EP4128410A1

EP4128410A1 - Lithium-ion battery and method for the manufacture thereof

Info

Publication number: EP4128410A1
Application number: EP21713766.0A
Authority: EP
Inventors: Fabien Gaben
Original assignee: I Ten SA
Current assignee: I Ten SA
Priority date: 2020-03-30
Filing date: 2021-03-23
Publication date: 2023-02-08
Also published as: TW202141837A; EP3890077A1; WO2021198843A1; JP2023519702A; CN115885403A; KR20220160672A; US20230122314A1; CA3173247A1; IL296779A

Abstract

A battery (1000) comprising at least one elementary cell (100) formed by an anode (20), an electrolyte (30) and a cathode (50), defining a stack (I), said stack (I) and said battery having six faces, specifically - two mutually opposing front faces (F1, F2), - two mutually opposing side faces (F3, F5), - and two mutually opposing longitudinal faces (F4, F6), it being understood that the first longitudinal face (F6) of the battery comprises at least one anode connection region (1002) and that a second longitudinal face (F4) of the battery comprises at least one cathode connection region (1006), said anode connection region (1002) and cathode connection region (1006) being laterally opposed, characterized in that - in a first longitudinal direction (XX') of the battery, each anode current collector substrate (10) projects simultaneously from each anode layer (20), from each electrolyte material layer (30) or separator layer impregnated with an electrolyte (31), from each cathode layer (50) and from each cathode current collector substrate layer (40) and - in a second longitudinal direction (XX'') of the battery, opposite said first longitudinal direction (XX'), each cathode current collector substrate (40) projects simultaneously from each anode layer (20), from each electrolyte material layer (30) or separator layer impregnated with an electrolyte (31), from each cathode layer (50) and from each anode current collector substrate layer (10).

Description

LITHIUM ION BATTERY AND ITS MANUFACTURING PROCESS

Technical field of the invention

The present invention relates to the field of batteries, and more particularly to lithium ion batteries. The invention relates to lithium ion batteries with a novel architecture which gives them an improved lifespan. The invention also relates to a new method of manufacturing such batteries.

State of the art

Fully solid rechargeable lithium ion batteries are known. WO 2016/001584 (1-TEN) describes a lithium ion battery made from anode sheets comprising a conductive substrate successively covered with an anode layer and an electrolyte layer, and cathode sheets comprising a conductive substrate successively covered with a cathode layer and an electrolyte layer; these sheets are cut, before or after deposition, in U-shaped patterns. These sheets are then stacked alternately in order to constitute a stack of several elementary cells. The cutting patterns of the anode and cathode sheets are placed in a "head to tail" configuration so that the stack of cathodes and anodes is laterally offset. After the stacking step, an encapsulation system in a thick layer of about ten microns is deposited on the stack and in the available cavities present within the stack. This ensures, on the one hand, the rigidity of the structure at the level of the section planes and, on the other hand, the protection of the battery cell against the atmosphere. Once the stack has been produced and encapsulated, it is cut along section planes to obtain unit batteries, with the exposure on each of the section planes of the cathodic connection areas and the anodic connection areas of the batteries. It turns out that during these cuts, the encapsulation system can be torn off, resulting in a discontinuity in the sealing of the battery. It is also known to add terminations (i.e. electrical contacts) where these cathodic and anodic connection areas are visible.

It appeared that this known solution may however have certain drawbacks. Indeed, depending on the positioning of the electrodes, in particular the proximity of the edges of the electrodes for multilayer batteries and the cleanliness of the cutouts, a leakage current may appear on the ends, typically in the form of a creeping short circuit. . This creeping short circuit decreases the performance of the battery. despite the use of an encapsulation system around the battery and around the cathodic and anodic connection areas. Furthermore, there is sometimes an unsatisfactory deposit of the encapsulation system on the battery, in particular on the edges of the battery at the level of the spaces created by the lateral offsets of the electrodes on the edges of the battery.

Also known from US 2018/212 210 in the name of the Suzuki company, a battery comprising first of all a plurality of elementary cells. The stack thus produced is placed in a metal case, with the interposition of a resin. This ensures the mechanical fixing of the cells, so as to prevent the latter from moving in service. This resin also avoids the risk of short circuits, which would be due to the cells coming into contact with the metal casing, in particular during any shocks or vibrations. Finally, JP 2007/005 279 will be mentioned in the name of the Matsushita company. This document discloses an entirely solid battery, obtained by sintering. This battery therefore does not include an electrolyte material or a separator layer impregnated with such an electrolyte. The present invention aims to remedy at least in part certain drawbacks of the prior art mentioned above, in particular to obtain rechargeable lithium ion batteries with high energy density and high power density.

