Improved life electrochemical cell device including improved sealing and electrical conduction means and method of manufacture thereof

Abstract

The battery comprises a stack of alternating at least one anode and at least one cathode, a so-called primary sealing system covering four of the six sides of the stack, at least one anode contact member capable of electrical contact between the stack and an external conductor, and at least one cathode contact member capable of electrical contact between the stack and an external conductor. The battery further comprises an additional sealing system having two front regions, each covering a front region of the primary sealing system, and two side regions, each covering a side region of the primary sealing system that is free of contact members. Each of the two front regions of the additional sealing system further covers the front end of each of the anode and cathode contact members, and each of the front regions of the additional sealing system forms surface continuity with the side regions of the additional sealing system.

Description

[Technical field]

[0001] The present invention relates to electrochemical devices of the battery type. It is particularly applicable to lithium-ion batteries. The present invention relates to a novel battery structure, which provides the battery with improved impermeable sealing and electrical conduction properties, as well as a longer life. The present invention further relates to a method for manufacturing these batteries. [Background technology]

[0002] Some batteries, especially thin-film batteries, are degraded by oxygen and moisture and require encapsulation to extend their life. Lithium-ion batteries, in particular, are very sensitive to moisture. The market demands a lifespan of 10 years or more, and encapsulation is required to guarantee that lifespan.

[0003] Thin-film lithium-ion batteries are multi-layer stacks of electrode and electrolyte layers, usually with a thickness of about 1 μm to about 10 μm. They may also consist of a stack of several unit cells. These batteries are known to be sensitive to self-discharge. Depending on the location of the electrodes, especially the proximity of the edges of the electrodes in multi-layer cells, and the cleanliness of the cuts, leakage currents can appear at the edges, i.e., insidious short circuits that reduce battery performance. This phenomenon is exacerbated if the electrolyte membrane is very thin.

[0004] Such solid-state thin-film lithium-ion batteries typically use an anode with a lithium metal layer. It has been observed that the volume of the anode material changes significantly during the charge-discharge cycles of the battery. More specifically, during the cycles, some of the lithium metal is transformed into lithium ions, which are inserted into the structure of the cathode material, causing the volume of the anode to decrease. This cyclical change in volume can deteriorate the mechanical and electrical contact between the electrode layer and the electrolyte layer, thus shortening the battery's lifespan.

[0005] Moreover, the cyclic volumetric fluctuations of the anode material induce cyclic volumetric fluctuations in the battery cell, which in turn generates cyclic stresses in the encapsulant, making it more susceptible to cracking and reducing its impermeability (or integrity), which is another cause of reduced battery life.

[0006] More specifically, the active materials in lithium-ion batteries are very sensitive to air, especially moisture. Mobile lithium ions spontaneously react with traces of moisture to form LiOH, which causes the battery to age. Lithium that has reacted with water can no longer store energy, shortening the battery's lifespan. For this reason, great care must be taken during battery manufacturing to maintain a completely anhydrous state. To guarantee the battery's lifespan, the battery is protected from the external environment by a hermetic seal that prevents water penetration, which would lead to further reduction in battery capacity.

[0007] The permeation of water through this seal is a well-known phenomenon. The impermeability of a seal is usually expressed as its Water Vapor Transmission Rate (WVTR). This rate varies depending on the material used, the manufacturing method and the thickness.

[0008] In lithium-ion batteries, the quality of the encapsulant is of utmost importance.

[0009] In addition, both the lithium ion conducting electrolyte and the intercalation agent are non-reactive with moisture. For example, Li4Ti5O 12 does not deteriorate even when in contact with air or small amounts of water. 4+x Ti5O 12 As soon as lithium is inserted in the form of (x>0), the excess lithium (x) is sensitive to the atmosphere and spontaneously reacts with traces of water to form LiOH, which means that the reacted lithium can no longer store electricity, reducing the capacity of the battery.

[0010] To prevent the active materials in lithium-ion batteries from being exposed to air and water and thus from deteriorating over time, they need to be protected by an encapsulation system. A number of encapsulation systems for thin-film batteries have been described in the literature.

[0011] US 2002 / 0071989 describes a sealing system for a solid-state thin-film battery that includes a stack of a first layer of a dielectric material selected from alumina (Al2O3), silica (SiO2), silicon nitride (Si3N4), silicon carbide (SiC), tantalum oxide (Ta2O5) and amorphous carbon, a second layer of dielectric material and an impermeable sealing layer disposed on the second layer and covering the entire battery.

[0012] US Patent No. 5,561,004 describes several systems for protecting thin-film lithium-ion batteries. The first proposed system involves a layer of parylene covered by an aluminum film deposited on the active components of the battery. However, this method is only effective for about a month to prevent air and water vapor diffusion. Another involves alternating layers of parylene (500 nm thick) and metal (approximately 50 nm thick). The document suggests that it would be desirable to recoat these cells with a UV-cured epoxy coating to reduce the rate at which the cells degrade due to atmospheric constituents.

[0013] Also, the applicant's application WO 2019 / 002768 describes a typical arrangement of an electrochemical device, which is referred to. As disclosed therein, such a device comprises a unit stack, each cell of which comprises an anode and a respective cathode current collecting substrate, an anode and a respective cathode layer, and at least one layer of a separator impregnated with an electrolyte material or electrolyte. The anode and the respective cathode contacts are provided on opposite sides of the stack.

[0014] Finally, reference is made to US Patent Application Publication No. 2019 / 368141, which discloses a battery intended to be integrated into roadways, comprising an encapsulant 150 and a curb 160 for keeping the battery elements contained within the roadway structure.

[0015] According to the prior art, most lithium-ion batteries are enclosed in metallized polymer foils (called "pouches") that are wrapped around the battery cells and heat sealed with connecting tabs. These packagings are relatively flexible, and the positive and negative connections of the battery are thus embedded in the heat-sealed polymer used to seal the packaging around the battery. However, the welds between these polymer foils are not completely impermeable to atmospheric gases, since the polymer used to heat seal the battery is relatively permeable to atmospheric gases. It has been observed that this permeability increases with increasing temperature, accelerating aging.

[0016] However, the surface area of ​​the weld exposed to the atmosphere is very small, and the remaining area is made of aluminum foil sandwiched between the polymer foils. Typically, the two foils are combined to minimize the effect of a hole in each foil, which would cause a defect. This greatly reduces the chance of two defects in each foil.

[0017] These packaging techniques allow the production of a 10 Ah battery (surface area 10 × 20 cm 2 ) guarantees a calendar life of about 10 to 15 years under normal conditions of use. However, if the battery is exposed to high temperatures, this life can be reduced to less than 5 years, which may be insufficient for many applications. Similar technology can be applied to other electronic components, such as capacitors and active components.

