the anodic transverse slots being substantially aligned vertically with each other, the cathodic transverse slots being substantially aligned vertically with each other, and the anodic transverse slots being offset longitudinally with respect to the cathodic transverse slots; - the edge-to-edge distance from each of the orifices to the nearest of the transverse anodic and cathodic slits is greater than or equal to 130 pm, preferably greater than or equal to 180 pm; - the two orifices longitudinally frame the transverse anodic and cathodic slits; - each transverse anodic slot and / or each transverse cathodic slot delimits a space free of any electrode material and current collector substrate, said free space separating, for each anode foil and each cathode foil, a primary body from a secondary body; - the longitudinal dimension of each transverse anodic slit and / or of each transverse cathodic slit is between 0.01 mm and 0.5 mm, preferably between 0.03 mm and 0.15 mm, preferably between 0.05 mm and 0.1 mm, more preferably about 0.07 mm; - the longitudinal gap between each transverse anodic slot and that of the longitudinal ends of the longitudinal slots to which it is closest is greater than 0.4 mm, preferably greater than 0.45 mm, preferably between 0.4 mm and 2 mm; - the longitudinal gap between each cathodic transverse slit and that of the longitudinal ends of the longitudinal slits to which it is closest is greater than 0.4 mm, preferably greater than 0.45 mm, preferably between 0.4 mm and 2 mm; - the current-conducting substrate comprises a metallic material, the active layer or layers comprise a porous electrode active material, and the separation layer comprises a porous inorganic material, preferably a porous ceramic; - the manufacturing process includes, prior to the first punching, a step of encapsulating the stack; - The stack encapsulation step includes at least one stack overlap sequence with: • 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 stack, and • at least a second covering layer composed of an electrically insulating material, deposited by deposition of atomic layers on said at least first covering layer,

[0011] said sequence being optionally repeated z times, with z > 1, preferably z > 2; - the manufacturing process includes, following the second punching, the creation of battery terminations; - The battery termination process includes depositing a layer of graphite-filled material, preferably graphite-filled epoxy resin-based, onto opposite end edges of the battery; and - the first and second punching operations are carried out through all the electrode sheets.

[0012] The invention also relates, according to a second aspect, to a battery produced by means of a manufacturing process according to the first aspect.

[0013] The invention also relates, according to a third aspect, to a battery formed by a superposition of anodes and cathodes arranged one above the other alternately in a stacking direction, said battery comprising two opposite end edges constituting longitudinal ends of the battery in a longitudinal direction orthogonal to the stacking direction, in which each end edge comprises a recessed central portion, framed transversely by two lateral portions each projecting longitudinally from the central portion.

[0014] According to particular embodiments of the invention, the battery according to the second or third aspect also has one or more of the following characteristics, taken individually or in any technically possible combination(s): - electrical terminations are formed at said end edges preferably at the level of the lateral portions of said end edges; - each anode comprises a primary anodic body and a secondary anodic body separated from each other by a space free of any electrode material and current-collecting substrate, the secondary anodic body extending along one of the end edges, and each cathode comprises a primary cathodic body and a secondary cathodic body separated from each other by a space free of any electrode material and current-collecting substrate, the secondary cathodic body extending along a second end edge opposite the first edge; and - the two free spaces are mutually symmetrical with respect to a median transverse axis of the battery. Brief description of the Figures

[0015] Other features and advantages of the invention will become apparent from the following description, given solely by way of example and with reference to the accompanying drawings, in which: - Figure 1 is a diagram illustrating a battery manufacturing process according to the invention. - [Fig.2] is an exploded perspective view of a stack of electrode sheets used in the manufacturing process of [Fig.1], - [Fig.3] is a cross-sectional view of a portion of a terminal anode foil from the stack of [Fig.2], - [Fig.4] is a cross-sectional view of a portion of an intermediate cathode foil from the stack of [Fig.2], - [Fig.5] is a cross-sectional view of a portion of an intermediate anode foil from the stack of [Fig.2], - [Fig.6] is a cross-sectional view of a portion of a terminal cathode foil from the stack of [Fig.2], - [Fig.7] is a front view of the stack of [Fig.2], - [Fig.8] is a front view of a detail marked VIII of [Fig.7], - [Fig.9] is a perspective view of the detail of [Fig.8], - [Fig. 10] is a cross-sectional view of a portion of the stack of [Fig. 2] according to a plan marked XX on the [Fig.8], - Figures 11 to 13 are cross-sectional views illustrating a first set of steps in the manufacturing process of [Fig.1], - [Fig. 14] is a detailed view of [Fig. 8] after the first set of steps illustrated by Figures 11 to 13, - [Fig. 15] is a cross-sectional view of the stacking of [Fig. 2] at the end of the first set of steps illustrated by Figures 11 to 13, following a plane marked XV-XV on [Fig. 14], - Figures 16 to 18 are cross-sectional views illustrating a second set of steps in the manufacturing process of [Fig. 1], - [Fig. 19] is a detailed view of [Fig. 8] after the second set of steps illustrated by Figures 16 to 18, - [Fig. 20] is a cross-sectional view of the stacking of [Fig. 2] at the end of the second set of steps illustrated by Figures 16 to 18, following a plane marked XX-XX on [Fig. 19], and - Figs. 21, 22 and 23 are respectively top, front and perspective views of a battery obtained by the manufacturing process of Fig. 1. Detailed description of an example of implementation

[0016] The manufacturing process 10 shown in [Fig.1] is intended for the manufacture of batteries.

[0017] This method 10 includes a first step SI of supplying a stack of electrode sheets, during which a stack 20 ([Fig.2]) is supplied.

[0018] With reference to [Fig. 2], the stack 20 comprises a plurality of electrode sheets 22, 24, 26, 28. In the example shown, there are ten of these sheets 22, 24, 26, 28. In practice, the number of electrode sheets 22, 24, 26, 28 in the stack 20 can be higher. This number is typically between two and one thousand, preferably between two and one hundred, for example between two and fifty.

[0019] Here and in the following, orientation terms are understood with reference to the following orthogonal coordinate system, shown in the figures, in which we distinguish: - a longitudinal direction X and a transverse direction Y, each substantially parallel to the faces of the electrode sheets 22, 24, 26, 28, and together defining a horizontal plane, and - a vertical direction Z, oriented from bottom to top, constituted by the stacking direction of electrode sheets 22, 24, 26, 28.

[0020] Each electrode sheet 22, 24, 26, 28 typically has a quadrilateral shape, for example, as shown, a square. The longitudinal X and transverse Y directions are then chosen so as to be substantially parallel to the edges of the electrode sheets 22, 24, 26, 28.

[0021] Preferably, each electrode sheet 22, 24, 26, 28 has, as shown, a plurality of perforations 30 designed to guide the sheets 22, 24, 26, 28 during stacking. These perforations 30 are intended to be aligned with each other during the stacking of the sheets 22, 24, 26, 28 so as to allow a specific arrangement of said sheets 22, 24, 26, 28 relative to each other. These perforations 30 can be made by any suitable means and are, for example, formed after the manufacturing of the electrode sheet 22, 24, 26, 28.

[0022] In the example shown, there are four perforations 30 per electrode sheet 22, 24, 26, 28, each perforation 30 being formed in an angle of the sheet 22, 24, 26, 28.

[0023] The electrode sheets 22, 24, 26, 28 comprise in particular anode sheets 22, 24, each intended to form the anode of at least one battery, and cathode sheets 26, 28, each intended to form the cathode of at least one battery. These anode sheets 22, 24 and cathode sheets 26, 28 are alternated within the stack 20.

[0024] The anode sheets 22, 24 comprise a plurality of intermediate anode sheets 24, each interposed between two cathode sheets 26, 28. They may also comprise at least one terminal anode sheet 22 delimiting a vertical end of the stack 20. The cathode sheets 26, 28 comprise a plurality of intermediate cathode sheets 28, each interposed between two anode sheets 22, 24. They may also comprise at least one terminal cathode sheet 26 delimiting a vertical end of the stack 20.

[0025] In the example shown, the stack 20 is formed of as many anode leaves 22, 24 as cathode leaves 26, 28. The anode leaves 22, 24 then include a terminal anode leaf 22 delimiting a vertical end of the stack 20, and the cathode leaves 26, 28 include a terminal cathode leaf 26 delimiting an opposite vertical end of the stack 20. As an alternative not shown, the anode leaves 22, 24 may include a plurality of intermediate anode leaves 24 each interposed between two cathode leaves 26, 28.

[0026] In an alternative (not shown), the stack 20 comprises one more anode sheet than the cathode sheets. The anode sheets then comprise two terminal anode sheets 22, each defining a respective vertical end of the stack 20, the cathode sheets being made up of intermediate cathode sheets 28. In a further alternative (also not shown), the stack 20 comprises one more cathode sheet than the anode sheets. The cathode sheets then comprise two terminal cathode sheets 26, each defining a respective vertical end of the stack 20, the anode sheets being made up of intermediate anode sheets 24.

[0027] With reference to Figures 3 to 6, each electrode sheet 22, 24, 26, 28 comprises a current-collecting substrate 32. This current-collecting substrate 32 is typically made of a thin plate having two large faces 34, 36 connected by an edge (not shown). It is, for example, made of a metallic material. It is advantageously liquid-tight. It preferably has a thickness (along the vertical Z direction) of between 3 pm and 15 pm, preferably between 4 pm and 10 pm, and more preferably of about 5 pm.

