Electrochemical battery device with improved lifetime, comprising improved sealing and electrical conduction means, and manufacturing method thereof

Abstract

Said battery comprises a stack (I) alternating between at least one anode (20) and at least one cathode (50), an encapsulating system which is referred to as the primary encapsulating system (1020) and covers four of the six faces of the stack (I), at least one anode contact member (1040) capable of ensuring electrical contact between the stack and an external conductive element, and at least one cathode contact member (1050) capable of ensuring electrical contact between the stack and an external conductive element. According to the invention, the battery also comprises an encapsulating system referred to as the additional encapsulating system (1030), said additional encapsulating system comprising two front regions (1031, 1032), each of which covers a respective front region (1021, 1022) of the primary encapsulating system, and two side regions (1033, 1035), each of which covers a respective side region (1023, 1025), which is free of any contact member, of the primary encapsulating system, each of the two front regions (1031, 1032) of the additional encapsulating system (1030) also covering the front ends (1041, 1042, 1051, 1052) of the anode contact members and the cathode contact members, respectively, and each of the front regions (1031, 1032) of the additional encapsulating system forming a continuous surface with the side regions (1033, 1035) of the additional encapsulating system.

Description

[0001] L

[0002] BATTERY-TYPE ELECTROCHEMICAL DEVICE WITH IMPROVED LIFESPAN, INCLUDING IMPROVED SEALING AND ELECTRICAL CONDUCTION MEANS, AND ITS METHOD OF

[0003] MANUFACTURING

[0004] Technical field of the invention

[0005] The present invention relates to electrochemical devices, specifically batteries. It is particularly applicable to lithium-ion batteries. The invention concerns a novel battery architecture that provides improved sealing, electrical conductivity, and lifespan. The invention also relates to a method for manufacturing these batteries.

[0006] State of the art

[0007] Certain types of batteries, particularly thin-film batteries, must be encapsulated to ensure their longevity because oxygen and moisture degrade them. Lithium-ion batteries, in particular, are highly sensitive to humidity. The market demands a lifespan exceeding 10 years; therefore, encapsulation methods must be available to guarantee this lifespan.

[0008] Thin-film lithium-ion batteries are multilayer stacks comprising electrode and electrolyte layers typically between approximately 1 µm and 10 µm thick. They can consist of stacks of several individual cells. These batteries are prone to self-discharge. Depending on the electrode positioning, particularly the proximity of the electrode edges in multilayer batteries and the cleanliness of the cuts, a leakage current can occur at the ends, a creeping short circuit that reduces battery performance. This phenomenon is exacerbated if the electrolyte film is very thin.

[0009] These all-solid-state, thin-film lithium-ion batteries most often use anodes with a metallic lithium layer. Anode materials exhibit significant volume changes during battery charge and discharge cycles. This is because, during a charge and discharge cycle, some of the metallic lithium is converted into lithium ions that integrate into the cathode material structure, resulting in a reduction in the anode's volume. This cyclical volume change can damage the mechanical and electrical contacts between the electrode and electrolyte layers, ultimately reducing battery performance over its lifespan.

[0010] The cyclic variation in the volume of the anode material also induces a cyclic variation in the volume of the battery cells. This generates cyclic stresses on the encapsulation system, which can initiate cracks that lead to a loss of seal (or even integrity) of the encapsulation system. This phenomenon is another cause of the decrease in battery performance over its lifespan.

[0011] Indeed, the active materials in lithium-ion batteries are highly sensitive to air, and particularly to humidity. Mobile lithium ions react spontaneously with traces of water to form LiOH, leading to a shortened battery life. The lithium that has reacted with water is no longer available for energy storage, thus reducing the battery's capacity through premature aging. Therefore, the utmost care must be taken during battery manufacturing to maintain perfectly anhydrous conditions. Similarly, to guarantee their long lifespan, batteries are protected from the external environment by airtight encapsulation, which prevents water permeation that could induce further capacity loss.

[0012] Water permeation through this encapsulation structure is a well-known phenomenon. The watertightness of an encapsulation is usually expressed as the water vapor transmission rate (WVTR). This rate depends on the materials used, their manufacturing process, and their thickness.

[0013] The quality of the encapsulation is of paramount importance for lithium-ion batteries.

[0014] Furthermore, not all insert materials and conductive electrolytes of lithium ions are reactive to moisture. For example, Li4Ti5O12 does not deteriorate in contact with the atmosphere or traces of water. However, as soon as it is charged with lithium in the form Li4+xTi5O12 with x>0, the excess inserted lithium (x) becomes sensitive to the atmosphere and reacts spontaneously with traces of water to form LiOH. The reacted lithium is then no longer available for electricity storage, leading to a loss of battery capacity. To prevent the exposure of the active materials of the lithium-ion battery to air and water and to avoid this type of aging, it is essential to protect it with an encapsulation system. Numerous encapsulation systems for thin-film batteries are described in the literature.

[0015] US document 2002 / 0071989 describes a system for encapsulating an all-solid thin-film battery comprising a stack of a first layer of a dielectric material selected from alumina (Al2O3), silica (S1O2), silicon nitride (S13N4), silicon carbide (SiC), tantalum oxide (Ta2Os) and amorphous carbon, a second layer of a dielectric material and a sealing layer disposed on the second layer and covering the entire battery.

[0016] US patent 5,561,004 describes several protection systems for a thin-film lithium-ion battery. The first proposed system consists of a parylene layer coated with an aluminum film deposited over the battery's active components. However, this protection system against air and water vapor diffusion is only effective for about one month. A second proposed system consists of alternating layers of parylene (500 nm thick) and metal (approximately 50 nm thick). The patent specifies that it is preferable to further coat these batteries with a UV-cured epoxy layer to reduce the rate of battery degradation by atmospheric elements.

[0017] Document WO 2019 / 002768, filed on behalf of the Applicant, should also be cited, as it describes a typical arrangement of an electrochemical device. As this document explains, such a device comprises an elementary stack, each cell of which includes anodic and cathodic current-collecting substrates, anode and cathode layers, and at least one layer of electrolyte material or an electrolyte-impregnated separator. Anode and cathodic contacts are provided on the opposite lateral faces of this stack.

[0018] Finally, we should mention US 2019 / 368141, which discloses a battery intended for integration into a road. This battery includes encapsulation 150, as well as edging 160 to hold the battery elements within the road structure.

[0019] According to the prior art, most lithium-ion batteries are encapsulated in metallized polymer sheets (called "pouches") that are closed around the battery cell and heat-sealed at the connector tabs. These packages are relatively flexible, and the positive and negative battery connections are embedded in the heat-sealed polymer used to close the package around the battery. However, this seal between the polymer sheets is not completely airtight against atmospheric gases, as the polymers used to heat-seal the battery are quite permeable to atmospheric gases. It has been observed that this permeability increases with temperature, which accelerates aging.