[0018] Therefore, there is a need for a sealing system and method to protect thin-film batteries and other electronic components from the effects of air, moisture, and temperature. In particular, there is a need for a system and method to protect thin-film lithium-ion batteries from air and moisture and from degradation when the batteries are subjected to charge-discharge cycles. The sealing system must provide an impermeable and hermetic seal, completely surround and cover the component or battery, be flexible to accommodate slight changes in the dimensions of the battery cell ("breathing"), and allow for electrical isolation of the edges of opposite polarity electrodes to prevent any insidious short circuits.

[0019] One object of the present invention is to at least partially overcome the aforementioned shortcomings of the prior art.

[0020] Another object of the invention is to propose a lithium-ion battery that has a very long life span and a low self-discharge rate.

[0021] In particular, it is an object to propose a method with which electronic or electrochemical devices, such as batteries, having a very long life span can be manufactured in a simple, easy to implement, reliable and rapid manner, in particular with reduced risk of short circuits and with an especially low self-discharge rate, making it possible to manufacture electrochemical devices, such as batteries, having a very long life span. Summary of the Invention

[0022] At least one of the above objects is achieved through at least one of the objects of the present invention described below. The present invention provides, as a first object, a battery (1000), said battery including: A stack (I) of at least one alternating anode (20) and at least one cathode (50), each formed by a stack of thin layers, said anodes (20) being At least one anode current collecting substrate (21); At least one thin layer of positive electrode active material (22); and optionally a thin layer of electrolyte material (23) or electrolyte-impregnated separator (23'), said cathode (50) comprising: At least one cathode current collecting substrate (51); At least one thin layer of negative electrode active material (52); Optionally, a thin layer of electrolyte material (53) or electrolyte-impregnated separator (53'), said stack comprising: The stack (I) comprises successively at least one anode current collecting substrate (21), at least one thin layer of anode active material (22), at least one thin layer of electrolyte material (23, 53) or separator (23', 53') impregnated with an electrolyte, at least one thin layer of cathode active material (52) and at least one cathode current collecting substrate (51), said stack (I) having six faces, namely: two so-called front faces (F1, F2) facing each other and in particular parallel to each other, generally parallel to the thin layer of positive electrode active material (22), the thin layer of electrolyte material (23, 53) or separator (23', 53') impregnated with an electrolyte, and the thin layer of negative electrode active material (52); a stack (I) of at least one alternating anode (20) and at least one cathode (50) defining four so-called side faces (F3, F4, F5, F6) which are in pairs facing each other and in particular parallel to each other in pairs; a so-called primary sealing system (1020) covering at least two of the six faces of the stack (I), said sealing system comprising two front sealing areas (1021, 1022) covering all or part of the front faces (F1, F2) and / or two side sealing areas (1023, 1025) covering all or part of two of the side faces (F3, F5), said side sealing areas being preferably opposite each other and in particular parallel to each other; at least one anode contact member (1040) capable of making an electrical contact between the stack and an external conductive element, said anode contact member at least partially covering a first face (F4) of said two side faces (F4, F6) not covered by said primary sealing system (1020), said first face (F4) defining at least one anode connection zone; at least one cathode contact member (1050) capable of making electrical contact between the stack and an external conductive element, said cathode contact member at least partially covering a second face (F6) of said two side faces not covered by said primary sealing system (1020), said second face (F6) defining at least one cathode connection zone; The anode (1040) and cathode (1050) contact members are preferably opposed to each other, in particular parallel to each other; The battery further comprises a so-called additional sealing system (1030), which comprises two frontal areas (1031, 1032), each covering a front side of the stack with optional interposition of the respective frontal areas (1021, 1022) of the primary sealing system, and which further comprises two side areas (1033, 1035), each covering a side of the stack without contact members with optional interposition of the respective side areas (1023, 1025) of the primary sealing system, each of the two frontal regions (1031, 1032) of the additional sealing system (1030) further covers a front end (1041, 1042, 1051, 1052) of each of the anode contact member and the cathode contact member, Each of the front regions (1031, 1032) of the additional sealing system forms surface continuity with the side regions (1033, 1035) of the additional sealing system.

[0023] According to other characteristics of the battery according to the invention, which may be taken in isolation or are any of the characteristics technically compatible, are the following:

[0024] The primary sealing system comprises two front sealing areas (1021, 1022) covering all or part of the front faces (F1, F2) and two side sealing areas (1023, 1025) covering all or part of two of the side faces (F3, F5).

[0025] The primary sealing system consists only of two front sealing areas (1021, 1022) covering all or part of the front faces (F1, F2).

[0026] The primary sealing system consists of only two side sealing areas (1023, 1025) covering all or part of two of the sides (F3, F5).

[0027] Each of the two frontal areas of the additional sealing system defines two protruding edges (1031A, 1031B, 1032A, 1032B) protruding from the respective frontal area of ​​the primary sealing system along a lateral axis (X) of the stack, each protruding edge covering an end of a respective one of the anode contact member or the cathode contact member.

[0028] Along the lateral axis (X) of the stack, the primary sealing system extends to the inner faces of the contact members, while the additional sealing system extends beyond the inner faces, in particular to the outer faces of these contact members.

[0029] Each of the two frontal regions of the additional sealing system delimits two protruding rims (1031C, 1031D, 1032C, 1032D), each of which protrudes both from a respective frontal region of the primary sealing system and from the anode and cathode contact members along another lateral axis (Y) of the stack, the protruding rims ensuring the surface continuity between the frontal region and the lateral region of the additional sealing system.

[0030] Opposite ends (1041, 1042, 1051, 1052) of each of the anode (1040) and cathode (1050) contact members are flush with the frontal regions (1021, 1022) of the primary sealing system (1020).

[0031] The primary sealing system (1020) includes at least one first cover layer disposed on the stack (I), preferably selected from among parylene, parylene F, polyimide, epoxy resin, silicone, polyamide, sol-gel silica, organosilica and / or mixtures thereof.

[0032] Each of the anode contact member (1040) and the cathode contact member (1050) comprises a first electrical connection layer made of a material filled with conductive particles and a second electrical connection layer comprising a metal foil or metal layer disposed on the first electrical connection layer.

[0033] The additional sealing system (1030) comprises a sealing layer selected from glass, ceramic and glass-ceramic, the sealing layer being preferably -5 g / m 2 ·D or less water vapor transmission rate (WVTR).