[0028] Each electrode sheet 22, 24, 26, 28 further comprises, on at least one of the faces 34, 36 of the current-collecting substrate 32, an active layer 40, 42. Each intermediate electrode sheet 24, 28 comprises an active layer 40, 42 on each of the faces 34, 36 of the current-collecting substrate 32. Each terminal electrode sheet 22, 26 comprises an active layer 40, 42 on only one of the faces 34, 36 of the current-collecting substrate 32, which is the one facing another electrode sheet 24, 28, or on each of the faces 34, 36 of the current-collecting substrate 32.

[0029] In the following, the active layer or each active layer 40, 42 of each anode sheet 22, 24 will be called the "anode active layer", and the active layer or each active layer 40, 42 of each cathode sheet 26, 28 will be called the "cathode active layer".

[0030] The active layer or layers 40, 42 of each electrode sheet 22, 24, 26, 28 are typically solid. They are then either dense or porous. Preferably, the active layer or layers 40, 42 of each electrode sheet 22, 24, 26, 28 are porous, with a porosity advantageously between 20% and 60% by volume, for example between 25% and 50%, with pores of average diameter less than 100 nm, preferably less than 80 nm, and preferably less than 50 nm.

[0031] Each active layer 40, 42 of each electrode sheet 22, 24, 26, 28 is formed of at least one active electrode material, that is to say, a material that actively participates in the electrochemical reactions of energy conversion and storage. This active electrode material is capable of being oxidized or reduced during electrochemical charging and discharging reactions of a battery incorporating said electrode sheet 22, 24, 26, 28.

[0032] For the anode foils, 22, 24, the active electrode material is suitable for being reduced during battery charging reactions and oxidized during discharge reactions. It is advantageously selected from the group consisting of: • LLiTisOn, Li4Ti5 xMxOi2 with M = V, Zr, Hf, Nb, Ta and 0 < x < 0.25; • Mixed oxides of titanium, niobium and lanthanum with the formula LiwTi |XLaxNb2 yM'yO7_zM2z in which: • 0.03 < x < 0.08 • M1 and M2 are at least one element chosen from the group consisting of V, Ta, Fe, Co, Ti, Bi, Sb, As, P, Cr, Mo, W, B, Na, Mg, Ca, Ba, Pb, Al, Zr, Si, Sr, K, Cs and Sn; • 0 <w<5, 0<y<2et0<z<0,3; • LaxTii 2xNb2+xO7 where 0 <x<0.5 ; • niobium oxides and mixed niobium oxides with titanium, germanium, cerium or tungsten, and preferably in the group formed by: • Nb2O5± δ, Nbi8Wi6O93± δ, Nbi6W5O55± δ with 0 <x<let0<ô<2, LiNbO3, • TiNb2O7± ô, LiwTiNb2O7 with w>0, Tii xM'xNb2 yM2yO7±ô or LiwTi i_xM1xNb2 yM2yO7± s in which M1 and M2 are each at least one element chosen from the group consisting of Nb, V, Ta, Fe, Co, Ti, Bi, Sb, As, P, Cr, Mo, W, B, Na, Mg, Ca, Ba, Pb, Al, Zr, Si, Sr, K, Cs and Sn, M1 and M2 being able to be identical or different from each other, and in which 0 <w<5et0<x<let0<y<2et0<ô< 0,3 ; • MxTii_2xNb2+xO7±ô • in which M is an element with an oxidation state of +III, more particularly M is at least one of the elements chosen from the group consisting of Fe, Ga, Mo, Al, B, and where 0 <x<0.20 et -0.3<ô <0.3 ; Ga0.ioTio.8oNb2.i007 ; Feo.ioTio.8oNb 2.10O7 ; • MxTi2_2xNbio+x029±ô • in which M is an element with an oxidation state of +III, more particularly M is at least one of the elements chosen from the group consisting of Fe, Ga, Mo, Al, B, and where 0 <x<0.40 et -0.3<ô <0.3 ; Tii^M'xNb^yM^Ov-zM^ or LiwTii_xM1xNb2_yM2yO7_zM3zin which M1 and M2 are each at least one element chosen from the group consisting of Nb, V, Ta, Fe, Co, Ti, Bi, Sb, As, P, Cr, Mo, W, B, Na, Mg, Ca, Ba, Pb, Al, Zr, Si, Sr, K, Cs and Sn, M1 and M2 can be identical or different from each other, M3 is at least a halogen, and in which 0 <w<5et0<x< let0<y<2etz< 0,3 ; TiNb2O7 ZM3Z or LiwTiNb2O7 ZM3Z in which M3 is at least one halogen, preferably selected from F, Cl, Br, I or a mixture thereof, and 0 < z < 0.3; * Tii_xGexNb2_yM yO7+ z,LiwTi]_xGexNb2_yM yO7+z Ti]_xCexNb2_yM yO7+z, LiwTii_xCexNb2 yM 1yO7±zin which • M1 is at least one element chosen from the group consisting of Nb, V, Ta, Fe, Co, Ti, Bi, Sb, As, P, Cr, Mo, W, B, Na, Mg, Ca, Ba, Pb, Al, Zr, Si, Sr, K, Cs and Sn; • 0 <w<5et0<x<let0<y<2etz< 0,3 ; * Tii_xGexNb2_yM yO7 ZM z, LiwTii_xGexNb2_yM yO7 ZM z, Tii_xCexNb2_y M'yO7_zM2z, LCTii-xCexNb^yM'yO^M^ in which • M1 and M2 are each at least one element chosen from the group consisting of Nb, V, Ta, Fe, Co, Ti, Bi, Sb, As, P, Cr, Mo, W, B, Na, Mg, Ca, Ba, Pb, Al, Zr, Si, Sr, K, Cs, Ce and Sn, • M1 and M2 can be identical or different from each other, • and in which 0 <w<5et0<x<let0<y<2etz< 0,3 ; TiO2; TiOxNy with x<2 and 0 <y<0,2 ; LiSiTON, tin and silicon-based oxynitrides, and more particularly the formulation SiSn0j87Oij2oNij72 and their lithia forms; • nitrides and oxynitrides of the MOxNy type where M is at least one element chosen from Ge, Si, Sn, Zn or a mixture of one or more of these elements, and where x>=0 and y >=0.3; • Lis- XMXN with M is at least one element chosen from Cu, Ni, Co or a mixture of one or more of these elements; • Li3 x M x N with M being cobalt (Co) and 0 < x < 0.5; Li3 x M x N with M being nickel (Ni) and 0 < x < 0.6; Li3 x M x N with M being copper (Cu) and 0 < x < 0.3.

[0033] For the cathode sheets 26, 28, the active electrode material is suitable for oxidization during battery charging reactions and reduction during discharge reactions. It is advantageously selected from the group consisting of: • the oxides LiMn2O4, Li1+xMn2 XO4 with 0 < x < 0.15, LiCoO2, LiNiO2, LiMn15 Ni0>5O4, LiMni sNi()3 xXxO4 where X is selected from Al, Fe, Cr, Co, Rh, Nd, other rare earths such as Sc, Y, Lu, La, Ce, Pr, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb, and where 0 < x < 0.1, LiMn2 xMxO4 with M = Er, Dy, Gd, Tb, Yb, Al, Y, Ni, Co, Ti, Sn, As, Mg or a mixture of these compounds and where 0 < x < 0.4, LiFeO2, LiMni / 3Ni| / 3CO| / 3O2 LiNi|)3Coi) |3Al|)i)3O2 LiAlxIVin2 xO4avcc0^ x < 0.15, LiNii / xCoi / yMni / zO2 with x+y+z =10; • LixMy02 where 0.6 <y<0.85; 0<x+y<2; et M est choisi parmi Al, Ti, Cr, Mn, Fe, Co, Ni, Cu, Zn, Zr, Nb, Mo, Ru, Sn, and Sb ou un mélange de ces éléments ; Li1.20Nb0.20Mn0.60O2 ; • Lij+xNbyMezApO2 where Me is at least one transition metal chosen from: Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Te, Ru, Rh, Pd, Ag, Cd, Hf, Ta, W, Re, Os, Ir, Pt, Au, Hg, Rf, Db, Sg, Bh, Hs and Mt, and where 0.6 <x<l; 0<y<0.5; 0.25<z<l; avec A Me et A Nb, et 0<p<0.2 ; • LixNby.aNaMzbPbO2.cFc where 1.2 <x<1.75; 0<y<0.55; 0.1<z<l; 0<a<0.5; 0<b<l; 0<c<0.8; et où M, N, et P sont chacun au moins un des éléments choisi dans le groupe constitué par Ti, Ta, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Al, Zr, Y, Mo, Ru, Rh, et Sb ; • Lij.25Nbo.25Mno.50O2; Lij.3Nbo.3Mno.4o02 ; Lij.3Nbo.3Feo.4o02 ; Lii.3Nbo.43Nio.2702 ; Lij.3Nbo.43Coo.2702 ; Lij4Nbo.2Mno.55O2; • LixNi0.2Mn0.6Oy where 0.00 <x<1.52; 1.07<y<2.4 ; Lij.2Nio.2Mno.6O2; • LiNixCoyMnj_x_yO2 where 0 < x and y < 0.5; LiNixCezCoyMnj x yO2 where 0 < x and y < 0.5 and 0 < z; • the phosphates LiFePO4, LiMnPO4, LiCoPO4, LiNiPO4, Li3V2(PO4)3> Li2 MPO4F with M = Fe, Co, Ni or a mixture of these different elements, LiMPO4F with M = V, Fe, T or a mixture of these different elements; the phosphates of formula LiMM'PO4, with M and M' (M M') selected from Fe, Mn, Ni, Co, V such as LiFexCoi xPO4et where 0 < x < 1; • Feo gCoo iOF; LiMSO4F with M = Fe, Co, Ni, Mn, Zn, Mg; • all lithiaated forms of the following chalcogenides: V2O5, V3O8, TiS2, titanium oxysulfides (TiO2 ... <y<l), les oxysulfures de tungstène (WOySz avec 0.6<y<3 et 0.1<z<2), CuS, CuS2, de préférence Li xV2O5avec 0 < x < 2, LixV3O8avec 0 < x < 1,7, LixTiS2 avec 0 < x < 1, les oxysulfures de titane et de lithium LixTiOySzavec z=2-y, 0,3<y<l et 0 < x < 1, LixWOySzavec z=2-y, 0,3<y<l et 0 < x < 1, LixCuS avec 0 < x < 1, LixCuS2 avec 0 < x < 1.