[0020] However, the surface area of ​​these welds exposed to the atmosphere remains very small, and the rest of the packaging consists of aluminum sheets sandwiched between these polymer sheets. Generally, two aluminum sheets are used together to minimize the effects of holes or defects in each sheet. The probability of two defects on each sheet being aligned is significantly reduced.

[0021] These packaging technologies make it possible to guarantee approximately 10 to 15 years of calendar life for a 10 Ah battery measuring 10 x 20 cm. 2 surface area, under normal operating conditions. If the battery is exposed to high temperatures, this lifespan can be reduced to less than 5 years; this is insufficient for many applications. Similar technologies can be used for other electronic components, such as capacitors and active components.

[0022] Consequently, there is a need for systems and methods for encapsulating thin-film batteries and other electronic components that protect them from air, moisture, and temperature effects. In particular, there is a need for systems and methods for encapsulating thin-film lithium-ion batteries that protect them from air and moisture, as well as from deterioration when the battery is subjected to charge and discharge cycles. The encapsulation system must be airtight and hermetic, must completely enclose and cover the component or battery, must be flexible enough to accommodate slight changes in the battery cell's dimensions ("breathing"), and must also provide galvanic separation between electrode edges of opposite polarity to prevent creeping short circuits.

[0023] One objective of the present invention is to remedy at least in part the disadvantages of the prior art mentioned above.

[0024] Another objective of the present invention is to provide lithium-ion batteries with a very long lifespan and low self-discharge. In particular, it aims to provide a process for the simple, easy-to-implement, reliable, and rapid manufacture of electronic or electrochemical devices, such as batteries, with a very long lifespan. Specifically, it aims to provide a process that reduces the risk of short circuits and, in particular, enables the manufacture of an electrochemical device, such as a battery, with low self-discharge and a very long lifespan.

[0025] Objects of the invention

[0026] At least one of the above objectives is achieved through at least one of the objects according to the invention as presented below. The present invention proposes as a first object a battery (1000), said battery comprising an alternating stack (I) of at least one anode (20) and at least one cathode (50), each consisting of a stack of thin films and in which the anode (20) comprises at least one anodic current-collecting substrate (21), at least one thin layer of an anode active material (22), and optionally a thin layer of an electrolyte material (23) or of a separator impregnated with an electrolyte (23'), and in which the cathode stack (50) comprises at least one cathodic current-collecting substrate (51), at least one thin layer of a cathode active material (52), and optionally a thin layer of an electrolyte material (53) or of a separator impregnated with an electrolyte (53').such that said stack comprises successively at least one anodic current-collecting substrate (21), at least one thin layer of an anode active material (22), at least one thin layer of an electrolyte material (23, 53) or of a separator impregnated with an electrolyte (23', 53'), at least one thin layer of a cathode active material (52), and at least one cathodic current-collecting substrate (51), said stack (I) defining six faces, namely two so-called front faces (F1, F2) that are mutually opposed, in particular mutually parallel, globally parallel to the thin layers of anode active material (22), to the thin layers of electrolyte material (23, 53) or of a separator impregnated with an electrolyte (23', 53'), and to the thin layers of cathode active material (52), as well as four so-called side faces (F3, F4, F5, F6) two by two mutually opposed, in particular two by two mutually parallel,a primary encapsulation system (1020) covering at least two of the six faces of said stack (I), this encapsulation system comprising two front encapsulation regions (1021, 1022) covering all or part of said front faces (F1, F2), and / or two lateral encapsulation regions (1023, 1025) covering all or part of two of said lateral faces (F3, F5), the lateral encapsulation regions preferably being mutually opposite, in particular mutually parallel, at least one anodic contact member (1040) suitable for ensuring electrical contact between the stack and an external conductive element, said anodic contact member covering at least part of a first (F4) of the two lateral faces (F4, F6) not covered by the primary encapsulation system (1020), said first face (F4) defining at least one anodic connection zone, at least one cathodic contact member (1050),capable of ensuring electrical contact between the stack and an external conductive element, said cathodic contact member covering at least partially a second (F6) of the two lateral faces not covered by the primary encapsulation system (1020), said second face (F6) defining at least one cathodic connection zone, said anodic (1040) and cathodic (1050) contact members preferably being mutually opposed, in particular mutually parallel, said battery being characterized in that it further comprises an additional encapsulation system (1030), this additional encapsulation system comprising two front regions (1031, 1032), each of which covers a front face of the stack with the possible interposition of a respective front region (1021, 1022) of the primary encapsulation system, this additional encapsulation system further comprising two lateral regions (1033,1035) each of which covers a lateral face of the stack with possible interposition of a respective lateral region (1023, 1025), devoid of contact members, of the primary encapsulation system, each of said two front regions (1031, 1032) of the additional encapsulation system (1030) further covering the front ends (1041, 1042, 1051, 1052) respectively of the anodic contact members and the cathodic contact members, each of the front regions (1031, 1032) of the additional encapsulation system forming a continuity of surfaces with the lateral regions (1033, 1035) of said additional encapsulation system.

[0027] According to other features of the battery according to the invention, taken individually or in any technically compatible combinations: said primary encapsulation system comprises two front encapsulation regions (1021, 1022) covering all or part of said front faces (F1, F2), as well as two lateral encapsulation regions (1023, 1025) covering all or part of two of said lateral faces (F3, F5). said primary encapsulation system comprises only two front encapsulation regions (1021, 1022) covering all or part of said front faces (F1, F2).said primary encapsulation system comprises only two lateral encapsulation regions (1023, 1025) covering all or part of two of said lateral faces (F3, F5), each of the two front regions of the additional encapsulation system delimits two salient edges (1031 A, 1031 B, 1032A, 1032B) each of which protrudes from the respective front region of the primary encapsulation system, along a lateral axis (X) of the stack, each salient edge covering a respective end of the anodic contact member or the cathodic contact member.along said lateral axis (X) of the stack, said primary encapsulation system extends to the inner face of the contact members, while said additional encapsulation system extends beyond said inner face, in particular to the outer face of these contact members. Each of the two front regions of the additional encapsulation system delimits two protruding edges (1031C, 1031D, 1032C, 1032D), each of which protrudes, along another lateral axis (Y) of the stack, both with respect to the respective front region of the primary encapsulation system and with respect to the anodic and cathodic contact members, said protruding edges ensuring said continuity of surfaces between the front regions and the lateral regions of the additional encapsulation system.The opposite ends (1041, 1042, 1051, 1052) of each contact member, respectively anodic (1040) and cathodic (1050), are flush with the front regions (1021, 1022) of the primary encapsulation system (1020). The primary encapsulation system (1020) comprises at least one first covering layer, preferably selected from parylene, type F parylene, polyimide, epoxy resins, silicone, polyamide, sol-gel silica, organic silica and / or a mixture thereof, disposed on the stack (I).each of the anodic contact member (1040) and the cathodic contact member (1050) comprises a first electrical connection layer of material loaded with electrically conductive particles and a second electrical connection layer comprising a metallic foil or metallic layer, disposed on the first electrical connection layer the additional encapsulation system (1030) comprises an encapsulation layer selected from glasses, ceramics and glass-ceramics, said encapsulation layer preferably having a water vapor permeance (WVTR) of less than 10. 5 g / m 2.d. the glasses, ceramics and glass-ceramics of the encapsulation layer are chosen from: low melting point glasses, preferably chosen from S1O2-B2O3; B12O3-B2O3, ZhO-Bΐ2q3-B2q3, TeO2-V20s and PbO-SiO2, oxides and / or nitrides and / or Ta20s and / or alumina (Al2O3) and / or oxynitrides and / or SixNy and / or SiO2 and / or SiON and / or amorphous silicon and / or SiC.