[0034] The glass, ceramic, and glass ceramic of the sealing layer are a low melting point glass preferably selected from SiO2-B2O3, Bi2O3-B2O3, ZnO-Bi2O3-B2O3, TeO2-V2O5, and PbO-SiO2; and oxides and / or nitrides and / or Ta2O5 and / or alumina (Al2O3) and / or oxynitrides and / or SixNy and / or SiO2 and / or SiON and / or amorphous silicon and / or SiC.

[0035] The present invention also relates to a method for producing the battery, the method comprising the steps of: (a) providing at least one anode current collecting substrate foil (hereinafter referred to as anode foil) coated with an anode layer and, optionally, with a layer of electrolyte material or separator impregnated with an electrolyte; (b) providing at least one cathode current collecting substrate foil (hereinafter referred to as cathode foil) coated with a cathode layer and, optionally, a layer of electrolyte material or separator impregnated with an electrolyte; (c) alternating at least one anode foil with at least one cathode foil to produce said stack (I) successively obtaining at least one anode current collecting substrate, at least one anode layer, at least one layer of separator impregnated with an electrolyte material or electrolyte, at least one cathode layer, and at least one cathode current collecting substrate; (d) heat treating and / or mechanically compressing the stack of alternating foils obtained in step c) to form an interlocked stack; (e) manufacturing said so-called primary sealing system (1020) to form a sealed and cut stack exposing at least the faces that define said anode and cathode connection zones, preferably at least the anode and cathode connection zones; (f) optionally impregnating the cut and sealed stack with a lithium ion carrying phase, such as a liquid electrolyte containing a lithium salt or an ionic liquid, such that the separator is impregnated with electrolyte; (g) placing each of the anode and cathode contact members on a respective side of the stack not covered by the primary sealing system; (h) manufacturing in the structure obtained after step g) an additional sealing assembly (1030') intended to seal said connection stack including said contact elements; (i) at least partially exposing the anode and cathode contact members to form the additional sealing system (1030).

[0036] According to other characteristics of the battery according to the invention, which may be taken in isolation or are any of the characteristics technically compatible, are the following:

[0037] It further comprises the step of manufacturing a so-called primary sealing assembly (1020') on said connecting stack (I), said primary sealing system being manufactured from said primary sealing assembly.

[0038] The primary sealing system is produced from the primary sealing assembly by making two so-called primary cuts along a first cutting plane (II-II).

[0039] The additional sealing system is produced from the additional sealing assembly by making two so-called additional cuts along a second cutting plane (VV) which extends outside the first cutting plane.

[0040] The at least partially exposing of the anode and cathode contact members according to step i) of the method may be performed by grinding or by cutting.

[0041] The step of manufacturing the so-called primary sealing system (1020) is characterized in that it comprises the deposition on the stack (I) of at least one first cover layer, preferably selected from among parylene, parylene F, polyimide, epoxy resin, silicone, polyamide, sol-gel silica, organosilica and / or mixtures thereof.

[0042] The step of manufacturing the additional sealing system intended to seal the interconnect stack including the contact elements is characterized in that it comprises the deposition of a sealing layer selected from among glass, ceramic and glass-ceramic.

[0043] The glass, ceramic, and glass ceramic are a low melting point glass preferably selected from SiO2-B2O3, Bi2O3-B2O3, ZnO-Bi2O3-B2O3, TeO2-V2O5, and PbO-SiO2; and oxides and / or nitrides and / or Ta2O5 and / or alumina (Al2O3) and / or oxynitrides and / or SixNy and / or SiO2 and / or SiON and / or amorphous silicon and / or SiC.

[0044] Said manufacturing of the anode and cathode contact members comprises: - depositing, on at least the anode connection zone and at least the cathode connection zone, a first electrical connection layer made of a material filled with conductive particles, preferably a first electrical connection layer made of a polymeric resin and / or a sol-gel material filled with conductive particles; Optionally, if the first layer consists of a polymeric resin and / or a sol-gel material filled with conductive particles, after a drying step, a step of polymerizing the polymeric resin and / or the sol-gel material; and depositing on the first layer a second electrical connection layer disposed on the first electrical connection layer, preferably a second electrical connection layer comprising a metal foil or a metal ink, it being noted that in the latter case the drying step may alternatively be performed after the deposition of the second electrical connection layer.

[0045] said manufacturing further comprising successive alternating layers of cathode and anode, each layer comprising a plurality of so-called blank zones, and said cutting making it possible to separate a given stack of batteries from at least one other stack of another battery.

[0046] When the blank zone has bars connected in pairs by channels, at least a portion of the bars being filled with encapsulant, the cut is made to obtain a stack with two opposing sides covered with the encapsulant.

[0047] When the blank zone has an overall I-shape, at least one row formed by a plurality of stacks is generated, the front face of which row is at least partially covered with encapsulant, and the cutting is performed to obtain a stack having a front face covered with the encapsulant.

[0048] According to the invention, the sealing is provided by two separate sealing systems, which differ in particular in terms of their dimensions. More specifically, the additional sealing system has larger dimensions than the primary sealing system and is capable of protruding from this primary system in at least one direction in space. Furthermore, the two systems advantageously differ in terms of the material from which they are made and in terms of their dimensions. The combination of these separate sealing systems, inter alia, procures a particularly satisfactory impermeability. Furthermore, according to the invention, the additional system can be manufactured after the contact elements have been positioned.

[0049] It should be noted that the prior art does not disclose such a combination between separate sealing systems. In particular, this combination does not appear in the teaching of the aforementioned WO 2019 / 002768. Essentially, this prior art document uses a single sealing system, as referred to in its main claim. [Brief description of the drawings]