[0034] The active layer or each active layer 40, 42 of each electrode sheet 22, 24, 26, 28 preferably has a thickness (along the vertical direction Z) between 2 pm and 300 pm, preferably between 4 pm and 200 pm.

[0035] The active layer or each active layer 40, 42 of each electrode sheet 22, 24, 26, 28 is obtained, for example, by a process as described in documents WO 2019 / 215407 A1 and FR 3 131 450 A1

[0036] At least a portion of the electrode sheets 22, 24, 26, 28 further comprises, on at least one of its faces, a separation layer 44, intended to form an electrolytic layer, covering an active layer 40, 42 of said electrode sheet 22, 24, 26, 28. By "intended to form an electrolytic layer," it is understood hereinafter and in the following that this separation layer 44 is capable of allowing the circulation of mobile ions from one of its faces to the other, typically because it comprises such mobile ions and / or is capable of being impregnated by a liquid comprising such mobile ions. It may thus be composed of a solid electrolyte, optionally capable of being impregnated by at least one liquid electrolyte and / or at least one ionic liquid, or of an electronically insulating material capable of being impregnated by at least one liquid electrolyte and / or at least one ionic liquid.This separation layer can be dense, i.e. having a volumetric porosity of less than 15%, preferably less than 10%, or it can be porous, preferably mesoporous.

[0037] In the example shown, each electrode sheet 22, 24, 26, 28 comprises, for each active layer 40, 42 composing said electrode sheet 22, 24, 26, 28, such a separation layer 44 covering this active layer 40, 42. Each intermediate electrode sheet 24, 28 thus comprises two separation layers 44, one on each of its faces, and each terminal electrode sheet 22, 26 comprises a single separation layer 44 covering the single active layer 40, 42 composing said terminal electrode sheet 22, 26, or two separation layers 44 each covering one of the two active layers 40, 42 composing said terminal electrode sheet 22, 26. Alternatively (not shown), only part of the electrode sheets 22, 24, 26, 28 comprise such a separation layer 44 and / or the electrode sheets 22, 24, 26, 28 do not comprise more than one such separation layer 44. For example, only the anode sheets 22, 24 or only the cathode sheets 26, 28 comprise, for each active layer 40, 42 composing said electrode sheet 22, 24, 26, 28, such a separation layer 44 covering this active layer 40, 42.

[0038] Preferably, the separation layer 44 comprises and is in particular made of an inorganic material, typically a ceramic. This material is advantageously chosen from Al2O3, SiO2, ZrO2, and / or a material selected from the group formed by: - garnets of formula Lid A*x A2y (TO4)Z where • A1 represents a cation with an oxidation state of +11, preferably Ca, Mg, Sr, Ba, Fe, Mn, Zn, Y, Gd; and where • A2 represents a cation of oxidation state +III, preferably Al, Fe, Cr, Ga, Ti, La; and where • (TO4) represents an anion in which T is an atom of degree oxidation +IV, located at the center of a tetrahedron formed by the oxygen atoms, and in which TO4 advantageously represents the silicate or zirconate anion, knowing that all or part of the elements T of an oxidation degree +IV can be replaced by atoms of an oxidation degree +III or +V, such as Al, Fe, As, V, Nb, In, Ta; • knowing that: d is between 2 and 10, preferably between 3 and 9, and even more preferably between 4 and 8; x is between 2.6 and 3.4 (preferably between 2.8 and 3.2); y is between 1.7 and 2.3 (preferably between 1.9 and 2.1) and z is between 2.9 and 3.1; - garnets, preferably chosen from: Li7La3ZrO2; Li6La2BaTa2O[2]; Li55La3Nb2O[2]; Li5La3M2O[2] with M = Nb or Ta or a mixture of the two compounds; Li7BaxLa3M2O[2] with 0 <x<l et M = Nb ou Ta ou un mélange des deux composés ; le Li7 xLa3Zr2 xMxOi 2 avec 0<x<2 et M = Al, Ga ou Ta ou un mélange de deux ou trois de ces composés ; - Lithified phosphates, preferably chosen from: NaSICON type lithified phosphates, Li3PO4; LiPO3; Li3AlO4Sci6(PO4)3 called "LASP"; Li2Zri2QCao, i(PO4)3; LiZr2(PO4)3; Li2Zr2(Pi2xSixO4)3 with 1.8 < x < 2.3; Li2Zr2(Pi2xXBXO4)3 with 0 < x < 0.25; Li3(Sc2XMX)(PO4)3 with M = AI or Y and 0 < x < 1; Li2Zr2(Sc2xX(PO4)3) with M = Al, Y, Ga or a mixture of the three compounds and 0 < x < 0.8; Lii +xMx(Gai _yScy)2_ X(PO4)3 with 0 < x < 0.8; 0 < y < 1 and M = Al or Y or a mixture of the two compounds; Lii +xMx(Ga)2_x(PO4)3 with M = Al, Y or a mixture of the two compounds and 0 < x < 0.8; Lii+xAlxTi2x(PO4)3 with 0 < x < 1 called “LATP”; or Lii +xAlxGe2_x(PO4)3 with 0 < x < 1 called “LAGP”; or the Lii +x+z Mx(Gei yTiy)2 xSizP3 zOi 2 with 0 < x < 0.8 and 0 < y < 1.0 and 0 < z < 0.6 and M = Al, Ga or Y or a mixture of two or three of these compounds; the Li3+y(Sc2 x Mx)QyP3 yOi 2 with M = Al and / or Y and Q = Si and / or Se, 0 < x < 0.8 and 0 < y < 1; or the Lii +x+yMxSc2_xQyP3_yOi 2 with M = Al, Y, Ga or a mixture of the three compounds and Q = Si and / or Se, 0 < x < 0.8 and 0 < y < 1; or the Lii +x+y+zMx(Gai yScy)2 XQZP3 zOi 2 with 0 < x < 0.8, 0 <y<l,0<z< 0,6 avec M = Al ou Y or a mixture of the two compounds and Q = Si and / or Se; or Li + xZr2 xBX(PO4)3 with 0 < x < 0.25; or Li + xZr2 xCax(PO4)3 with 0 < x < 0.25; or Li + xM3 x M2 xP3O[2 with 0 < x < 1 and M3 = Cr, V, Ca, B, Mg, Bi and / or Mo, M = Sc, Sn, Zr, Hf, Se or Si, or a mixture of these compounds; lithia borates, preferably chosen from: Li3(Sc2 xMx)(BO3)3 with M = Al or Y and 0 < x < 1; Lii +xMx(Sc)2_x(BO3)3 with M = Al, Y, Ga or a mixture of the three compounds and 0 < x < 0.8; Lii +xMx(Gai _yScy)2 x(BO3)3 with 0 < x < 0.8, 0 < y < 1 and M = Al or Y; Lii +xMx(Ga)2_x(BO3)3 with M = Al, Y or a mixture of the two compounds and 0 < x < 0.8; Li3BO3, Li3BO3-Li2SO4, Li3BO3-Li2SiO4, Li3BO3-Li2SiO4-Li2SO4; oxynitrides, preferably chosen from Li3PO4 XN2 x / 3, Li4SiO4.xN2X / 3, Li4GeO4 xN2x / 3 with 0 < x < 4 or Li3BO3 XN2 x / 3 with 0 < x < 3; lithium compounds based on lithium oxynitride and phosphorus, called "LiPON", in the form of LixPOyNz with x~2.8 and 2y+3z~7.8 and 0.16 < z < 0.4, and in particular Li2 QP03j3Noj46, but also the compounds LiwPOxN ySz with 2x+3y+2z = 5 = w or the compounds LiwPOxNySz with 3.2 < x < 3.8, 0.13 < y < 0.4, 0 < z < 0.2, 2.9 < w < 3.3 or the compounds in the form of Lit PxAlyOuNvSw with 5x+3y=5, 2u+3v+2w=5+t, 2.9 < t < 3.3, 0.84 < x < 0.94, 0.094 < y < 0.26, 3.2 < u < 3.8, 0.13 < v < 0.46, 0 < w < 0.2; materials based on lithium phosphorus or boron oxynitrides, respectively called "LiPON" and "LIBON", may also contain silicon, sulfur, zirconium, aluminum, or a combination of aluminum, boron, sulfur and / or silicon, and boron for materials based on lithium phosphorus oxynitrides; the lithium compounds based on lithium oxynitride, phosphorus and silicon called "LiSiPON", and in particular Lii . çSio . 28?1 . oOl . 1N1 . 0; - lithium oxynitrides of the types LiBON, LiBSO, LiSiPON, LiSON, thio-LiSiCON, LiPONB (where B, P and S represent boron, phosphorus and sulfur respectively); - lithium oxynitrides of the LiBSO type such as (l-%)LiBO2- %Li2SO4 with 0.4 < x < 0.8; - the lithia oxides, preferably chosen from Li7La3Zr20i 2 or Li5+xLa3 (Zrx,A2 x)Oi 2 with A = Sc, Y, Al, Ga and 1.4 < x < 2 or Li0 >35La055TiO3 or Li3xLa2 / 3 xTiO3 with 0 < x < 0.16 (LLTO); - silicates, preferably chosen from Li2Si2O5, Li2SiO3, Li2Si2O6, LiAISiO4, Li4SiO4, LiAISi2O6; - solid anti-perovskite type electrolytes selected from: Li3OA with A a halide or a mixture of halides, preferably at least one of the elements selected from F, Cl, Br, I or a mixture of two, three or four of these elements; Li(3x)Mx / 2OA with 0 < x < 3, M a divalent metal, preferably at least one of the elements selected from Mg, Ca, Ba, Sr or a mixture of two, three or four of these elements, A a halide or a mixture of halides, preferably at least one of the elements selected from F, Cl, Br, I or a mixture of two, three or four of these elements; Li(3x)M3x / 3OA with 0 < x < 3, M3 a trivalent metal, A a halide or a mixture of halides, preferably at least one of the elements selected from F, Cl, Br, I or a mixture of two, three or four of these elements; or LiCOXzY(iz) with X and Y halides as mentioned above in relation to A, and 0 < z < 1;- the compounds Lao>5iLio >34Ti2> 9 4, Li3, 4V0> 4GeO,6O4, Li2O-Nb2O5, LiAlGaSPO4; - formulations based on Li2CO3, B2O3, Li2O, Al(PO3)3LiF, P2S3, Li2S, Li3 N, Lix 4Zn(GeO4)4, Li3, eGe0 .eVo >4O4, LiTi2(PO4)3, Li3 j25Geoj25Po >2sS4, Lii j3A10 >3Tii 7(PO4)3, Li[+X AIx M2 x(PO4)3 (where M = Ge, Ti, and / or Hf, and where 0 < x < 1 ), Lit +x+yAlxTi2_xSiyP3_yOi 2 (where 0 < x < 1 and 0 < y < 1).