[0028] The invention also relates to a method for manufacturing a battery as described above, said manufacturing method comprising: supplying at least one sheet of anodic current-collecting substrate coated with an anode layer, and optionally coated with a layer of electrolyte material or a separator impregnated with an electrolyte, hereinafter referred to as the anodic sheet; supplying at least one sheet of cathodic current-collecting substrate coated with a cathode layer, and optionally coated with a layer of electrolyte material or a separator impregnated with an electrolyte, hereinafter referred to as the cathodic sheet; and carrying out said alternating stacking (I) of at least one anodic sheet and at least one cathodic sheet, so as to successively obtain at least one anodic current-collecting substrate, at least one anode layer, and at least one layer of electrolyte material or a separator impregnated with an electrolyte. electrolyte,at least one cathode layer, and at least one cathode current-collecting substrate, carrying out heat treatment and / or mechanical compression of the stack of alternating sheets obtained in step c), so as to form a consolidated stack, carrying out said primary encapsulation system (1020), so as to form an encapsulated and cut stack exposing at least the anodic and cathodic connection zones, preferably at least the faces defining the anodic and cathodic connection zones, optionally, impregnating the cut and encapsulated stack with a lithium ion carrier phase such as liquid electrolytes or an ionic liquid containing lithium salts, so that said separator is impregnated with an electrolyte, placing the anodic and cathodic contact elements, each on a respective lateral face of the stack not covered by the primary encapsulation system,the fabrication of an additional encapsulation assembly (1030') on the structure obtained after step g), intended to encapsulate the consolidated stack comprising the contact elements, and the exposure of at least part of the anodic and cathodic contact elements, so as to form said additional encapsulation system (1030).

[0029] According to other features of the battery according to the invention, taken individually or in any technically compatible combinations: this method further comprises the fabrication of a so-called primary encapsulation assembly (1020'), on the consolidated stack (I), said primary encapsulation system being fabricated from said primary encapsulation assembly. The primary encapsulation system is fabricated from the primary encapsulation assembly by implementing two so-called primary cuts, according to first cutting planes (II). The additional encapsulation system is fabricated from the additional encapsulation assembly by implementing two so-called additional cuts.along second cutting planes (VV) extending outside the first cutting planes. The exposure of at least part of the anodic and cathodic contact elements according to step i) of the process is carried out by polishing or cutting. The fabrication of the so-called primary encapsulation system (1020) comprises the deposition of 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, onto the stack (I). The fabrication of the additional encapsulation system intended to encapsulate the consolidated stack comprising contact elements comprises the deposition of an encapsulation layer chosen from glasses, ceramics and glass-ceramics. The glasses, ceramics and glass-ceramics are chosen from: low melting point glasses, preferably chosen from S1O2-B2O3; B12O3-B2O3,ZhO-Bΐ2q3-B2q3, TeO2-V20s and PbO-SiO2, oxides and / or nitrides and / or Ta20s and / or alumina (Al2O3) and / or oxynitrides and / or SixNy and / or SiO2 and / or SiON and / or amorphous silicon and / or SiC. The fabrication of anodic and cathodic contact elements comprises: the deposition, on at least the anodic connection zone and at least the cathodic connection zone, of a first electrical connection layer of material loaded with electrically conductive particles, preferably said first layer being formed of polymeric resin and / or a material obtained by a sol-gel process loaded with electrically conductive particles, optionally, when said first layer is formed of polymeric resin and / or a material obtained by a sol-gel process loaded with electrically conductive particles, a drying step followed by a polymerization step of said polymeric resin and / or said material obtained by a sol-gel process, and the deposition,on the first layer, a second electrical connection layer is disposed on the first electrical connection layer, said second electrical connection layer preferably comprising a metallic foil or metallic ink, it being understood that in the latter case, said drying step may alternatively be carried out after the deposition of said second electrical connection layer. The process further comprises the creation of an alternating succession of cathodic and anodic layers respectively, each layer comprising a plurality of so-called void areas, as well as the creation of cutouts enabling the separation of a given stack of a battery from at least one other stack of another battery. If the void areas have bars connected in pairs by channels, at least a portion of the bars is filled with encapsulation material.Then, the cuts are made so as to obtain stacks in which two opposite lateral faces are coated with said encapsulation material. If the empty areas have an overall I-shape, at least one line formed by a plurality of stacks is created, the front faces of this line are at least partially covered with encapsulation material, and the cuts are made so as to obtain stacks in which the front faces are coated with said encapsulation material.

[0030] According to the invention, encapsulation is achieved by two distinct encapsulation systems. These systems differ, particularly with regard to their dimensions. The additional encapsulation system is larger than the primary encapsulation system, allowing it to protrude from the primary system in at least one spatial direction. Furthermore, and advantageously, these two systems differ in their constituent material and dimensions. The combination of these distinct encapsulation systems ensures, among other things, a particularly satisfactory seal. Moreover, according to the invention, the additional system can be implemented after the contact elements have been installed.

[0031] It should be noted that the prior art does not disclose such a combination of distinct encapsulation systems. In particular, this combination does not appear in the teaching of document WO 2019 / 002768, which is mentioned above. In essence, this prior art document uses a single encapsulation system, as is also mentioned in its main claim. Description of figures

[0032] Certain aspects of the invention and embodiments of the invention are illustrated, with reference to the accompanying figures, given solely by way of non-limiting examples, in which:

[0033] Figure 1 schematically represents a front view with tear-off of a stack (I) defining 6 faces, precursor of a battery according to the invention, comprising successively at least one anode current collector substrate (21), at least one thin layer of an anode active material (22), at least one thin layer of an electrolyte material (23, 53) or of a separator impregnated with an electrolyte (23', 53'), at least one thin layer of a cathode active material (52), and at least one cathode current collector substrate (51).