[0050] Certain aspects and embodiments of the present invention are illustrated with reference to the accompanying drawings, given by way of non-limiting examples only. [Figure 1]FIG. 1 shows diagrammatically a cut-away front view of a stack (I) defining six sides, in the prior form of a battery according to the invention, comprising successively at least one anode current collecting substrate (21), at least one thin layer of anode active material (22), at least one thin layer of electrolyte material (23, 53) or separator (23′, 53′) impregnated with electrolyte, at least one thin layer of cathode active material (52), and at least one thin layer of cathode current collecting substrate (51). [Diagram 2] FIG. 2 shows diagrammatically a cutaway front view of a stack sealed with a primary sealing system. [Diagram 3] FIG. 3 shows diagrammatically a cutaway front view of a stack sealed with a primary sealing system, with the anode and cathode connection zones exposed along the cut plane II-II visible in FIG. [Figure 4] FIG. 4 shows diagrammatically a cutaway front view of the stack in the previous form of the cell, showing the internal structure of the stack covered by the primary sealing system and the internal structure of the contact elements according to the invention. [Diagram 5] FIG. 5 shows diagrammatically a cutaway front view of a stack sealed with a primary sealing system and a so-called additional sealing system, illustrating the internal structure of the cell. [Figure 6] FIG. 6 shows diagrammatically a front view of a stack sealed in the primary sealing system and in the so-called additional sealing system with a cut plane showing the internal structure of the cell, with the anode and cathode connection zones exposed along the cut plane VV visible in FIG. [Figure 7] FIG. 7 shows diagrammatically a side view of a cell according to the invention, showing the outer surface of the anode contact member surrounded at its periphery by an additional sealing system. [Figure 8] FIG. 8 is a cross-sectional view illustrating an alternative embodiment of the present invention in which the primary sealing system covers only two sides of the unit stack. [Figure 9] FIG. 9 is a cross-sectional view illustrating an alternative embodiment of the present invention in which the primary sealing system covers only two sides of the unit stack. [Figure 10]FIG. 10 is a perspective view showing anode and cathode foils in a superimposed arrangement present in two alternative embodiments of the method of manufacturing a battery according to the present invention. [Figure 11] FIG. 11 is a perspective view showing anode and cathode foils in a superimposed arrangement present in two alternative embodiments of the method of manufacturing a battery according to the present invention. [Figure 12] FIG. 12 is a front view illustrating a step in the manufacture of a battery according to the alternative embodiment of FIG. [Figure 13] FIG. 13 is a front view illustrating a step in the manufacture of a battery according to the alternative embodiment of FIG. [Figure 14] FIG. 14 is a front view showing a step in the manufacture of a battery according to the alternative embodiment of FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0051] 1 shows an electrochemical device according to a first alternative embodiment, which is a cell designated as a whole by the reference number 1. This cell consists, in a manner known per se, of an alternating stack (I) of at least one anode (20) and at least one cathode (50).

[0052] The anode (20) comprises at least one anode current collecting substrate (21) and at least one thin layer of anode active material (22). In the illustrated example, the anode further comprises a thin layer of electrolyte material (23) or electrolyte-impregnated separator (23'), although this is optional.

[0053] The cathode (50) further comprises at least one cathode current collecting substrate (51) and at least one thin layer of cathode active material (52). In the illustrated embodiment, the cathode further comprises a thin layer of electrolyte material (53) or electrolyte-impregnated separator (53'), although this is optional.

[0054] As a result, said stack comprises, in succession, at least one anode current collecting substrate (21), at least one thin layer (22) of at least one anode active material, at least one thin layer of electrolyte material (23, 53) or electrolyte-impregnated separator (23', 53'), at least one thin layer (52) of cathode active material and at least one cathode current collecting substrate (51).

[0055] Advantageously, after the stack has been manufactured, the battery can be assembled by heat treatment and / or mechanical compression. The heat treatment of the stack making it possible to assemble the battery is advantageously carried out at a temperature comprised between 50° C. and 500° C., preferably below 350° C. The mechanical compression of the stack is advantageously carried out at a pressure comprised between 10 MPa and 100 MPa, preferably between 20 MPa and 50 MPa.

[0056] The stack I is generally parallelepipedal and has six faces. By convention, the so-called end faces or front faces, which are substantially parallel to the different layers and which are opposite, are firstly indicated by the references F1 and F2. The stack 2 also defines four side faces F3 to F6, which are parallel and opposite to each other in pairs. A Cartesian coordinate system XYZ is defined relating to this stack, in which the Z direction is said to be the front direction, in the sense that it is perpendicular to the front face, while the other X and Y directions are said to be the side directions.

[0057] The stack can be manufactured by any suitable method. The architecture of the battery consisting of the primary sealing system, the additional sealing system and the contact members according to the invention is particularly adapted for stacks having laterally opposed anode and cathode connection zones. In the example shown in FIG. 1, which represents a first embodiment of the stack, the layers forming the stack have recesses (1070) such that each unit cell defines a continuous zone of the cathode current collector allowing electrical contact at the cathode connection zone and a continuous zone of the anode current collector allowing electrical contact at the anode connection zone. This arrangement allows the anode connection zone and the cathode connection zone to be laterally opposed to each other.

[0058] FIG. 1 shows this stack I taken apart, without the other final components of the battery. To manufacture this battery, as shown in FIG. 2, first the six sides of the stack I must be covered with a primary sealing assembly, indicated by reference number 1020'. The six areas forming this assembly 1020' are indicated by reference numbers 1021' to 1026', each covering six sides of the stack. This assembly 1020' is intended to form a primary sealing system 1020 for protecting the battery from the atmosphere, as will be seen below. This primary sealing system is advantageously chemically stable and can withstand high temperatures. It can be impermeable to the atmosphere to provide an additional barrier layer function, but the main barrier layer function is provided by the additional seal, as will be seen herein below. The material intended to form this primary seal may be of any suitable type, in particular this primary seal system 1020 comprises at least one first cover layer, preferably selected from among parylene, parylene F, polyimide, epoxy resin, silicone, polyamide, sol-gel silica, organosilica and / or mixtures thereof, disposed on the stack (I).

[0059] Typically, this first cover layer is selected from the group consisting of silicone (e.g. deposited by impregnation or by plasma enhanced chemical vapor deposition from hexamethyldisiloxane (HMDSO)), epoxy resin, polyimide, polyamide, polyparaxylylene (poly(p-xylylene) better known as parylene), and / or mixtures thereof. This first cover layer protects the sensitive elements of the battery from its environment. The thickness of the first cover layer is preferably comprised between 0.5 μm and 3 μm.

[0060] Different variants of parylene can be used. Advantageously, this first cover layer can be made of parylene C, parylene D, parylene N (CAS1633-22-3), parylene F or a mixture of parylenes C, D, N and / or F. Parylene is a dielectric, transparent, semi-crystalline material with high thermodynamic stability, excellent solvent resistance and very low permeability. Parylene also has barrier properties to protect the cell from its external environment. This first cover layer advantageously results from the condensation of gaseous monomers deposited on the surface by chemical vapor deposition (CVD), resulting in a conformal, thin and uniform coverage of all accessible surfaces of the stack. This first cover layer is advantageously hard and cannot be considered a flexible surface.