[0039] Preferably, the separation layer 44 is porous, advantageously with a porosity greater than 25% by volume, for example greater than 30% by volume. Preferably, the separation layer 44 has a porosity less than 60% by volume, for example less than 50% by volume. Preferably, the open pores of said separation layer 44 have an average diameter of less than 200 nm, typically less than 100 nm, for example between 2 nm and 80 nm, in particular between 2 nm and 50 nm, and represent a volume greater than 25% of the total volume of the separation layer 44, and preferably greater than 30%.

[0040] The or each separation layer 44 of each electrode sheet 22, 24, 26, 28 preferably has a thickness (along the vertical direction Z) of less than 30 pm, for example between 3 pm and 20 pm, and in particular between 2.5 pm and 5 pm.

[0041] The separation layer or layers 44 of each electrode sheet 22, 24, 26, 28 is obtained, for example, by a process as described in document WO 2019 / 215411 AL

[0042] The electrode sheets 22, 24, 26, 28 are arranged within the stack 20 such that each active layer 40, 42 is opposite another active layer 40, 42, separated from it by at least one separating layer 44. In the example shown, each active layer 40, 42 is thus opposite another active layer 40, 42, separated from it by two separating layers 44. Alternatively (not shown), each active layer 40, 42 is opposite another active layer 40, 42, separated from it by a single separating layer 44, or some active layers 40, 42 are opposite another active layer 40, 42, separated from it by a single separating layer 44, while other active layers 40, 42 are in relation to another active layer 40, 42 being separated from it by two separation layers 44.

[0043] With reference to [Fig. 7], each electrode sheet 22, 24, 26, 28 (only the terminal anode sheet 22 being visible in this Figure) comprises a perforated central area 50, in which recesses 52 are formed. This central area 50 is bordered by a peripheral frame 54 which is solid, i.e., devoid of recesses (except for the perforations 30). The function of this frame 54 is, in particular, to ensure easy handling of the sheet 22, 24, 26, 28.

[0044] The recesses 52 are arranged in rows Li to Lx, placed side by side along the longitudinal direction X, and in rows Ri to Ry arranged side by side along the transverse direction Y. By way of non-limiting example, in the manufacture of surface-mount component (SMD) batteries, the electrode sheets 22, 24, 26, 28 can be 100 mm x 100 mm plates. The number of lines Li to Ly is then typically between 10 and 500, and the number of rows Ri to Rx is also between 10 and 500. Depending on the desired battery capacity, these dimensions can vary, and the number of lines and rows per electrode sheet 22, 24, 26, 28 can be adjusted accordingly. The dimensions of electrode sheets 22, 24, 26, 28 can be adjusted according to requirements.The number of lines and rows and the dimensions of the sheets are identical for all electrode sheets 22, 24, 26, 28.

[0045] As shown in [Fig. 7], two adjacent rows are separated by material bridges 56, the height of which (measured along the longitudinal direction X) is denoted H56, and which is between 0.05 mm and 5 mm. Two adjacent rows are separated by material strips 58, the width of which (measured along the transverse direction Y) is denoted L58, and which is between 0.05 mm and 5 mm. These material bridges and strips 56, 58 of the electrode sheets 22, 24, 26, 28 provide them with sufficient mechanical rigidity to allow them to be easily handled.

[0046] The recesses 52 are through-holes, that is, they open onto the upper and lower faces of the electrode sheet 22, 24, 26, 28, respectively. The recesses 52 can be made in a manner known per se, directly on the substrate 32, before any deposition of active materials, by chemical etching, electroforming, laser cutting, micro-perforation, or stamping. These recesses 52 can also be made on substrates 32 coated with one or two active layer(s) 40, 42 or on electrode sheets 22, 24, 26, 28 including one or two separating layer(s) 44, in a manner known per se, for example, by laser cutting, femtosecond laser cutting, micro-perforation, or stamping.

[0047] With reference to [Fig.8], each recess 52 is substantially H-shaped. It is composed of a pair of longitudinal slots 60, straight along the longitudinal direction X and parallel to each other, and a transverse slot 62, 64 preferably straight along the transverse direction Y, connecting the longitudinal slots 60 to each other.

[0048] Each longitudinal slot 60 extends from a first longitudinal end 66 to a second longitudinal end 68. The first longitudinal ends 66 of the two slots 60 are substantially aligned transversely with each other and the second longitudinal ends 68 of the two slots 60 are substantially aligned transversely with each other, that is to say that said first longitudinal ends 66, respectively said second longitudinal ends 68, are not offset longitudinally by more than 50 pm from each other.

[0049] The transverse slot 62, 64 is close to one of said longitudinal ends 66, 68, that is to say that its distance D along the longitudinal direction X to the longitudinal end 66, 68 of which it is close is less than its distance along the longitudinal direction X to the middle of each slot 60.

[0050] For the anode leaves 22, 24, the transverse slot 62 is called the anodic transverse slot and is close to the first longitudinal end 66 of the slots 60. For the cathode leaves 26, 28, the transverse slot 64 is called the cathodic transverse slot and is close to the second longitudinal end 68 of the slots 60. The recesses 52 of the cathode leaves 26, 28 are thus arranged “head- spade" with respect to the recesses 52 of the anode leaves 22, 24. Advantageously, the recesses 52 of the cathode leaves 26, 28 form the symmetricals of the recesses 52 of the anode leaves 22, 24 with respect to the median axis, noted M, of said recesses 52.

[0051] With reference to [Fig. 10], the transverse slot 62, 64 and each longitudinal slot 60 define a space free of any electrode material and current collector substrate. The presence of this space free of any electrode material and current collector substrate prevents any risk of short circuit and makes it possible to manufacture a battery with low self-discharge.For the transverse slots 62, 64, this free space separates a main body 72, 74 (anodic main body 72 for the anode leaves 22, 24 and cathodic main body 74 for the cathode leaves 26, 28), extending from the transverse slot 62, 64 to the longitudinal end 66, 68 of the slots furthest from it, from a secondary body 76, 78 (anodic secondary body 76 for the anode leaves 22, 24 and cathodic secondary body 78 for the cathode leaves 26, 28) extending from the transverse slot 62, 64 to the longitudinal end 66, 68 of the slots closest to it.