It aims in particular to increase the production efficiency of rechargeable lithium ion batteries with high energy density and high power density, and to achieve more efficient encapsulations at lower cost.

It aims in particular to propose a method which reduces the risk of a creeping or accidental short-circuit and which makes it possible to manufacture a battery having a low self-discharge.

It aims in particular to provide a method which makes it possible to manufacture, in a simple, reliable and rapid manner, a battery having a very long service life.

It also aims to provide a method for manufacturing batteries that is simple, rapid and economical. Objects of the invention

A first object of the invention is a battery comprising at least one elementary cell, each elementary cell successively comprising an anode current collector substrate, an anode layer, at least one layer of an electrolyte material and / or at least one layer of an electrolyte material. at least one separator layer impregnated with an electrolyte, a cathode layer, and a cathodic current collector substrate, knowing that in the case where said battery comprises a plurality of elementary cells, said elementary cells are arranged one below the others, namely superimposed in a frontal direction on the main plane of the battery, so that, preferably: o the anode current collector substrate is the anode current collector substrate of two adjacent elementary cells, and in that o the substrate cathodic current collector is the cathodic current collector substrate of two adjacent elementary cells, said at least elementary cell re or said elementary cells define a stack, said stack and said battery having six faces, namely

• two so-called mutually opposite front faces, in particular mutually parallel, generally parallel to the anode current collector substrate (s), to the anode layer (s), to the anode layer (s) an electrolyte material or the separator layer (s) impregnated with an electrolyte, the cathode layer (s), and the cathode current collector substrate (s),

• two so-called mutually opposite side faces, in particular mutually parallel, · and two so-called longitudinal faces, mutually opposite, in particular mutually parallel, it being understood that the first longitudinal face of the battery comprises at least one anode connection zone and that a second longitudinal face of the battery comprises at least one cathodic connection zone, said anodic and cathodic connection zones being laterally opposed, characterized in that

- In a first longitudinal direction of the battery, each anode current collector substrate protrudes with respect to both each anode layer, each layer of electrolyte material or separator layer impregnated with an electrolyte, at each cathode layer as well as to each cathode current collector substrate layer, and

- According to a second longitudinal direction of the battery, opposite to said first longitudinal direction, each cathodic current collector substrate protrudes with respect to both each anode layer, each layer of electrolyte material or separator layer impregnated with 'an electrolyte, to each cathode layer as well as to each anode current collector substrate layer.

In a particular embodiment: each anode current collector substrate protrudes relative to a first end plane, this first plane being defined by the first longitudinal ends of each anode layer, of each layer of material. electrolyte or separator layer, of each cathode layer as well as of each cathode current collector substrate layer, and / or - each cathode current collector substrate protrudes from a second end plane, this second plane being defined by the second longitudinal ends of each anode layer, of each layer of electrolyte material or separator layer, of each cathode layer as well as of each layer of anode current collector substrate.

According to a very particularly advantageous embodiment of the invention, the battery according to the invention comprises an encapsulation system covering at least partially the outer periphery of the stack, said encapsulation system comprising at least one covering layer waterproof, having a water vapor permeance (WVTR) of less than 10 ⁵ g / m ² .d, this encapsulation system being in direct contact at least with said layer of electrolyte material and / or with said layer separator impregnated with an electrolyte, at each longitudinal face. Preferably, the encapsulation system is in direct contact, at each longitudinal face, also with the anode layer, the cathode layer, as well as the current collecting substrate which does not protrude.

Advantageously, the encapsulation system is electrically insulating, the conductivity of this encapsulation system being advantageously less than 10 ^e-11 S.nr ¹ , in particular less than 10 ^{e 12} S.nr ¹ . Advantageously, the encapsulation system at least partly covers the outer periphery of the stack, said encapsulation system covering the front faces of the stack, the side faces and at least partly the longitudinal faces, so that - only each anode edge of each anode current collector substrate protruding from both each anode layer, each layer of electrolyte material or separator layer, each cathode layer and each layer of cathodic current collector substrate in the first longitudinal direction of the battery, is flush with a first longitudinal face, and that - only each cathode edge of each cathodic current collector substrate protruding with respect to both each anode layer, to each layer of electrolyte material or separator layer, to each cathode layer as well as to each anode current collector substrate layer according to the second longitudinal direction of the battery, is flush with a second longitudinal face, said second longitudinal face preferably being opposite and parallel to the first longitudinal face, it being understood that each anode edge defines an anode connection zone and that each cathode edge defines a zone of cathode connection.