[0061] Once the six faces of the stack are covered by the six regions of the abovementioned sealing assembly 1020', the anode and cathode connection zones are exposed by any suitable means, by the plane II-II of FIG. 2, which is typically parallel to the front faces F4 and F6. This assembly 1020' can advantageously be manufactured by successive depositions of parylene-ALD-parylene layers. The anode and cathode connection zones are preferably exposed by so-called primary cuts. These cuts preferably make it possible to remove the side regions 1024', 1026' of the sealing assembly, as shown in FIG. 3, so that the anode and cathode connection zones are exposed. Alternatively, such exposure can be obtained by a step different from the cutting. It can be carried out by any suitable means, such as in particular chemical etching, laser cutting (or laser ablation), femtosecond laser cutting, micro-perforation or stamping. Such exposure is preferably carried out by saw cutting, polishing, in particular polishing with felt and polishing paste, scraping and / or plasma etching.

[0062] Once these primary cuts are completed, a stack is obtained that is covered with a primary sealing system, indicated with reference 1020. The areas forming this sealing system, covering the faces F1, F2, F3 and F5 of the stack, are indicated with references 1021, 1022, 1023 and 1025. In the case of a battery impregnated with liquid electrolyte, the impregnation of the battery with liquid electrolyte is advantageously carried out, after obtaining a stack covered by the primary sealing system, with exposed anode and cathode connections present on the respective opposing sides F4 and F6, by a phase carrying lithium ions, such as a liquid electrolyte containing a lithium salt or an ionic liquid. This phase carrying lithium ions penetrates the cell's voids, in particular the separator of the cell, by capillary action.

[0063] On the opposing sides F4 and F6 where the anode and cathode connection zones are exposed, optionally after impregnation of the cell with a liquid electrolyte, the anode 1040 and respectively cathode 1050 contact elements are arranged, as shown in Figure 4. The so-called front ends of these contact elements 1040 and 1050 adjacent to the front part of the stack are indicated with the references 1041 and 1042, and 1051 and 1052. The steps shown in Figures 2 to 4 are of conventional type and will not be described in more detail below.

[0064] Preferably, contact elements are deposited on and around the cathode and anode connection zones, preferably on the sides defining these anode and cathode connection zones. These contact elements preferably consist of a stack of layers comprising, in succession: a first electrical connection layer comprising a material filled with conductive particles, preferably a polymeric resin and / or a sol-gel material filled with conductive particles, more preferably a polymeric resin filled with graphite, a second electrical connection layer, which is arranged on the first layer and consists of a metal foil or metal layer; It is.

[0065] The first electrical connection layer allows the subsequent second electrical connection layer to be secured while still allowing the connection to be "flexible" so that the electrical contact does not break down when the electrical circuit is subjected to thermal and / or vibrational stresses.

[0066] The second electrical connection layer is a metal foil or layer. This metal foil or layer may be flat or textured. This second electrical connection layer is used to provide the cell with a lasting protection against moisture while connecting, on the one hand, the anode connection zone on the side F4 of the cell and, on the other hand, the cathode connection zone on the opposite side F6 of the cell. In general, for a given thickness of material, metals make it possible to produce films that are more impermeable than ceramic-based films and even more impermeable than polymer-based films, which are generally less impermeable to the passage of water molecules. By reducing the WVTR at the contact members, the calendar life of the battery can be increased.

[0067] Advantageously, a third electrical connection layer comprising a conductive ink can be deposited on the second electrical connection layer. The purpose is to reduce the WVTR and increase the life of the battery. The water vapor transmission rate (WVTR) can be measured using the method described in the publication "Structural properties of ultraviolet cured polysilazane gas barrier layers on polymer substrates" by A. Mortier et al., which is the subject of US Pat. No. 7,624,621 and is also described in Thin Solid Films 6+550 (2014) pp. 85-89.

[0068] The contact elements allow for alternating positive and negative electrical connections at each of the two ends. These contact elements allow for parallel electrical connections between the different battery elements, so that only the cathode connection protrudes at one end and the anode connection is available at the other end.

[0069] Then, as shown in FIG. 5, the six faces of the intermediate structure of FIG. 4 are covered by an additional sealing assembly 1030' intended to form an additional sealing system 1030, as described herein. This additional sealing system protects the entire cell from the diffusion of molecules from the atmosphere, making it ultimately impermeable. This additional seal (or additional sealing layer) is preferably deposited by atomic layer deposition (ALD), by PECVD, by HDPCVD (High Density Plasma Chemical Vapor Deposition) or by ICP CVD (Inductively Coupled Plasma Chemical Vapor Deposition) in order to obtain a conformal coverage of all the accessible surfaces of the intermediate structure. As with the primary seal described herein, said additional seal can advantageously be manufactured by successively depositing layers of parylene-ALD-parylene.

[0070] The thickness of this additional sealing layer is advantageously selected as a function of the desired gas impermeability level, i.e. the desired WVTR, and depends on the deposition technique used, in particular selected from among ALD, PECVD, HDPCVD and ICP CVD. The thickness of this additional sealing layer is preferably comprised between 10 nm and 15 μm. This system or this additional sealing layer is impermeable and preferably has a thickness of 10 -5 g / m 2 The water vapor transmission rate (WVTR) is less than 1 / 2 d. The water vapor transmission rate can be measured for the purposes of US Pat. No. 7,624,621 and as described in the publication "Structural properties of ultraviolet cured polysilazane gas barrier layers on polymer substrates" by A. Mortier et al., Thin Solid Films 6+550 (2014) pp. 85-89.

[0071] The six regions forming this additional assembly 1030' are designated with the reference numbers 1031' to 1036' and cover the six faces of the stack respectively. The material intended to form this additional encapsulant can be chosen from glasses, ceramics and glass-ceramics, preferably: a low-melting glass, preferably selected from among SiO2-B2O3, Bi2O3-B2O3, ZnO-Bi2O3-B2O3, TeO2-V2O5 and PbO-SiO2; - oxides and / or nitrides and / or Ta2O5 and / or alumina (Al2O3) and / or oxynitrides and / or SixNy and / or SiO2 and / or SiON and / or amorphous silicon and / or SiC.

[0072] The intermediate structure shown in FIG. 5 is then subjected to so-called additional cutting operations, carried out by any suitable means, along the plane VV of FIG. 5. These cuts are typically parallel to the plane II-II described herein, but extend outside the latter in the X direction. These cuts, which can preferably completely or partially remove the side regions 1034', 1036' of the additional sealing assembly, result in a complete or partial exposure of the contact elements 1040 and 1050, as shown in FIG. 6. When making these cuts, the border parts of the material forming the contact elements can also be removed, while maintaining their functionality. Advantageously, a sufficient part of the second electrical connection layer made of metal foil is left intact. Advantageously, the exposure of the first electrical connection layer is also prevented.