[0052] Each recess 52 typically has the following dimensions: - a longitudinal extension H52, corresponding to the distance from the first longitudinal end 66 to the second longitudinal end 68 of each slot 60, substantially between 2 mm and 10 mm; - a transverse extension L52 between 2 mm and 10 mm; - a transverse gap D60 between the longitudinal slots 60 of between 0.21 mm and 8 mm and preferably approximately equal to 2.5 mm; - a longitudinal slot width L60, corresponding to the width of each longitudinal slot 60 taken along the transverse direction Y, between 0.02 mm and 5 mm; - a transverse slot width H62, corresponding to the width of the transverse slot 62, 64 taken along the longitudinal direction X, between 0.01 mm and 0.5 mm, preferably between 0.03 mm and 0.15 mm, advantageously between 0.05 mm and 0.1 mm, for example about 0.07 mm; - a longitudinal gap D between the transverse slot 62, 64 and that of the longitudinal ends, respectively 66, 68, of which it is closest, greater than 0.4 mm, preferably greater than 0.45 mm, preferably between 0.4 mm and 2 mm.

[0053] The dimensions of the recesses 52 are substantially identical for all electrode sheets 22, 24, 26, 28. Moreover, for each electrode sheet 22, 24, 26, 28, all the recesses 52 of said electrode sheet 22, 24, 26, 28 advantageously have substantially the same dimensions.

[0054] Within each electrode sheet 22, 24, 26, 28, the longitudinal slits 60 of the recesses 52 in the same row are substantially aligned with each other, that is to say that the centers of said longitudinal slits 60 are not offset transversely by more than 50 pm, and the transverse slits 62, 64 of the recesses 52 in the same row are substantially aligned with each other, that is to say that the centers of said transverse slits 62, 64 are not offset longitudinally by more than 50 pm.

[0055] With reference to Figures 9 and 10, each recess 52 of an electrode sheet 22, 24, 26, 28 is superimposed on a recess 52 of each other electrode sheet 22, 24, 26, 28 so that the slots 60 of these recesses 52 together form a pair of main slots 70 passing through the stack 20 in the vertical direction Z. These main slots 70, parallel to each other, are each elongated in the longitudinal direction X. They are intended to delimit the lateral edges of a battery.

[0056] Each anode foil 22, 24 thus has, for each pair of main slots 70, a transverse anodic slot 62 connecting the main slots 70 to each other and each cathode foil 26, 28 has, for each pair of main slots 70, a transverse cathodic slot 64 connecting the main slots 70 to each other.The anodic transverse slots 62 are substantially aligned vertically with each other, that is to say that the centers of said anodic transverse slots 62 are not offset horizontally by more than 50 pm from each other, the cathodic transverse slots 64 are substantially aligned vertically with each other, that is to say that the centers of said cathodic transverse slots 64 are not offset horizontally by more than 50 pm from each other, and the anodic transverse slots 62 are offset longitudinally with respect to the cathodic transverse slots 64.

[0057] Returning to [Fig. 1], step S1 is followed by a step S2 for consolidating the stack 20. This step, known per se, is intended to ensure the overall mechanical stability of the stack 20. To this end, said consolidation S2 includes, for example, heat treatment of the stack 20, during which the stack 20 undergoes heat treatment simultaneously with mechanical compression in the vertical direction Z. For example, the heat treatment is carried out at a temperature between 50°C and 500°C, preferably below 350°C, and the mechanical compression is carried out at a pressure between 10 and 100 MPa, preferably between 20 and 50 MPa. This heat treatment may optionally be supplemented by other heat treatment and / or heat compression steps. aiming to consolidate the stack 20. Alternatively, step S2 includes a simple heat treatment, without mechanical compression, or a simple mechanical compression, without heat treatment.

[0058] In the example shown, step S2 is followed by step S3 of encapsulation of stack 20.

[0059] This step S3 includes depositing an encapsulation system onto the stack 20 to protect the future batteries from the atmosphere. This encapsulation system must be chemically stable, resistant to high temperatures, and impermeable to the atmosphere to perform its barrier layer function.

[0060] Preferably, the deposition of this encapsulation system is preceded by a step (not shown) of covering the stack 20 with a pretreatment layer intended to facilitate the adhesion of the encapsulation system.

[0061] Advantageously, the encapsulation system repository comprises at least one stacking overlap sequence 20 with: - 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 20, - a second covering layer composed of an electrically insulating material, deposited by depositing atomic layers on said first covering layer.

[0062] This sequence is preferably repeated z times with z > 1, preferably z > 2. This multilayer sequence has a barrier effect. The more the overlapping sequence is repeated, the greater this barrier effect will be. It will be all the more significant as the number of thin layers deposited increases.

[0063] Typically, the first coating layer is made of polymer, for example silicone (deposited, for example, by impregnation or by plasma-enhanced chemical vapor deposition from hexamethyldisiloxane (HMDSO)), or epoxy resin, or polyimide, polyamide, or poly-para-xylylene (better known as parylene). This first coating layer protects the sensitive components of the battery from its environment. The thickness of said first coating layer is preferably between 0.5 µm and 10 µm, preferably between 2 µm and 9 µm.

[0064] Advantageously, the first coating layer can 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 polyparaxylylene or poly(p-xylylene)) is a transparent, semi-crystalline, dielectric material that exhibits high thermodynamic stability, excellent solvent resistance, and very low permeability. Parylene also has Barrier properties that protect the battery from its external environment. Battery protection is enhanced when this first coating layer is made from type F parylene. This first coating layer is advantageously obtained from the condensation of gaseous monomers deposited by chemical vapor deposition (CVD) on 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.

[0065] The second coating layer is composed of an electrically insulating material, preferably inorganic. It is deposited by atomic layer deposition (ALD) so as to obtain conformal coverage of all accessible surfaces of the stack previously covered by 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.

[0066] ALD deposition techniques are particularly well-suited for coating highly rough surfaces in a completely watertight and conformal manner. They allow for the creation of conformal layers, free of defects such as holes (so-called "pinhole-free" layers), and represent very good barriers. Their WVTR coefficient is extremely low. The WVTR (water vapor transmission rate) coefficient allows for the evaluation of the water vapor permeance of the encapsulation system. The lower the WVTR coefficient, the more watertight the encapsulation system.

[0067] The second coating layer may be made of ceramic material, glassy material, or glass-ceramic material, for example in the form of an oxide, such as Al2O3, nitride, phosphate, oxynitride, or siloxane. This second coating layer preferably has a thickness between 10 nm and 60 nm, advantageously between 20 nm and 40 nm, for example, approximately 30 nm.

[0068] This second coating layer deposited by ALD on the first coating layer ensures, on the one hand, the watertightness of the structure, i.e., prevents the migration of water inside the object, and on the other hand, protects the first coating layer from the atmosphere, particularly from air and Humidity and thermal exposure are protected to prevent degradation. This second coating layer improves the lifespan of the encapsulated battery.

[0069] It should be noted that this S3 encapsulation step, although preferred, is optional, and can be replaced by another subsequent encapsulation step.

[0070] The process 10 further includes a step S4 of first punching of the stack 20 once it has been consolidated and, where appropriate, encapsulated.

[0071] With reference to Figures 11 to 13, this first punching S4 is carried out by means of a first punching system 80 comprising a first die 82, a first side clamp 84 and a plurality of first punches 86 (only one of them being visible on the [Fig. 13]).

[0072] The matrix 82 delimits a surface 90 for receiving the stack 20, substantially horizontal. It also features a plurality of openings 92 (only one of which is visible in the Figures) opening into the receiving surface 90. These openings 92 are greater than or equal in number to the punches 86. They are preferably arranged in a matrix, with a number of rows greater than or equal to the number of rows LB ..., Lx of recesses 52 per electrode sheet 22, 24, 26, 28, plus one, and a number of columns greater than or equal to the number of rows Rb ..., Ry of recesses 52 per electrode sheet 22, 24, 26, 28. Each opening 92 has a horizontal cross-section substantially complementary to the horizontal cross-section of at least one of the punches 86. By "substantially complementary," it is understood here and thereafter that these cross-sections are complementary to each other, except for the clearance necessary for the punch 86 to pass through the opening 92.

[0073] The side clamp 84 defines a contact surface 94 with the stack 20. This surface 94 is substantially horizontal and faces the receiving surface 90 of the die 82. The side clamp 84 further has a plurality of passages 96 (only one of which is visible in the Figures) opening into the contact surface 94. These passages 96 are greater than or equal in number to the punches 86. They are preferably arranged in a matrix, with a number of rows greater than or equal to the number of rows Lb ..., Lx of recesses 52 per electrode sheet 22, 24, 26, 28, plus one, and a number of columns greater than or equal to the number of rows Rb ..., Ry of recesses 52 per electrode sheet 22, 24, 26, 28. Each passage 96 has a horizontal section substantially complementary to the horizontal section of at least one of the punches 86.

[0074] Each punch 86 is, for example, a flat punch, meaning that the surface through which it contacts the stack 20 is flat. Alternatively, each punch 86 is a W-shaped punch, meaning that the surface through which it contacts the stack 20 has a projecting peripheral edge.

[0075] The punches 86 are preferably aligned with each other along the Y direction and are for example equal in number to the number of rows ..., Ry of recesses 52 per electrode sheet 22, 24, 26, 28. Alternatively, the punches 86 are aligned with each other along the X direction and are equal in number to the number of lines Li, ..., Lx of recesses 52 per electrode sheet 22, 24, 26, 28, plus one. Alternatively, the punches 86 are arranged in a matrix in a plane parallel to the receiving surface 90, with a number of rows less than or equal to the number of rows Lb ..., Lx of recesses 52 per electrode sheet 22, 24, 26, 28, plus one, and a number of columns less than or equal to the number of rows Rh ..., Ry of recesses 52 per electrode sheet 22, 24, 26, 28.