[0034] Figure 2 schematically represents a front view with the removal of a stack encapsulated in a primary encapsulation system.

[0035] Figure 3 schematically represents a front view with removal of a stack encapsulated in a primary encapsulation system and whose anodic and cathodic connection areas have been exposed according to the section planes ll-ll which are visible on figure 2.

[0036] Figure 4 schematically represents a front view with removal of a stack, precursor of a battery, showing the internal structure of the stack covered by a primary encapsulation system and that of the contact members according to the invention.

[0037] Figure 5 schematically represents a front view with the removal of a stack encapsulated in a primary encapsulation system and in an additional encapsulation system, revealing the internal structure of the battery.

[0038] Figure 6 schematically represents a front view with the removal of a stack encapsulated in a primary encapsulation system and in an additional encapsulation system, revealing the internal structure of the battery and whose anodic and cathodic connection areas have been exposed according to the VV section planes which are visible in Figure 5.

[0039] Figure 7 schematically represents a side view of a battery according to the invention, showing the outer face of an anodic contact element surrounded by the additional encapsulation system. Figures 8 and 9 are cross-sectional views illustrating alternative embodiments of the invention in which the primary encapsulation system covers only two faces of the elementary stack.

[0040] Figures 10 and 11 are perspective views, showing anodic and cathodic sheets which are arranged in a superimposed manner, involved in two variants of a method for manufacturing a battery according to the invention.

[0041] Figure 12 is a front view, illustrating a step involved in the production of the battery according to the variant of Figure 8.

[0042] Figures 13 and 14 are front views, illustrating steps involved in the construction of the battery according to the variant in Figure 9.

[0043] Figure 1 illustrates an electrochemical device conforming to a first embodiment, which is a battery designated as a whole by reference 1. This battery comprises, in a manner known per se, an alternating stack (I) between at least one anode (20) and at least one cathode (50).

[0044] This anode (20) comprises at least one anodic current-collecting substrate (21), at least one thin layer of an anode active material (22). In the illustrated example, this anode also comprises a thin layer of an electrolyte material (23) or an electrolyte-impregnated separator (23'), which is however optional.

[0045] Furthermore, the cathode (50) comprises at least one cathodic current-collecting substrate (51), at least one thin layer of a cathode active material (52). This cathode also comprises, in the illustrated example, a thin layer of an electrolyte material (53) or of a separator impregnated with an electrolyte (53'), which is however optional.

[0046] Therefore, the aforementioned stack successively comprises at least one anode current collector substrate (21), at least one thin layer of an anode active material (22), at least one thin layer of an electrolyte material (23, 53) or of a separator impregnated with an electrolyte (23', 53'), at least one thin layer of a cathode active material (52), and at least one cathode current collector substrate (51).

[0047] Advantageously, after stacking, the battery assembly can be carried out by heat treatment and / or mechanical compression. The heat treatment of the stack enabling battery assembly is advantageously performed at a temperature between 50°C and 500°C, preferably below 350°C. The mechanical compression of the stack is advantageously carried out at a pressure between 10 MPa and 100 MPa, preferably between 20 MPa and 50 MPa.

[0048] This stacking I, generally parallelepiped in shape, has six faces. First, we denote F1 and F2 as the opposite front faces, which, by convention, are approximately parallel to the different layers described above. Stacking 2 also defines four lateral faces, F3 to F6, which are pairwise mutually parallel and opposite. We define an orthogonal coordinate system XYZ associated with this stacking, in which the Z direction is called frontal, in that it is perpendicular to the front faces mentioned above, while the other directions X and Y are called lateral.

[0049] This stacking can be achieved by any suitable method. The battery architecture, comprising a primary encapsulation system, an additional encapsulation system, and contact elements according to the invention, is particularly well-suited to stacks in which the anodic and cathodic connection zones are laterally opposed. In the example illustrated in Figure 1, which represents a first embodiment of the stack, the constituent layers of the stack have recesses (1070) such that each elementary cell defines a continuous zone of the cathodic current collector, enabling electrical contact at the cathodic connection zone, and a continuous zone of the anodic current collector, enabling electrical contact at the anodic connection zone. This arrangement allows the anodic and cathodic connection zones to be laterally opposed.

[0050] Figure 1 illustrates this stack I in isolation, without the other final battery components. To fabricate this battery, as shown in Figure 2, the first step is to cover the 6 faces of the stack I with a primary encapsulation assembly, denoted 1020'. The 6 constituent regions of this assembly 1020', which respectively cover the 6 faces of the stack, are denoted 1021' to 1026'. This assembly 1020' is intended to form, as will be seen below, a primary encapsulation system 1020, providing protection for the battery against the atmosphere. This primary encapsulation system must be chemically stable and resistant to high temperatures. It may, if necessary, be impermeable to the atmosphere to provide a complementary barrier layer function. However, as will be seen below, the main barrier layer function is ensured by the additional encapsulation.The material intended to form this primary encapsulation is of any suitable type, in particular this primary encapsulation system 1020 comprises at least a first covering layer, preferably selected from parylene, type F parylene, polyimide, epoxy resins, silicone, polyamide, sol-gel silica, organic silica and / or a mixture thereof, disposed on the stack (I).

[0051] Typically, this first coating layer is selected from the group consisting of: silicones (deposited, for example, by impregnation or plasma-enhanced chemical vapor deposition using hexamethyldisiloxane (HMDSO)), epoxy resins, polyimide, polyamide, poly-para-xylylene (also called poly(p-xylylene), more commonly known as parylene), and / or a mixture thereof. This first coating layer protects the battery's sensitive components from its environment. The thickness of this first coating layer is preferably between 0.5 µm and 3 µm.

[0052] Various types of parylene can be used. Advantageously, this 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 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 help 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.

[0053] Once the six faces of the stack have been covered by the six regions of the encapsulation assembly 1020', the anodic and cathodic connection areas are exposed by any suitable means, along the planes 11-11 of Figure 2, which are typically parallel to the front faces F4 and F6. This assembly 1020' can advantageously be produced by successive deposition of parylene-ALD-parylene layers. Exposure of the anodic and cathodic connection areas is preferably achieved by so-called primary cuts. These cuts preferably remove the lateral regions 1024' and 1026' of the encapsulation assembly, leading to the exposure of the anodic and cathodic connection areas, as shown in Figure 3. Alternatively, such exposure can be achieved by a different cutting step.It can be achieved by any suitable means, including chemical etching, laser cutting (or laser ablation), femtosecond laser cutting, micro-perforation, or stamping. Such exposure is preferably achieved by sawing, polishing (particularly using felt and polishing compound), abrasion, and / or plasma etching.