[0073] In this situation, the metal foil or metal layer can be textured to facilitate the re-establishment of the electrical connection after the above-mentioned additional cut has been made. Alternatively, such exposure can be obtained by a step different from the cutting. It can be performed in particular by polishing, plasma etching, chemical etching, laser cutting (or laser ablation), femtosecond laser cutting, micro-perforation or stamping. In particular, if the contact elements are exposed by saw cutting, polishing with felt and polishing paste, the use of textured metal foils is advantageous, which makes it easier to re-establish the electrical connection, especially at localized protrusions. Alternatively, a resist can be applied to the metal parts of the current collector before the sealing. When this resist is removed, the electrical contacts are exposed again.

[0074] Once these additional cuts are made, a stack is obtained that is covered first with the primary sealing system 1020 and then with the additional sealing system 1030. The areas forming this additional system 1030, which cover the respective areas 1021, 1022, 1023 and 1025 of the primary system 1020, are indicated with the reference numbers 1031, 1032, 1033 and 1035.

[0075] 6, the dimensions of the frontal areas 1031 and 1032 of the additional system 1030 are greater in the X direction than the dimensions of the frontal areas 1021 and 1022 of the primary system 1020. More specifically, in this X direction, each frontal area 1021 and 1022 of the so-called primary systems extends to the inner side of the opposing contact elements 1040, 1050. Moreover, in this direction, each of the so-called additional frontal areas 1031 and 1032 is flush with the outer side of these contact elements.

[0076] Each of these regions 1031, 1032 consequently delimits in this X-direction a so-called protruding edge 1031A, 1031B and 1032A, 1032B, which respectively cover ends 1041, 1051, 1042, 1052 of the contact members 1040, 1050. In other words, the encapsulants 1020, 1030 formed by both the primary and the additional systems delimit shoulders, indicated with references 1060 and 1061, against which the upper and lower ends of the contact members extend, respectively.

[0077] 6, the respective opposing ends 1041, 1042 and 1051, 1052 of the anode 1040 and cathode 1050 contact members are flush with the frontal regions 1021 and 1022, respectively, of the sealing system 1020. In other words, said opposing ends extend substantially in the X-direction to the free upper surface of region 1021 and the free lower surface of region 1022, respectively.

[0078] The placement of an additional sealing system on the primary sealing system and around the contact members allows the final battery to be endowed with excellent impermeability, in particular a very low water vapor transmission rate, which increases the battery's lifespan. More specifically, this architecture allows blocking the diffusion of water or oxygen molecules at the ends 1042, 1041 of the contact members. More specifically, the conductive adhesive used to make the contacts is not as impermeable to the diffusion of water molecules as metal foils can be.

[0079] 7, the dimension in the Y direction of the frontal regions 1031, 1032 is greater than the dimension of both the frontal regions 1021, 1022 and the contact elements 1040, 1050. As a result, each of these regions 1031, 1032 is delimited in this Y direction by a so-called protruding rim 1031C, 1031D and 1032C, 1032D. These different rims, together with the two side regions 1033 and 1035, ensure a surface continuity of additional sealing between each frontal region 1031 or 1032.

[0080] The above-described battery according to the embodiment shown in Figures 1-7 includes a primary sealing system having four regions, each covering a respective face of the primary stack. Alternatively, however, the primary sealing system can have a fewer number of regions. In particular, such a system can include only two regions present on opposing faces of the stack.

[0081] First, the areas of the primary sealing system can cover only the sides of the stack that are not occupied by the contact members, as shown in Figure 8. Alternatively, these areas of the primary sealing system can cover only the end faces of the stack, in which case they will be parallel to the layers that form the stack, as shown in Figure 9. The method of manufacturing these cells shown in Figures 8 and 9 will now be described with reference to Figures 12 onwards.

[0082] As a preliminary observation, in a manner known per se, a number of unit stacks as described herein can be produced simultaneously, which improves the efficiency of the overall method for producing a battery according to the invention, in particular stacks with large dimensions formed by a repetitive alternating succession of cathode and respectively anode layers or foils can be produced.

[0083] The physicochemical structure of each anode or cathode foil is of a type known, for example from the applicant's patent FR 3091036, but will only be briefly described, as it does not fall within the scope of the present invention. Each anode foil or each cathode foil comprises an anode active layer or a respective cathode active layer. Each of these active layers can be solid, i.e. they can have a dense or porous nature. Furthermore, in order to prevent electrical contact between two adjacent foils, on at least one of these two foils, a layer of electrolyte or a separator impregnated with a liquid electrolyte is placed in contact with the opposite foil. Although not shown in the figures illustrating the invention, the electrolyte layer or the separator impregnated with a liquid electrolyte is sandwiched between two foils of opposite polarity, i.e. the anode foil and the cathode foil.

[0084] These foils or layers are recessed so as to define so-called void zones that allow a separation between the different final cells. Within the scope of the present invention, these void zones can be assigned different shapes. As already proposed by the Applicant in patent FR 3091036, these void zones can be H-shaped. The attached FIG. 10 shows a stack 1100 between an anode foil or layer 1101 and a cathode foil or layer 1102. As shown in this figure, cuts have been made in these different foils to form said H-shaped anode 1103 and respective cathode 1104 void zones.

[0085] Alternatively, these void zones can be I-shaped. Figure 11 attached shows a stack 1200 between an anode foil or layer 1201 and a cathode foil or layer 1202. As shown in Figure 11, cuts are made in these different foils to form the I-shaped anode 1203 and respective cathode 1204 void zones.

[0086] Preferably, once the manufacturing of the different unit stacks is complete, each anode and each cathode of a given battery comprises a respective primary body separated from a respective secondary body by a space free of any electrode material, electrolyte and / or current conducting substrate. According to additional alternative embodiments not shown, the blank zones can be provided such that their shape is different from an H or I shape, for example U-shaped. Nevertheless, an H or I shape is preferred.

[0087] As shown in figure 12, the cell of figure 8 can be manufactured using the foil sequence shown in figure 10. Figure 12 shows an enlarged view of the generally H-shaped void zones. More specifically, as known from the aforementioned patent FR 3 091 036, these void zones have vertical bars 1103 connected in pairs by horizontal channels 1110. According to this alternative embodiment, the bars 1103 receive a material 221 intended to form all or part of the primary sealing system.

[0088] Moreover, as also known from the aforementioned French patent document, the different unit stacks are separated by adjacent bars. These unit stacks, which are identical to one another, are indicated in FIG. 12 by the successive references II, I and III from left to right. According to this alternative embodiment, a vertical cut is then made, indicated by the reference DY. This not only makes it possible to separate the stacks from one another in a known manner, but also makes it possible to simultaneously obtain separate unit stacks covered by the lateral areas of the primary seal. In the embodiment shown in FIG. 12, two vertical cuts DY are made, since the bars 1103 are relatively wide. According to an advantageous alternative embodiment, not shown, these bars can be manufactured such that they are much narrower. In such a case, one vertical cut can be made.