[0076] The die 82 and the side clamp 84 are movable relative to each other along the vertical direction Z between a spread-out configuration, shown in [Fig. 11] (for the sake of simplicity the side clamp 84 has not been shown in this configuration), and a close-up configuration shown in Figures 12 and 13. The punches 86 are movable relative to the die 82 along the vertical direction Z between a spread-out position, shown in Figures 11 and 12 (for the sake of simplicity the punches 86 have not been shown in this position), in which the punches 86 are away from the die 82, and a recessed position, shown in [Fig. 13], in which each punch 86 is at least partially engaged in the associated opening 92.

[0077] In the case where the punches 86 have a number of lines strictly less than the number of lines LB ..., Lx of recesses 52 per electrode sheet 22, 24, 26, 28, plus one, or a number of columns strictly less than the number of rows Rb ..., Ry of recesses 52 per electrode sheet 22, 24, 26, 28, said punches 86 are advantageously also mobile relative to the die 82 and the side clamp 84 along at least one of the horizontal directions X and Y.

[0078] In an alternative (not shown), the first punching system 80 comprises only the die 82 and the punches 86. It should be noted, however, that the presence of the side clamp 84 improves the quality of the punching performed by the first system 80.

[0079] During step S4, the stack 20 is first installed on the receiving surface 90 so that its stacking direction is substantially orthogonal to said receiving surface 90 ([Fig. 1 1]). The die 82 and the side clamp 84 are then in a spread configuration, and the punches 86 are in a spread position. Then the side clamp 84 is brought closer to the die 82 so that they clamp the stack 20, optionally encapsulated, along the vertical direction Z, each passage 96 of the side clamp 84 being arranged opposite a respective opening 92 of the die 82. having substantially the same horizontal cross-section as the passage 96 ([Fig. 12]). Finally, the punches 86, positioned so that each faces a passage 96 and an opening 92 with horizontal cross-sections substantially complementary to its own, are moved into their depressed position. In doing so, the punches 86 punch through the stack 20 and cut off scraps 100 ([Fig. 13]), creating orifices 102, 104 ([Fig. 14]) in the stack 20. When the punches 86 have a number of rows strictly less than the number of rows Lb ..., Lx of recesses 52 per electrode sheet 22, 24, 26, 28, plus one, or a number of columns strictly less than the number of rows Rb ..., Ry of recesses 52 per electrode sheet 22, 24, 26, 28, this last operation is repeated as many times as necessary until all the desired orifices 102, 104 are obtained, the punches 86 being repositioned each time so that each punch 86 faces a new passage 96 / opening 92 couple. .

[0080] Alternatively, the first punching system 80 comprises a single punch 86. The last operation is then repeated as many times as the number of holes 102, 104 to be made.

[0081] The first punching S4 is carried out through all the electrode sheets 22, 24, 26, 28. Thus, each orifice 102, 104 is through, that is to say, it opens into opposite faces of the stack 20. In other words, each orifice 102, 104 extends from one terminal electrode sheet 22, 24 to the other and through each of said terminal electrode sheets 22, 24.

[0082] With reference to Figures 14 and 15, the first punching S4 is carried out so as to form, for each pair of main slots 70, two orifices 102, 104 interposed transversely between said longitudinal slots 70 and spaced longitudinally apart from each other. These orifices 102, 104 comprise a first orifice 102, near the first longitudinal end 66 of the longitudinal slots 60 composing the main slots 70 of the pair, and a second orifice 104 near the second longitudinal end 68 of the longitudinal slots 60 composing the main slots 70 of the pair.

[0083] Each orifice 102, 104 preferably has, as shown, a horizontal cross-section in the shape of a quadrilateral and in particular substantially rectangular.

[0084] Each orifice 102, 104 is at a distance from each main slot 70, such that a material bridge 106 is formed between each orifice 102, 104 and each main slot 70. In particular, the edge-to-edge distance Li06 from each orifice 102, 104 to each main slot 70 is advantageously between 40% and 60%, preferably between 45% and 55%, preferably between 49% and 51%, of half the transverse edge-to-edge distance D70 between the main slots 70 of the pair. Advantageously, the edge-to-edge distance Li06 from each orifice 102, 104 to each main slot 70 is approximately equal to one-quarter of the edge-to-edge transverse distance D70 between the main slots 70 of the pair. Alternatively, the edge-to-edge distance Li06 from each orifice 102, 104 to each main slot 70 is approximately equal to 1.25 mm.

[0085] Each orifice 102, 104 has a transverse dimension L102, L104, which is typically between 40% and 60%, preferably between 45% and 55%, for example between 49% and 51%, of the edge-to-edge transverse distance D70 between the main slots 70 (which is equal to the gap D60). Advantageously, each orifice 102, 104 has a transverse dimension L102, L104 substantially equal to half the edge-to-edge transverse distance D70 between the main slots 70. Alternatively, each orifice 102, 104 has a transverse dimension L102 between 1.125 mm and 1.375 mm, preferably between 1.225 mm and 1.275 mm.

[0086] In particular, each orifice 102, 104 is substantially centered between the main slots 70 of the pair, that is to say, it is substantially equidistant from said main slots 70.

[0087] Furthermore, the two orifices 102, 104 longitudinally frame the transverse anodic and cathodic slots 62, 64 connecting the main slots 70 of the pair. In other words, said transverse anodic and cathodic slots 62, 64 are longitudinally interposed between the two orifices 102, 104.

[0088] The edge-to-edge distance D102 from the first orifice 102 to the nearest anodic transverse slots 62 is greater than or equal to 130 pm, preferably greater than or equal to 180 pm. The edge-to-edge distance D104 from the second orifice 104 to the nearest cathodic transverse slots 64 is also greater than or equal to 130 pm, preferably greater than or equal to 180 pm. Thus, the edge-to-edge distance from each of the orifices 102, 104 to the nearest of the anodic and cathodic transverse slots 62, 64 is greater than or equal to 130 pm, preferably greater than or equal to 180 pm. This edge-to-edge distance is also less than the longitudinal gap D between the transverse slots 62, 64 and the longitudinal ends 66, 68 of the longitudinal slots 60 composing the main slots 70 of the pair.

[0089] Each orifice 102, 104 has an inner edge 108 close to the other orifice 102, 104 formed for the same pair of main slots 70 and an outer edge 109 opposite said inner edge 108. The inner edge 108 is longitudinally recessed from the longitudinal ends of the main slots 70, that is to say it is interposed, along the longitudinal direction X between the middle of the main slots 70 and their longitudinal ends.

[0090] As can be seen in [Fig. 14], each orifice 102, 104 is substantially centered, along the longitudinal direction X, on the material bridge 56 separating two adjacent rows of recesses 52 and has a height Hi02, along the longitudinal direction X, greater than the height of said material bridge 56. Each orifice 102, 104 is thus common to two pairs of neighboring main slots 70 (with the exception of the orifices 102, 104 formed at the end of a row), the first orifice 102 of a pair of main slots 70 constituting the second orifice 104 of the pair of main slots 70 of the upper row and the second orifice 104 of a pair of main slots 70 constituting the first orifice 102 of the pair of main slots 70 of the lower row. It should be noted that, in Figures 14 and 15, the numerical references of the orifices 102, 104 were thus chosen by reference to the pair of main slits 70 represented in the center of these Figures.

[0091] It has been observed that, surprisingly, this first punching S4 allows a clean and precise cut of the electrode sheets 22, 24, 26, 28, without folding of the collector substrates 32 and without tearing of the secondary bodies 76, 78, which subsequently allows easy impregnation of the active layers 40, 42 and the separation layers 44 of the electrode sheets 22, 24, 26, 28 through the orifices 102, 104.

[0092] Returning to [Fig. 1], the first punching S4 is followed by an impregnation step S5 in which the stack 20, more particularly the active layers 40, 42 and the separation layers 44 of the electrode sheets 22, 24, 26, 28, is impregnated with a cation carrier phase. This cation carrier phase comprises, for example, at least one liquid electrolyte and / or at least one ionic liquid. The at least one liquid electrolyte and / or the at least one ionic liquid typically contains cationic salts, such as lithium, sodium, or potassium salts. This cation carrier phase enters the stack 20 through the openings 102, 104 and, from there, spreads into the electrode sheets 22, 24, 26, 28 by capillary action.

[0093] It should be noted that this optional step S5 is reserved for the case of quasi-solid batteries impregnated with at least one liquid electrolyte and / or at least one ionic liquid. Furthermore, even in the case of quasi-solid batteries, this step S5 can be omitted; it is then replaced by a subsequent impregnation step.

[0094] The process 10 further includes a step S6 of second punching of the stack 20 following the first punching S4 and, where applicable, the impregnation S5.

[0095] With reference to Figures 16 to 18, this second punching S6 is carried out by means of a second punching system 110 comprising a second die 112, a second side clamp 114 and a plurality of second punches 116 (only one of them being visible on [Fig. 16]).