[0054] At the end of these primary cuts, we obtain a stack covered by a primary encapsulation system, designated by the reference 1020. We note 1021, 1022, 1023 and 1025 the constituent regions of this encapsulation system, which cover the front faces F1 F2 F3 and F5 of the stack.

[0055] In the case of batteries impregnated with a liquid electrolyte, the impregnation of the battery with a liquid electrolyte is advantageously carried out, after obtaining the stacks covered by a primary encapsulation system and whose anodic and cathodic connections present on the opposite lateral faces respectively F4 and F6 are exposed, by a lithium ion carrier phase such as liquid electrolytes or an ionic liquid containing lithium salts; this lithium ion carrier phase penetrates into the porosities of the battery, in particular into the battery separators by capillarity.

[0056] At the opposing lateral faces F4 and F6, where the anodic and cathodic contact areas are exposed, and optionally after impregnating the battery with a liquid electrolyte, the anodic contact members 1040 and cathodic contact members 1050 are then positioned, as shown in Figure 4. The so-called front ends of these contact members 1040 and 1050, which are located near the front faces of the stack, are denoted 1041 and 1042, as well as 1051 and 1052. The steps illustrated in Figures 2 to 4 are of a conventional type and are therefore not described in further detail below.

[0057] Preferably, the contact elements are deposited on and around the cathodic and anodic connection zones, preferably on the lateral faces defining these anodic and cathodic connection zones. These contact elements are preferably made up of a stack of layers comprising successively: a first electrical connection layer comprising a material loaded with electrically conductive particles, preferably a polymeric resin and / or a material obtained by a sol-gel process, loaded with electrically conductive particles and even more preferably a graphite-loaded polymeric resin, and a second electrical connection layer consisting of a metallic foil or a metallic layer, disposed on the first layer.

[0058] The first layer of electrical connection allows the subsequent second layer of electrical connection to be fixed while providing "flexibility" to the connection without breaking the electrical contact when the electrical circuit is subjected to thermal and / or vibrational stresses.

[0059] The second electrical connection layer is a metallic foil or layer. This foil or layer can be flat or textured. This second electrical connection layer is used to provide long-lasting protection against moisture for the batteries while connecting, on one side of the F4 battery, the anodic connection areas, and on the other side of the F6 battery, the cathodic connection areas. Generally speaking, for a given material thickness, metals allow for the creation of highly watertight films, more watertight than ceramic-based films and even more watertight than polymer-based films, which are generally less permeable to water molecules. This layer increases the battery's calendar life by reducing the water vapor transmission rate (WVTR) at the contact points.

[0060] Advantageously, a third electrical connection layer, including a conductive ink, can be deposited on the second electrical connection layer; this serves to reduce the WVTR, thereby increasing battery life. Water vapor permeance (WVTR) can be measured 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 layers on polymer substrates" by A. Mortier et al., published in the journal Thin Solid Films 6+550 (2014) 85-89.

[0061] The contact elements allow for alternating positive and negative electrical connections at each end. These contact elements enable parallel electrical connections between the different battery cells. For this purpose, only the cathode connections are present at one end, while the anodic connections are available at the other. Then, as shown in Figure 5, the six faces of the intermediate structure in Figure 4 are covered with an additional encapsulation assembly 1030', designed to form, as will be seen later, an additional encapsulation system 1030. This additional encapsulation system protects the entire cell from diffusion molecules from the atmosphere and ultimately makes it airtight.This additional encapsulation (or additional encasing layer) is preferably deposited by atomic layer deposition (ALD), PECVD, HDPCVD (high-density plasma chemical vapor deposition), or ICPCVD (inductively coupled plasma chemical vapor deposition), so as to obtain conformal coverage of all accessible surfaces of the intermediate structure. As with the primary encapsulation described above, the additional encapsulation can advantageously be achieved by successive depositions of parylene-ALD-parylene layers.

[0062] The thickness of this additional encapsulation 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, particularly ALD, PECVD, HDPCVD, and HDCVDICPCVD. The thickness of this additional encapsulation layer is preferably between 10 nm and 15 pm. This system or additional encapsulation layer is airtight and preferably has a water vapor permeance (WVTR) of less than 10 -5 g / m 2 .d. The measurement of water vapor permeance can be done using a method which is the subject of US 7,624,621 and which is also described in the publication "Structural properties of ultraviolet cured polysilazane gas barrier iayers on polymer substrates" by A. Mortier et al., published in the journal Thin Solid Films 6+550 (2014) 85-89.

[0063] The 6 constituent regions of this additional assembly 1030' are denoted 103T to 1036', which respectively cover the 6 faces of the stack. The material intended to form this additional encapsulation can be chosen from among glasses, ceramics and glass-ceramics, preferably from: low-melting-point glasses, preferably chosen from S1O2-B2O3; B12O3-B2O3, ZhO-Bΐ2q3-B2q3, TeO2-V2Os and PbO-SiO2, oxides and / or nitrides and / or Ta2Os and / or alumina (Al2O3) and / or oxynitrides and / or SixNy and / or S1O2 and / or SiON and / or amorphous silicon and / or SiC. The intermediate structure of figure 5 is then subjected to so-called additional cutting operations, by any appropriate means, according to the planes VV of figure 5. These cutting planes are typically parallel to those ll-ll described above, extending however outside of the latter in the X direction.These cutouts, which allow for the complete or partial removal of the lateral regions 1034' and 1036' of the additional encapsulation assembly, lead to the complete or partial exposure of the contact members 1040 and 1050, as shown in Figure 6. During these cutouts, it is also possible to remove a marginal portion of the material forming the contact member, while preserving its functionality. Advantageously, a sufficient portion of the second electrical connection layer, consisting of a metal foil, is left intact. Advantageously, the exposure of the first electrical connection layer is also avoided.

[0064] In this context, the metal foil or metal layer can be textured to facilitate re-establishing electrical connections after additional cuts have been made. Alternatively, such exposure can be achieved through a process other than cutting. This can be accomplished by polishing, plasma etching, chemical etching, laser cutting (or laser ablation), femtosecond laser cutting, micro-perforation, or stamping. It is particularly advantageous to use textured metal foils when exposing the contact elements by sawing or polishing, especially using felt and polishing compound; this facilitates re-establishing electrical connections, particularly at local protrusions. As an alternative, the metal part of the current collector can also be masked before the additional encapsulation is applied.When this protective layer is removed, the electrical contact is then exposed.

[0065] At the end of these additional cuts, we obtain a stack covered first by the primary encapsulation system 1020, then by the additional encapsulation system 1030. We note 1031, 1032, 1033 and 1035 the constituent regions of this additional system 1030, which cover the respective regions 1021, 1022, 1023 and 1025 of the primary system 1020.