[0089] As shown in Figures 13 and 14, the cell of Figure 9 can be manufactured using the foil stack shown in Figure 11. According to a step not shown, this foil stack is completely covered with a sealant intended to form the primary sealing system. When this covering is completed, only the unit stacks located at the periphery of the foil are covered not only on their end faces but also on some of their sides, while all of the "middle" unit stacks are only covered on their opposite end faces.

[0090] Next, a number of horizontal cuts are made, only one of which is shown in Figure 11 and designated by the reference DX. Once these horizontal cuts have been made, a number of strips are laid down, one of which is shown in Figure 13. Each strip is formed by a row of unit stacks placed adjacent to one another.

[0091] 13 shows three adjacent stacks I, II and III, it being understood that each strip contains a significantly larger number of such stacks. Only two unit stacks located at opposite ends of each row are covered by encapsulant on their end faces and part of their sides, whereas the other so-called central unit stack is covered only on its end face.

[0092] Finally, vertical cuts are made along each row, as shown in Figure 14, which separates a given stack from each adjacent stack. These vertical cuts produce stacks whose edges are only coated with encapsulant, such as stack I in Figure 14.

[0093] A battery according to the invention comprising such a structure can be used as is or can be integrated into an electronic circuit. The sides of the battery comprising the exposed contact members can be made with electrical contacts compatible with a solder reflow assembly step. In such a case and as a function of the end use of the battery, the contact members, preferably the sides of the battery according to the invention comprising the contact members, can be covered with a multi-layer system consisting of a first layer of a conductive ink, preferably a conductive polymer such as a silver-filled epoxy resin, a second layer of nickel, in particular deposited by electrodeposition on this first layer, and a third layer of tin, deposited by electrodeposition on this second layer.

[0094] The first conductive polymer layer, preferably made of silver-filled epoxy resin, ensures "flex" at the connection without breaking down the electrical contacts when the electrical circuit is exposed to thermal and / or vibration stresses. The nickel layer protects the polymer layer during the welding assembly step, and the tin layer ensures weldability of the cell interface.

[0095] A battery according to the present invention may advantageously be integrated and / or overmolded into a flat integrated circuit package, such as a QFN (Quad Flat No-leads package), which physically and electrically connects the integrated circuit to a printed circuit board.

[0096] 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 dimensioned to have a capacity of about 1 mAh or less (commonly known as a "microbattery"), to have a power of more than about 1 mAh up to about 1 Ah (commonly known as a "minibattery"), or to have a capacity of more than about 1 Ah (commonly known as a "high power battery"). Generally, microbatteries are designed to be compatible with microelectronics manufacturing methods.

[0097] For each of these three power ranges of batteries, the following can be manufactured: - of the type having a "solid" layer, i.e. without an impregnated liquid or paste phase (which may be a lithium ion conducting medium capable of acting as an electrolyte); or of the type having a layer of a mesoporous "solid" impregnated with a liquid or paste phase (typically a lithium ion conducting medium) which naturally penetrates into the layer and no longer exits from it, so that the layer can be considered as quasi-solid, or those having impregnated porous layers (i.e. layers having a network of open pores which can be impregnated with a liquid or pasty phase, these layers having wetting properties).

Claims

1. A battery (1000), A stack (I) of at least one alternating anode (20) and at least one cathode (50), each formed by a stack of thin layers, said anodes (20) being At least one anode current collecting substrate (21); and at least one thin layer of positive electrode active material (22), said negative electrode (50) comprising: At least one cathode current collecting substrate (51); and a thin layer of at least one cathode active material (52), wherein at least one of said thin layers of at least one anode active material (22) and at least one of said thin layers of at least one cathode active material (52) comprises a thin layer of electrolyte material (23, 53) or a thin layer of an electrolyte-impregnated separator (23', 53'), said stack comprising: The stack (I) comprises successively at least one anode current collecting substrate (21), at least one thin layer of anode active material (22), at least one thin layer of electrolyte material (23, 53) or separator (23', 53') impregnated with an electrolyte, at least one thin layer of cathode active material (52) and at least one cathode current collecting substrate (51), said stack (I) having six faces, namely: two so-called front faces (F1, F2) facing each other and substantially parallel to said thin layer of positive electrode active material (22), said thin layer of electrolyte material (23, 53) or separator impregnated with an electrolyte (23', 53'), and said thin layer of negative electrode active material (52); a stack (I) of alternating at least one anode (20) and at least one cathode (50) defining four so-called side faces (F3, F4, F5, F6) facing each other in pairs; a so-called primary sealing system (1020) covering at least two of the six faces of the stack (I), said sealing system comprising two front sealing areas (1021, 1022) covering all or part of the front faces (F1, F2) and / or two side sealing areas (1023, 1025) covering all or part of two of the side faces (F3, F5); at least one anode contact member (1040) capable of making an electrical contact between the stack and an external conductive element, said anode contact member at least partially covering a first face (F4) of said two side faces (F4, F6) not covered by said primary sealing system (1020), said first face (F4) defining at least one anode connection zone; at least one cathode contact member (1050) capable of making an electrical contact between the stack and an external conductive element, said cathode contact member at least partially covering a second face (F6) of said two side faces not covered by said primary sealing system (1020), said second face (F6) defining at least one cathode connection zone, The battery further comprises a so-called additional sealing system (1030), which comprises two frontal areas (1031, 1032), each covering a front side of the stack with or without a respective frontal area (1021, 1022) of the primary sealing system, and which further comprises two side areas (1033, 1035), each covering a side of the stack without contact members with or without a respective side area (1023, 1025) of the primary sealing system, each of the two frontal areas (1031, 1032) of the additional sealing system (1030) further covers a front end (1041, 1042, 1051, 1052) of each of the anode contact member and the cathode contact member, A battery, wherein each of the front regions (1031, 1032) of the additional sealing system forms surface continuity with the side regions (1033, 1035) of the additional sealing system.

2. 2. The battery of claim 1, wherein the primary sealing system includes two front sealing areas (1021, 1022) covering all or part of the front surface (F1, F2) and two side sealing areas (1023, 1025) covering all or part of two of the side surfaces (F3, F5).

3. 2. The battery of claim 1, wherein the primary sealing system includes only two front sealing areas (1021, 1022) covering all or part of the front faces (F1, F2).

4. 2. The battery of claim 1, wherein the primary sealing system includes only two side sealing areas (1023, 1025) covering all or part of two of the sides (F3, F5).