[0096] The matrix 112 defines a substantially horizontal surface 120 for receiving the stack 20. It also has a plurality of openings 122 (only one of which is visible in the Figures) opening into the receiving surface 120. These openings 122 are greater than or equal in number to the punches 116. They are preferably arranged in a matrix, with a number of rows greater than or equal to the number of rows ..., Lx of recesses 52 per electrode sheet 22, 24, 26, 28, plus one, and a number of columns greater than or equal to the number of rows Rb ..., Ry of recesses 52 per electrode sheet 22, 24, 26, 28. Each opening 112 has a horizontal cross-section substantially complementary to the horizontal cross-section of at least one of the punches 116.

[0097] The side clamp 114 defines a contact surface 124 with the stack 20. This surface 124 is substantially horizontal and faces the receiving surface 120 of the die 112. The side clamp 114 further has a plurality of passages 126 (only one of which is visible in the Figures) opening into the contact surface 124. These passages 126 are greater than or equal in number to the punches 116. They are preferably arranged in a matrix, with a number of rows greater than or equal to the number of rows Lb ..., Lx of recesses 52 per electrode sheet 22, 24, 26, 28, plus one, and a number of columns greater than or equal to the number of rows Rb ..., Ry of recesses 52 per electrode sheet 22, 24, 26, 28. Each passage 126 has a horizontal section substantially complementary to the horizontal section of at least one of the punches 116.

[0098] Each punch 116 is, for example, a flat punch, meaning that the surface through which it contacts the stack 20 is flat. Alternatively, each punch 116 is a W-shaped punch, meaning that the surface through which it contacts the stack 20 has a projecting peripheral edge.

[0099] The punches 116 are preferably aligned with each other along the Y direction and are for example equal in number to the number of rows RB ..., Ry of recesses 52 per electrode sheet 22, 24, 26, 28. Alternatively, the punches 116 are aligned with each other along the X direction and are equal in number to the number of lines LB ..., Lx of recesses 52 per electrode sheet 22, 24, 26, 28, plus one. Alternatively, the punches 116 are arranged in a matrix in a plane parallel to the receiving surface 120, with a number of rows less than or equal to the number of rows Li, ..., Lx of recesses 52 per electrode sheet 22, 24, 26, 28, plus one, and a number of columns less than or equal to the number of rows RB ..., Ry of recesses 52 per electrode sheet 22, 24, 26, 28.

[0100] The matrix 112 and the side clamp 114 are movable relative to each other along the vertical direction Z between a spread configuration, shown in [Fig. 16] (for the sake of simplicity the side clamp 114 has not been shown in this configuration), and a close configuration shown in Figures 17 and 18. The punches 116 are movable relative to the die 112 along the vertical direction Z between a spread position, shown in Figures 16 and 17 (for the sake of simplicity the punches 116 have not been shown in this position), in which the punches 116 are away from the die 112, and a recessed position, shown in [Fig. 18], in which each punch 116 is at least partially engaged in the associated opening 122.

[0101] In the case where the punches 116 have a number of lines strictly less than the number of lines Lb ..., Lx of recesses 52 per electrode sheet 22, 24, 26, 28, plus one, or a number of columns strictly less than the number of rows Rb ..., Ry of recesses 52 per electrode sheet 22, 24, 26, 28, said punches 116 are advantageously also movable with respect to the die 112 and the side clamp 114 along at least one of the horizontal directions X and Y.

[0102] In an alternative (not shown), the second punching system 110 comprises only the die 112 and the punches 116. It should be noted, however, that the presence of the side clamp 114 improves the quality of the punching performed by the second system 110.

[0103] During step S6, the stack 20 is first installed on the receiving surface 110 so that its stacking direction is substantially orthogonal to said receiving surface 110 ([Fig. 16]). The die 112 and the side clamp 114 are then in a spread configuration and the punches 116 are in a spread position. Then the side clamp 114 is brought closer to the die 112 so that they enclose the stack 20, optionally encapsulated, along the vertical direction Z, each passage 126 of the side clamp 114 being arranged opposite a respective opening 122 of the die 112 having substantially the same horizontal cross-section as the passage 126 ([Fig. 17]). Finally, the punches 116, positioned so that each faces a passage 126 and an opening 122 with horizontal sections substantially complementary to its own, are moved to their pressed position.In doing so, the punches 116 punch the stack 20 and cut off scraps 130 ([Fig. 18]), leaving cutouts 132, 134 ([Fig. 19]) in the stack 20. When the punches 116 have a number of lines strictly less than the number of lines Lb ..., Lx of cutouts 52 per electrode sheet 22, 24, 26, 28, plus one, or a number of columns strictly less than the number of rows Rh ..., Ry of cutouts 52 per electrode sheet 22, 24, 26, 28, this latter operation is repeated as many times as necessary until all the cutouts 132, 134 desired are obtained, the punches 116 being . each time repositioned so that each punch 116 faces a new passage 126 / opening 122 pair.

[0104] Alternatively, the second punching system 110 comprises a single punch 116. The last operation is then repeated as many times as the number of cuts 132, 134 to be made.

[0105] The second punching S6 is carried out through all the electrode sheets 22, 24, 26, 28. Thus, each cut 132, 134 is through, that is to say, it opens into opposite faces of the stack 20. In other words, each cut 132, 134 extends from one terminal electrode sheet 22, 24 to the other and through each of said terminal electrode sheets 22, 24.

[0106] With reference to Figures 19 and 20, the second punching S6 is made so as to form, for each orifice 102, 104, a cut, respectively 132, 134, passing through said orifice 102, 104, that is to say extending from one edge to the other of said orifice 102, 104 and beyond. This cutout 132, 134 also extends through the material bridges 106 so as to connect the main slots 70 to each other, thus isolating a cut-out portion 136 of the stack 20 from the rest of the stack 20. For this purpose, each cutout 132, 134 typically has a width Li32, taken along the transverse direction Y, greater than the transverse distance D7 edge-to-edge between the main slots 70 and which is preferably less than the transverse extension L52 of the recesses 52 forming said main slots 70. In addition, each cutout 132, 134 is advantageously transversely centered on the corresponding orifice 102, 104.

[0107] Each cut 132, 134 preferably has, as shown, a horizontal section in the shape of a quadrilateral and in particular substantially rectangular.

[0108] This second punching S6 is in particular made at a distance from the inner edges 108 of the orifices 102, 104. In other words, the second punching S6 is made so that no second punch 116 touches the inner edge 108 of one of the orifices 102, 104. The longitudinal ends 142, 144 of the cut portion 136 thus have a crenellated shape, with a central portion 146 in recess, corresponding to the inner edge 108 of an orifice 102, 104 and two lateral portions 148, transversely framing the central portion 146 and delimited by the cut 132, 134, projecting along the longitudinal direction X relative to the central portion 146.

[0109] Thus, the inner edge 108 of the holes 102, 104 is not altered by the second punching S6 and retains its qualities. Furthermore, the quality of the cutouts 132, 134 obtained is improved.

[0110] It will be noted that, since each orifice 102, 104 constitutes both the first orifice 102 associated with a first pair of main slots 70 and the second orifice 104 associated with a second pair of main slots 70, each cut 132, 134 is made at a distance from each of the longitudinal edges 108, 109 of each orifice 102, 104.

[0111] Each cutout 132, 134 has, in particular, a height Hn2, taken along the longitudinal direction X, less than the height H102 of the corresponding orifice 102, 104. As shown, each cutout 132, 134 is advantageously longitudinally centered on the corresponding orifice 102, 104.

[0112] In some cases, when impregnation is not carried out before the second punch S6, as is the case with step S5, it is then carried out after the second punch S6. It should be noted, however, that carrying out this impregnation between the first and second punches S4, S6 is preferred. This offers several advantages: - firstly, impregnation is facilitated; it is indeed easier to carry out impregnation on the whole stack 20 than on the cut portions 136 of the latter; - then, this allows to obtain clean cut ends, devoid of cation carrier phase, at the lateral portions 148 of the longitudinal ends 142, 144 of the cut portions 136; the adhesion of the glue to these cut ends is thus improved, which allows a better electrical connection of the battery terminations to the electrode sheets 22, 24, 26, 28.

[0113] It is thus observed that, when the impregnation is carried out between the first punching S4 and the second punching S6 as described above, the batteries obtained have a higher capacity than when the impregnation is carried out after the second punching S6.

[0114] Returning to [Fig. 1], the second punching S6 is followed by a step S7 for creating battery terminations. In the case of a quasi-solid battery, this step S7 is carried out on a cut portion 136 of the stack 20 previously impregnated.

[0115] During this step S7, terminations (electrical contacts) are added where the cathodic, respectively anodic, current-collecting substrates are apparent, i.e. at the longitudinal ends 142, 144 of the cut portion 136 and preferably at the lateral portions 148 of the latter.

[0116] To this end, the terminations are made using techniques known to those skilled in the art in the vicinity of these lateral portions 148. To do this, a first layer of a graphite-filled material, preferably based on graphite-filled epoxy resin, can be deposited on the lateral portions 148 of each longitudinal end 142, 144 of the cut portion 136. Optionally, a A second layer can then be deposited on top of the first layer; this second layer comprises metallic copper and is typically obtained from an ink loaded with copper nanoparticles. These layers are deposited, for example, by immersing the lateral portions 148 of the longitudinal ends 142, 144 in baths of the materials of said layers.