[0066] In cross-sectional view, as shown in Figure 6, the dimension along the X direction of the frontal regions 1031 and 1032 of the additional system 1030 is greater than the dimension of the frontal regions 1021 and 1022 of the primary system 1020. More precisely, along this X direction, each frontal region, referred to as primary, 1021 and 1022 extends to the inner face of the opposing contact members 1040 and 1050. Furthermore, along this direction, each frontal region, referred to as additional, 1031 and 1032 is flush with the outer face of these contact members.

[0067] Therefore, each of these regions 1031 and 1032 delimits, along this direction X, so-called salient edges 1031 A 1031 B, as well as 1032A 1032B. Each of these edges 1031 A 1031 B 1032A 1032B covers a respective end 1041 1051 1042 1052 of the contact members 1040 1050. Put another way, the encapsulation material 1020 1030, formed by both the primary and additional systems, delimits shoulders noted 1060 and 1061, against which the upper and lower ends of the contact members extend, respectively.

[0068] Moreover, as shown in this same figure 6, the opposite ends, respectively 1041 1042, as well as 1051 1052, of each contact member respectively anodic 1040 and cathodic 1050, are flush with the front regions 1021 and 1022 of the encapsulation system 1020. In other words, the said opposite ends extend substantially, along the X direction, at the level of the free faces, respectively upper of the region 1021 and lower of the region 1022.

[0069] The arrangement of the additional encapsulation system on top of the primary encapsulation system and around the contact points gives the final battery excellent sealing, in particular a very low water vapor transmission rate. This increases the battery's lifespan. More specifically, this design prevents the diffusion of water or oxygen molecules at the 1042 and 1041 ends of the contact points. This is because the conductive adhesives used to create the contact are not as impermeable to water diffusion as the metal foil.

[0070] Furthermore, as shown in Figure 7, the dimension along the Y direction of the frontal regions 1031 and 1032 is greater than the dimension of both the frontal regions 1021 and 1022, as well as the contact members 1040 and 1050. Consequently, each of these regions 1031 and 1032 delimits, along this Y direction, so-called salient edges 1031C and 1031D, as well as 1032C and 1032D. These different edges ensure a continuity of surfaces of the additional encapsulation between each frontal region 1031 or 1032 and the two lateral regions 1033 and 1035. The battery above, conforming to the embodiments of Figures 1 to 7, comprises a primary encapsulation system having four regions, each of which covers a respective face of the primary stack. As an alternative, however, it can be predicted that this primary encapsulation system has a smaller number of regions.In particular, such a system may consist of only two regions, which are present on opposite faces of the stack.

[0071] First, as shown in Figure 8, the primary encapsulation system regions can be predicted to cover only the lateral faces of the stack, which are not occupied by the contact elements. Alternatively, as shown in Figure 9, these primary encapsulation system regions can be predicted to cover only the front faces of the stack, which are therefore parallel to its constituent layers. Manufacturing processes for these batteries in Figures 8 and 9 will be described with reference to Figures 12 and following.

[0072] As a preliminary point, as is known, several elementary stacks such as the one above can be produced simultaneously. This increases the efficiency of the overall manufacturing process for batteries according to the invention. In particular, it is possible to produce a large stack, formed by an alternating succession of cathodic and anodic layers, or sheets.

[0073] The physicochemical structure of each anode or cathode foil, which is of a type known, for example, from patent FR 3 091 036 in the name of the applicant, is not part of the invention and will be described only briefly. Each anode foil, or cathode foil respectively, comprises an active anode layer, or an active cathode layer respectively. Each of these active layers may be solid, i.e., dense or porous. Furthermore, in order to prevent any electrical contact between two adjacent foils, an electrolyte layer or a separator impregnated with a liquid electrolyte is disposed on at least one of these two foils, in contact with the opposite foil. The electrolyte layer or the separator impregnated with a liquid electrolyte, not shown in the figures describing the present invention, is interposed between two foils of opposite polarity, i.e., between the anode foil and the cathode foil.These layers are notched to define so-called void zones that allow separation between the different final batteries. Within the framework of the present invention, these void zones can be given different shapes. As already proposed by the Applicant in patent FR 3 091 036, these void zones can be H-shaped. The attached Figure 10 illustrates the stacking 1100 of anode sheets, or layers 1101, and cathode sheets, or layers 1102. As this figure shows, cutouts are made in these different sheets to create the H-shaped void zones, respectively anodic 1103 and cathodic 1104.

[0074] As an alternative, these free areas can also have an I shape. The attached Figure 11 illustrates the stacking 1200 between anode sheets or layers 1201, as well as cathode sheets or layers 1202. As shown in this Figure 11, cutouts are made in these different sheets, so as to create the said empty areas in the shape of an I, respectively anodic 1203 and cathodic 1204.

[0075] Preferably, upon completion of the fabrication of the various elementary stacks, each anode and each cathode of a given battery comprises a respective primary core, separated from a respective secondary core by a space free of any electrode material, electrolyte, and / or current-conducting substrate. As a further variant, not shown, the empty spaces may be provided in shapes other than an H or an I, in particular a U shape. However, H or I shapes are preferred.

[0076] As shown in Figure 12, the battery of Figure 8 can be made using the succession of sheets shown in Figure 10. In this Figure 12, a void area, which is generally H-shaped, is illustrated on a larger scale. More precisely, as known from patent FR 3 091 036 mentioned above, these void areas have vertical bars 1103, which are connected in pairs by horizontal channels 1110. According to this variant, the bars 1103 receive a material 221, intended to form all or part of the primary encapsulation system.

[0077] Furthermore, as is also known from the French patent above, different elementary stacks are delimited by adjacent bars. These elementary stacks, which are mutually identical, are successively designated II, I, and III from left to right in Figure 12. According to the present embodiment, vertical cuts, denoted DY, are then made. This allows not only the stacks to be separated from one another, as is known, but also the simultaneous creation of separate elementary stacks that are covered by the lateral regions of the primary encapsulation. In the embodiment of Figure 12, two vertical cuts DY are made, given that the 1103 bars are relatively wide. As an advantageous alternative, not shown, these bars can be made significantly narrower. In this case, it is possible to make a single vertical cut.

[0078] As shown in Figures 13 and 14, the battery in Figure 9 can be made using the layered sheets shown in Figure 11. In a step not shown, this layered sheet is entirely covered with an encapsulating material, forming the primary encapsulation system. Once this covering is complete, only the individual stacks located at the peripheral edges of the sheets are covered, not only on their front faces but also on some of their lateral faces. In contrast, all the "central" individual stacks are covered only on their opposite front faces.

[0079] Next, a plurality of horizontal cuts must be made, only one of which is illustrated in Figure 11 with the reference DX. Once these horizontal cuts have been made, a plurality of bars are available, one of which is shown in Figure 13. Each bar is formed by a single line of elementary stacks, which are arranged next to each other.