5. 4. The battery of claim 2 or 3, wherein each of the two frontal areas of the additional sealing system delimits two protruding edges (1031A, 1031B, 1032A, 1032B) protruding from the respective frontal area of ​​the primary sealing system along a lateral axis (X) of the stack, each protruding edge covering an end of a respective one of the anode contact member or the cathode contact member.

6. 6. The battery of claim 5, wherein along the lateral axis (X) of the stack, the primary sealing system extends to an inner surface of the contact member, while the additional sealing system extends beyond the inner surface.

7. 7. The battery of claim 5 or 6, wherein each of the two frontal regions of the additional sealing system delimits two protruding rims (1031C, 1031D, 1032C, 1032D), each of which protrudes both from a respective frontal region of the primary sealing system and from the anode and cathode contact members along another lateral axis (Y) of the stack, the protruding rims ensuring the surface continuity between the frontal region and the lateral region of the additional sealing system.

8. The battery of any one of claims 1 to 7, wherein respective opposing ends (1041, 1042, 1051, 1052) of the anode (1040) and cathode (1050) contact members are flush with the frontal area (1021, 1022) of the primary sealing system (1020).

9. 9. The battery of any one of claims 1 to 8, wherein the primary sealing system (1020) comprises at least one first cover layer disposed on the stack (I) selected from among parylene, parylene F, polyimide, epoxy resin, silicone, polyamide, sol-gel silica, organo-silica and / or mixtures thereof.

10. 10. The battery of claim 1, wherein each of the anode contact member (1040) and the cathode contact member (1050) comprises a first electrical connection layer made of a material filled with conductive particles and a second electrical connection layer disposed on the first electrical connection layer, the second electrical connection layer comprising a metal foil or metal layer.

11. The battery of any one of claims 1 to 10, wherein the additional sealing system (1030) comprises a sealing layer selected from glass, ceramic and glass-ceramic.

12. The battery of claim 11, wherein the sealing layer has a water vapor transmission rate (WVTR) of less than 10 −5 g / m 2 ·d.

13. The glass, ceramic, and glass ceramic of the sealing layer are Low melting point glass, Oxide and / or nitride and / or Ta ２ O ５ and / or alumina (Al ２ O ３ ) and / or oxynitrides and / or SixNy and / or SiO ２ and / or SiON and / or amorphous silicon and / or SiC.

14. A method for producing the battery according to any one of claims 1 to 13, comprising the steps of: (a) providing at least one anode current collecting substrate foil (hereinafter referred to as anode foil) coated with an anode layer and with or without a layer of electrolyte material or a separator impregnated with an electrolyte; (b) providing at least one cathode current collecting substrate foil (hereinafter referred to as cathode foil) coated with a cathode layer and with or without a layer of electrolyte material or a separator impregnated with an electrolyte; (c) alternating at least one anode foil and at least one cathode foil to produce said stack (I) successively obtaining at least one anode current collecting substrate, at least one anode layer, at least one layer of separator impregnated with an electrolyte material or electrolyte, at least one cathode layer, and at least one cathode current collecting substrate; (d) heat treating and / or mechanically compressing the stack of alternating foils obtained in step c) to form an interlocked stack; (e) manufacturing said so-called primary sealing system (1020) to form a sealed and cut stack exposing at least the anode and cathode connection zones; (f) placing each of the anode and cathode contact members in the anode and cathode connection zones, respectively, not covered by the primary sealing system; (g) manufacturing in the structure obtained after step f) an additional sealing assembly (1030') intended to seal said interconnect stack including said contact elements; (h) at least partially exposing said anode and cathode contact members to form said additional sealing system (1030).

15. Between steps (e) and (f), 15. The method of making the battery of claim 14, further comprising the step of impregnating the cut and sealed stack with a phase that carries lithium ions, such as a liquid electrolyte or ionic liquid containing a lithium salt, such that the separator is impregnated with electrolyte.

16. A method for manufacturing a battery as described in claim 14 or 15, wherein the anode connection zone and the cathode connection zone are defined on each side of the stack.

17. The method according to any one of claims 14 to 16, further comprising a step of manufacturing a so-called primary sealing assembly (1020') on the connecting stack (I), and the primary sealing system is manufactured from the primary sealing assembly.

18. 18. The method according to claim 17, wherein the primary sealing system is produced from the primary sealing assembly by making two so-called primary cuts along a first cutting plane (II-II).

19. 19. The method according to claim 18, wherein the additional sealing system is produced from the additional sealing assembly by making two so-called additional cuts along a second cutting plane (V-V) extending outside the first cutting plane.

20. 20. The method according to any one of claims 14 to 19, wherein the step of at least partially exposing the anode and cathode contact members according to method step h) is performed by grinding or by cutting.

21. 21. Method according to any one of claims 13 to 20, characterized in that the step of manufacturing the so-called primary sealing system (1020) comprises the deposition on the stack (I) of at least one first cover layer selected from among parylene, parylene F, polyimide, epoxy resin, silicone, polyamide, sol-gel silica, organo-silica and / or mixtures thereof.

22. 22. The method according to claim 13, characterized in that the step of manufacturing the additional sealing system intended to seal the connecting stack including contact elements comprises the deposition of a sealing layer selected from among glass, ceramic and glass-ceramic.

23. The glass, ceramic, and glass ceramic are Low melting point glass, Oxide and / or nitride and / or Ta ２ O ５ and / or alumina (Al ２ O ３ ) and / or oxynitrides and / or SixNy and / or SiO ２ and / or SiON and / or amorphous silicon and / or SiC.

24. Said manufacturing of the anode and cathode contact members comprises: depositing a first electrical connection layer of a material filled with conductive particles over at least the anode connection zone and at least the cathode connection zone; 24. The method according to claim 13, further comprising the step of: depositing on said first layer a second electrical connection layer, said second electrical connection layer being arranged on said first electrical connection layer.

25. 25. The method according to any one of claims 13 to 24, further comprising the production of successive alternating layers of cathode and anode, each layer comprising a number of so-called void zones, and the cutting making it possible to separate a given stack of batteries from at least one other stack of another battery.

26. 26. A method according to claim 25 for producing a battery according to claim 2, wherein the void zone has bars connected in pairs by channels, in which at least a portion of the bars are filled with encapsulant, and the cutting is performed so as to obtain a stack having two opposite sides covered with the encapsulant.

27. 26. A method according to claim 25 for manufacturing a battery according to claim 3, wherein the void zone has an overall I-shape, and in this method at least one row formed by a plurality of stacks is produced, the front side of the row being at least partially covered with encapsulant, and the cutting is performed so as to obtain a stack having a front side covered with the encapsulant.

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