[0117] The terminations allow for the resumption of alternately positive and negative electrical connections on each of the longitudinal ends 142, 144 of the cut portion 136. These terminations allow for parallel electrical connections between the anode layers 22, 24 on the one hand and the cathode layers 26, 28 on the other. The electrical insulation of each termination with respect to the cathode layers 26, 28 on the one hand and the anode layers 22, 24 on the other is ensured by the free space provided by, respectively, the transverse cathode slots 64 and the transverse anodic slots 62.

[0118] Optionally, the process 10 further includes, following the S7 termination step, a step (not shown) of installing each cut portion 136 on a connection grid (not shown), followed by another step S8 of encapsulating this cut portion 136.

[0119] During this step S8, the cut portion 136 is encapsulated by means of a deposition process of an encapsulation system similar to that described for step S3.

[0120] Advantageously, the encapsulated cut portion 136 is then coated with a final covering layer to mechanically protect the cut portion 136 and optionally give it an aesthetic appearance. This final covering layer protects and improves the battery's lifespan. Preferably, this final covering layer is also chosen to withstand high temperatures and has sufficient mechanical strength to protect the battery during its subsequent use. To this end, the thickness of this final covering layer is typically greater than 200 µm, preferably greater than 300 µm, such a thickness being sufficient to protect the battery against mechanical damage, and is, for example, between 600 and 800 µm.

[0121] 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 obtained by overmolding.

[0122] With reference to Figures 21 to 23, a parallelepiped-shaped battery 150 is thus obtained, having a large upper face 152 and a large lower face 154 connected to each other by a slice 156, this slice 156 comprising two opposing end edges 158, 160 constituting longitudinal ends of battery 150 along the longitudinal direction X and two lateral edges 161a, 161b each extending from one end edge 158, 160 to the other.

[0123] Each end edge 158, 160 comprises a central portion 166 in recess, framed transversely by two lateral portions 168 each projecting along the longitudinal direction X relative to the central portion 166.

[0124] Electrical terminations (not shown) are formed at said end edges 158, 160, preferably at the lateral portions 168 of these edges 158, 160.

[0125] The battery 150 is formed by a superposition of anodes 162 and cathodes 164 arranged alternately above one another in the vertical direction Z. Each anode 162 comprises a current-collecting substrate and, on at least one face of the current-collecting substrate, an active anode layer, and each cathode 164 comprises a current-collecting substrate and, on at least one face of the current-collecting substrate, an active cathode layer. At least a portion of the anodes 162 and cathodes 164 further comprises, on at least one of its faces, an electrolytic layer covering the active anode and / or cathode layer, said electrolytic layer being interposed between two opposing active layers. The number of cathodes 164 corresponds to the number of cathode leaves 26, 28 in the stack 20. The number of anodes 162 corresponds to the number of anode leaves 22, 24 in the stack 20.These numbers can be identical, or differ from each other by one unit.

[0126] Each anode 162 comprises a main body 170 and a secondary body 171 along a first 158 ​​of the end edges 158, 160. The main body 170 and the secondary body 171 are separated by a space 172 free of any electrode and current-collecting substrate material, connecting the lateral edges 162, 164. Similarly, each cathode 164 comprises a main body 176, a secondary body 177 along a second 160 of the end edges 158, 160 opposite the first edge 158, and a space 178 free of any electrode and current-collecting substrate material, connecting the lateral edges 162, 164. These two free spaces 172, 178 are advantageously mutually symmetrical with respect to a median transverse axis (not shown) of the battery 150 and each have a width L172, taken along the longitudinal direction X, corresponding to the width H62 of the transverse anodic and cathodic slots 62, 64 described above.Furthermore, the maximum width L171 of each secondary body 171, 177, taken along the longitudinal direction X and measured between the free space, respectively 172, 178, and a lateral portion 168 of the end edge 158, 160, corresponds to the longitudinal gap D described above. Finally, the minimum width 1m of each secondary body 171, 177, taken along the longitudinal direction X and measured between the free space, . respectively 172, 178, and the central portion 166 of the end edge 158, 160, corresponds to the edge-to-edge distance D104 described above.

[0127] Thus, thanks to the process 10 described above, it is possible to cut batteries from a stack of electrode sheets while preserving their physical and mechanical integrity and facilitating their impregnation with a cation-carrying phase such as at least one liquid electrolyte and / or at least one ionic liquid comprising, for example, cationic salts, such as lithium, sodium, or potassium salts. The manufacture of solid or semi-solid batteries obtained by cutting from a stack of electrode sheets is thus facilitated, and their cost reduced. Furthermore, the capacity of the batteries obtained by this process 10 is improved compared to prior manufacturing techniques.

[0128] It should be noted that although, in the example described above, the recesses 52 in the electrode sheets 22, 24, 26, 28 are separated from each other by material bridges 56 and material strips 58, so that the main slot pairs 70 are individualized, the invention is not limited to this single embodiment. Thus, in an alternative (not shown), the electrode sheets 22, 24, 26, 28 do not include material strips 58, so that the recesses 52 in the same row are placed side by side. Each slot 60 is then common to two adjacent recesses 52 along the transverse direction Y and each main slot 70 formed by the superposition of the slots 60 of the electrode sheets 22, 24, 26, 28 is common to two pairs of adjacent slots 70 along the transverse direction Y.

Claims

Demands

1. A method (10) for manufacturing a battery (150), comprising the following steps: - supply (SI) of a stack (20) of electrode sheets (22, 24, 26, 28), each electrode sheet (22, 24, 26, 28) comprising: • a current-collecting substrate (32), and • on at least one face of the collecting substrate of current (32), an active layer (40, 42), at least part of the electrode sheets (22, 24, 26, 28) further comprising, on at least one of its faces, a separation layer (44), intended to form an electrolytic layer, covering the active layer (40, 42), the electrode sheets (22, 24, 26, 28) being arranged within the stack (20) so that each active layer (40, 42) is opposite another active layer (40, 42) while being separated from it by at least one separation layer (44), the stack also having at least one pair of longitudinal slots (70), substantially parallel to each other, intended to delimit the lateral edges of a battery (150), - implementation (S2) of a heat treatment and / or mechanical compression of the stack (20), - first punching (S4) of the stack (20) so as to form, for each pair of longitudinal slots (70), two orifices (102, 104) interposed between said longitudinal slots (70) and spaced longitudinally apart from each other, each of the orifices (102, 104) being at a distance from each longitudinal slot (70), and - second punching (S6) of the stack (20) so as to form, for each orifice (102, 104) formed during the first punching (S4), a cut (132, 134) passing through said orifice (102, 104), said cut (132, 134) connecting the longitudinal slots (70) to each other.

2. A manufacturing method (10) according to claim 1, wherein each orifice (102, 104) has a transverse dimension (L102, L104) less than or equal to 60%, preferably less than 55%, by example less than or equal to 51%, of the transverse edge-to-edge distance (D7 o) between the longitudinal slots (70) of the pair.

3. A manufacturing method (10) according to claim 1 or 2, wherein each orifice (102, 104) has a transverse dimension (L104, L104) greater than or equal to 40%, preferably greater than 45%, for example greater than or equal to 49%, of the transverse edge-to-edge distance (D70) between the longitudinal slots (70) of the pair.

4. A manufacturing method (10) according to any one of the preceding claims, wherein each orifice (102, 104) is substantially centered between the longitudinal slots (70) of the pair.

5. A manufacturing method (10) according to any one of the preceding claims, wherein each orifice (102, 104) has an inner edge (108) close to the other orifice (102, 104) formed for the same pair of longitudinal slots (70) and an outer edge (109) opposite said inner edge (108), the second punching (S6) being carried out at a distance from said inner edge (108).

6. A manufacturing process (10) according to any one of the preceding claims comprising, between the first punching (S4) and the second punching (S6), the impregnation (S5) of the stack (20) by a cation-carrying phase.

7. A manufacturing method (10) according to any one of the preceding claims, wherein the electrode sheets (22, 24, 26, 28) comprise anode sheets (22, 24) and cathode sheets (26, 28), said anode sheets (22, 24) and cathode sheets (26, 28) being alternated within the stack (20), each anode sheet (22, 24) having, for each pair of longitudinal slots (70), an anodic transverse slot (62) connecting the longitudinal slots (70) to each other and each cathode sheet (26, 28) having, for each pair of longitudinal slots (70), a cathodic transverse slot (64) connecting the longitudinal slots (70) to each other, the anodic transverse slots (62) being substantially aligned vertically with each other, the transverse cathode slits (64) being substantially aligned vertically with each other,and the transverse anodic slits (62) being longitudinally offset with respect to the transverse cathodic slits (64).

8. A manufacturing method (10) according to claim 7, wherein the edge-to-edge distance (D104) from each of the orifices (102, 104) to the nearest of the transverse anodic and cathodic slots (62, 64) is greater than or equal to 130 pm, preferably greater than or equal to 180 pm.

9. Battery (150) produced by means of a manufacturing process (10) according to any one of the preceding claims.

10. Battery (150) formed by a superposition of anodes (162) and cathodes (164) arranged one above the other alternately in a stacking direction (Z), said battery (150) comprising two opposite end edges (158, 160) constituting longitudinal ends of the battery (150) in a longitudinal direction (X) orthogonal to the stacking direction (Z), in which each end edge (158, 160) comprises a recessed central portion (166), framed transversely by two lateral portions (168) each projecting longitudinally from the central portion (166).

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