[0080] Figure 13 illustrates three adjacent stacks, I, II, and III, with the understanding that each strip contains a significantly larger number of such stacks. Only the two elementary stacks, located at opposite ends of each row, are covered by the encapsulating material on both their front faces and some of their lateral faces. In contrast, the other elementary stacks, referred to as the middle stacks, are covered only on their front faces.

[0081] Finally, as shown in Figure 14, vertical cuts are made at each row. This allows a given stack to be separated from each adjacent stack. After these vertical cuts, a stack, such as stack I in Figure 14, is obtained, with only the front faces coated by the encapsulation material. The battery according to the invention, comprising such an architecture, can be used as is or integrated into an electronic circuit. Electrical contacts compatible with solder-reflow assembly steps can be made on the exposed contact surfaces of the battery.In this case, and depending on the end use of the battery, the contact elements, preferably the faces of the battery according to the invention comprising the contact elements, can be covered with a multilayer system consisting of a first layer of conductive polymer, such as a conductive ink, preferably a silver-filled epoxy resin, a second layer of nickel, in particular deposited by electrolytic deposition on this first layer and a third layer of tin deposited by electrolytic deposition on this second layer.

[0082] The first layer of conductive polymer, preferably silver-filled epoxy resin, provides flexibility to the connector without breaking electrical contact when the circuit is subjected to thermal and / or vibrational stresses. The nickel layer protects the polymer layer during soldering, and the tin layer ensures the solderability of the battery interface.

[0083] The battery according to the invention can advantageously be integrated and / or overmolded in a flat integrated circuit package which physically and electrically connects the integrated circuits to a printed circuit board, such as a QFN (Quad Fiat No-leads package) type package.

[0084] The battery according to the invention can be a lithium-ion microbattery, a lithium-ion minibattery, or a high-power lithium-ion battery. In particular, it can be designed and sized to have a capacity less than or equal to approximately 1 mAh (commonly called a "microbattery"), to have a power output greater than approximately 1 mAh up to approximately 1 Ah (commonly called a "minibattery"), or to have a capacity greater than approximately 1 Ah (commonly called a "power battery"). Typically, microbatteries are designed to be compatible with microelectronic manufacturing processes.

[0085] 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 conductive 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 conductive medium, which enters spontaneously inside the layer and does not leave this layer, so that this layer can be considered quasi-solid, or with impregnated porous layers (i.e. layers having a network of open pores which can be impregnated with a liquid or paste phase, and which gives these layers wet properties).

Claims

DEMANDS 1. Battery (1000), said battery comprising an alternating stack (I) of at least one anode (20) and at least one cathode (50), each consisting of a stack of thin films and wherein the anode (20) comprises at least one anodic current-collecting substrate (21), at least one thin layer of an anode active material (22), and optionally a thin layer of an electrolyte material (23) or of a separator impregnated with an electrolyte (23'), and wherein the cathode stack (50) comprises at least one cathodic current-collecting substrate (51), at least one thin layer of a cathode active material (52), and optionally a thin layer of an electrolyte material (53) or of a separator impregnated with an electrolyte (53'), such that said stack successively comprises at least one anodic current-collecting substrate (21), at least one thin layer of an active anode material (22), at least one thin layer of an electrolyte material (23,53) or of a separator impregnated with an electrolyte (23', 53'), at least one thin layer of a cathode active material (52), and at least one cathode current-collecting substrate (51), said stack (I) defining six faces, namely two so-called front faces (F1, F2) mutually opposed, in particular mutually parallel, globally parallel to the thin layers of anode active material (22), to the thin layers of electrolyte material (23, 53) or of the separator impregnated with an electrolyte (23', 53'), and to the thin layers of cathode active material (52), as well as four so-called side faces (F3, F4, F5, F6) pairwise mutually opposed, in particular pairwise mutually parallel, a so-called primary encapsulation system (1020) covering at least two of the six faces of said stack (I), this encapsulation system comprising two regions front encapsulation (1021 1022) covering all or part of said front faces (F1, F2),and / or two lateral encapsulation regions (1023, 1025) covering all or part of two of said lateral faces (F3, F5), the regions, of lateral encapsulation preferably being mutually opposed, in particular mutually parallel, at least one anodic contact member (1040), suitable for ensuring electrical contact between the stack and an external conductive element, said anodic contact member covering at least partially a first (F4) of the two lateral faces (F4, F6) not covered by the primary encapsulation system (1020), said first face (F4) defining at least one anodic connection zone, at least one cathodic contact member (1050), suitable for ensuring electrical contact between the stack and an external conductive element, said cathodic contact member covering at least partially a second (F6) of the two lateral faces not covered by the primary encapsulation system (1020), said second face (F6) defining at least one cathodic connection zone, said anodic (1040) and cathodic (1050) contact members preferably being,mutually opposed, in particular mutually parallel, said battery being characterized in that it further comprises an additional encapsulation system (1030), this additional encapsulation system comprising two front regions (1031, 1032), each of which covers a front face of the stack with the possible interposition of a respective front region (1021, 1022) of the primary encapsulation system, this additional encapsulation system further comprising two lateral regions (1033, 1035), each of which covers a lateral face of the stack with the possible interposition of a respective lateral region (1023, 1025), devoid of a contact element, of the primary encapsulation system, each of said two front regions (1031, 1032) of the additional encapsulation system (1030) further covering the front ends (1041, 1042, 1051, 1052) respectively anodic contact elements and cathodic contact elements,each of the frontal regions (1031, 1032) of the additional encapsulation system forming a continuity of surfaces with the lateral regions (1033, 1035) of said additional encapsulation system.

2. Battery according to claim 1, wherein said primary encapsulation system comprises two front encapsulation regions (1021 1022) covering all or part of said front faces (F1, F2), as well as two lateral encapsulation regions (1023, 1025) covering all or part of two of said lateral faces (F3, F5).

3. Battery according to claim 1, wherein said primary encapsulation system comprises only two front encapsulation regions (1021 1022) covering all or part of said front faces (F1, F2).

4. Battery according to claim 1, wherein said primary encapsulation system comprises only two lateral encapsulation regions (1023, 1025) covering all or part of two of said lateral faces (F3, F5), 5. Battery according to any one of claims 2 or 3, wherein each of the two front regions of the additional encapsulation system delimits two salient edges (1031 A, 1031 B, 1032A, 1032B) each of which protrudes from the respective front region of the primary encapsulation system, along a lateral axis (X) of the stack, each salient edge covering a respective end of the anodic contact member or the cathodic contact member.

6. Battery according to the preceding claim, wherein, along said lateral axis (X) of the stack, said primary encapsulation system extends to the inner face of the contact members, while said additional encapsulation system extends beyond said inner face, in particular to the outer face of these contact members.

7. Battery according to any one of claims 5 or 6, wherein each of the two front regions of the additional encapsulation system delimits two protruding edges (1031C, 1031D, 1032C, 1032D) each of which protrudes, along another lateral axis (Y) of the stack, both with respect to the respective front region of the primary encapsulation system and with respect to the anodic and cathodic contact members, said protruding edges ensuring said continuity of surfaces between the front regions and the lateral regions of the additional encapsulation system.

8. Battery according to any one of the preceding claims, wherein the opposite ends (1041, 1042, 1051, 1052) of each contact member respectively anodic (1040) and cathodic (1050), are flush with the front regions (1021, 1022) of the primary encapsulation system (1020).

9. Battery according to any one of the preceding claims, wherein the primary encapsulation system (1020) comprises at least one first covering layer, preferably selected from parylene, type F parylene, polyimide, epoxy resins, silicone, polyamide, sol-gel silica, organic silica and / or a mixture thereof, disposed on the stack (I).

10. Battery according to any one of the preceding claims, wherein each of the anodic contact member (1040) and the cathodic contact member (1050) comprises a first electrical connection layer of material charged with electrically conductive particles and a second electrical connection layer comprising a metallic foil or metallic layer, disposed on the first electrical connection layer.

11. Battery according to any one of the preceding claims, wherein the additional encapsulation system (1030) comprises an encapsulation layer selected from glasses, ceramics and glass-ceramics, said encapsulation layer preferably having a water vapor permeance (WVTR) of less than 10 5 g / m 2 .d.

12. Battery according to the preceding claim, wherein the glasses, ceramics and glass-ceramics of the encapsulation layer are selected from: low melting point glasses, preferably selected from S1O2-B2O3; B12O3-B2O3, ZhO-Bΐ2q3-B2q3, TeO2-V2Os and PbO-SiO2, oxides and / or nitrides and / or Ta2Os and / or alumina (Al2O3) and / or oxynitrides and / or SixNy and / or SiO2 and / or SiON and / or amorphous silicon and / or SiC.

13. A method for manufacturing a battery according to any one of the preceding claims, said manufacturing method comprising: a) supplying at least one sheet of anodic current-collecting substrate coated with an anode layer, and optionally coated with a layer of electrolyte material or a separator impregnated with an electrolyte, hereinafter referred to as an anodic sheet, b) supplying at least one sheet of cathodic current-collecting substrate coated with a cathode layer, and optionally coated with a layer of electrolyte material or a separator impregnated with an electrolyte, hereinafter referred to as a cathodic sheet, (c) the fabrication of said alternating stack (I) of at least one anodic foil and at least one cathodic foil, so as to successively obtain 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; (d) the fabrication of a heat treatment and / or mechanical compression of the stack of alternating foils obtained in step (c), so as to form a consolidated stack; (e) the fabrication of said primary encapsulation system (1020), so as to form an encapsulated and cut stack exposing at least the anodic and cathodic connection areas, preferably at least the faces defining the anodic and cathodic connection areas; (f) optionally, the impregnation of the cut and encapsulated stack.by a lithium ion carrier phase such as liquid electrolytes or an ionic liquid containing lithium salts, so that said separator is impregnated with an electrolyte, (g) the placement of the anodic and cathodic contact members, each on a respective lateral face of the stack not covered by the primary encapsulation system, (h) the fabrication of an additional encapsulation assembly (1030') on the structure obtained after step (g), intended to encapsulate the consolidated stack comprising the contact members, and (i) the exposure of at least part of the anodic and cathodic contact members, so as to form said additional encapsulation system (1030).

14. Method according to the preceding claim, further comprising the realization of a primary encapsulation assembly (1020'), on the consolidated stack (I), said primary encapsulation system being made from said primary encapsulation assembly.

15. Method according to the preceding claim, wherein the primary encapsulation system is made from the primary encapsulation assembly by implementing two so-called primary cuts, according to first cutting planes (II II).

16. Method according to the preceding claim, wherein the additional encapsulation system is made from the additional encapsulation assembly by implementing two so-called additional cuts, according to second cutting planes (VV) extending outside the first cutting planes.

17. A method according to any one of claims 12 to 16, wherein the exposure of at least part of the anodic and cathodic contact elements according to step i) of the method is carried out by polishing or by cutting.

18. A method according to any one of claims 12 to 17, characterized in that the realization of the so-called primary encapsulation system (1020) comprises the deposition of at least one first covering 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 stack (I).

19. A method according to any one of claims 12 to 18, characterized in that the realization of the additional encapsulation system intended to encapsulate the consolidated stack comprising contact elements, comprises the deposition of an encapsulation layer selected from glasses, ceramics and glass-ceramics.

20. A method according to the preceding claim, wherein the glasses, ceramics, and glass-ceramics are selected from: low-melting-point glasses, preferably selected from S1O2-B2O3; B12O3-B2O3, Z h O-Bΐ2q3-B2q3, TeO2-V20s and PbO-SiO2, oxides and / or nitrides and / or Ta20s and / or alumina (Al2O3) and / or oxynitrides and / or SixNy and / or SiO2 and / or SiON and / or amorphous silicon and / or SiC.

21. A method according to any one of claims 12 to 20, characterized in that the production of anodic and cathodic contact elements comprises: the deposition on at least the anodic connection zone and at least the cathodic connection zone, of a first electrical connection layer of material loaded with electrically conductive particles, preferably said first layer being formed of polymeric resin and / or a material obtained by a sol-gel process loaded with electrically conductive particles, Optionally, when said first layer is formed of polymer resin and / or of a material obtained by a sol-gel process loaded with electrically conductive particles, a drying step followed by a polymerization step of said polymer resin and / or of said material obtained by a sol-gel process, and the deposition, on the first layer, of a second electrical connection layer disposed on the first electrical connection layer, said second electrical connection layer comprising, preferably, a metallic foil or a metallic ink, knowing that in the latter case, said drying step may alternatively be carried out after the deposition of said second electrical connection layer.

22. A method according to any one of claims 12 to 21, further comprising the production of an alternating succession of cathodic and anodic layers respectively, each layer comprising a plurality of so-called empty zones, as well as the production of cutouts enabling the separation of a given stack of a battery from at least one other stack of another battery.

23. A method according to the preceding claim, for manufacturing a battery according to claim 2, in which the empty areas have bars connected 2 to 2 by channels, a method in which at least a part of the bars is filled with encapsulation material, and then said cuts are made so as to obtain stacks of which 2 opposite lateral faces are coated with said encapsulation material.

24. A method according to claim 22, for manufacturing a battery according to claim 3, wherein the empty areas have an overall I-shape, a method wherein at least one line formed by a plurality of stacks is made, the front faces of this line are at least partially covered with encapsulation material, and said cuts are made so as to obtain stacks whose front faces are coated with said encapsulation material.

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