According to yet another aspect of the invention, the encapsulation system comprises: - optionally, a first covering layer, preferably chosen from parylene, type F parylene, polyimide, epoxy resins, silicone, polyamide, sol-gel silica, organic silica and / or a mixture of these, deposited on at least part of the outer periphery of the stack,

- optionally a second covering layer composed of an electrically insulating material deposited by deposition of atomic layers, on at least partly the outer periphery of the stack, or on the first covering layer,

- at least a third waterproof covering layer, preferably having a water vapor permeance (WVTR) of less than 10 ⁵ g / m ² .d, this third covering layer being composed of a ceramic material and / or a low-melting point glass, preferably a glass with a melting point of less than 600 ° C, deposited on at least part of the outer periphery of the stack, or on the first covering layer, it being understood that when said second covering layer is present, - a succession of said second covering layer and said third covering layer can be repeated z times with z ³ 1 and deposited at the outer periphery of at least the third covering layer, and

- the last layer of the encapsulation system being a tight covering layer, preferably having a water vapor permeance (WVTR) of less than 10 ⁵ g / m ² .d and being composed of a ceramic material and / or a low melting point glass.

According to yet another aspect of the invention at least the anode connection zone, preferably the first longitudinal face comprising at least the anode connection zone, is covered by an anode contact member, and at least the cathode connection zone, preferably the second longitudinal face comprising at least the cathodic connection zone, is covered by a cathodic contact member, it being understood that said anodic and cathodic contact members are able to ensure electrical contact between the stack and an external conductive element .

According to yet another aspect of the invention, each of the anodic and cathodic contact members comprises:

a first electrical connection layer, arranged on at least the anode connection zone and at least the cathode connection zone, preferably on the first longitudinal face comprising at least the cathode connection zone and on the second longitudinal face comprising at least the cathodic connection zone, this first 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 polymeric resin loaded with graphite,

a second electrical connection layer comprising a metal foil arranged on the first layer of material loaded with electrically conductive particles.

According to yet another aspect of the invention, the smallest distance between the first longitudinal face comprising at least one anode connection zone and the first end plane defined by the first longitudinal ends of each anode layer, of each layer of electrolyte material and / or separator layer, of each cathode layer as well as each layer of cathode current collector substrate is between 0.01 mm and 0.5 mm, and / or the smallest distance between the second longitudinal face comprising at least one cathode connection area and the second end plane defined by the second longitudinal ends of each anode layer, each electrolyte material layer and / or separator layer, each cathode layer as well as each anode current collector substrate layer, is between 0.01 mm and 0.5 mm.

Another object of the invention is a method of manufacturing at least one battery, each battery comprising at least one elementary cell, each elementary cell successively comprises a substrate collecting anode current, an anode layer, at least one layer of an electrolyte material and / or at least one layer of a separator impregnated with an electrolyte, a cathode layer, and a cathodic current collector substrate, knowing that in the case where said battery comprises a plurality of cells elementary, said elementary cells are arranged one below the other, namely superimposed in a direction frontal to the main plane of the battery, so that, preferably: the anode current collector substrate is the anode current collector substrate of two adjacent elementary cells, and in that o the cathodic current collecting substrate is the cathodic current collecting substrate of two elementary cells adjacent cells, said at least elementary cell or said elementary cells define a stack, said stack and said battery having six faces, namely,

- two so-called mutually opposite front faces, in particular mutually parallel, generally parallel to the anode current collector substrate (s), to the anode layer (s), to the anode layer (s) an electrolyte material or the separator layer (s) impregnated with an electrolyte, the cathode layer (s), and the cathode current collector substrate (s),

- two so-called mutually opposite side faces, in particular mutually parallel,

- and two so-called longitudinal faces, mutually opposite, in particular mutually parallel, it being understood that the first longitudinal face of the battery comprises at least one anode connection zone and that a second longitudinal face of the battery comprises at least one cathodic connection zone, said anode and cathode connection zones being laterally opposed, so than

- According to a second longitudinal direction of the battery, opposite to said first longitudinal direction, each cathodic current collector substrate protrudes with respect to both each anode layer, each layer of electrolyte material or separator layer impregnated with 'an electrolyte, to each cathode layer as well as to each layer of anode current collecting substrate, said manufacturing process comprising: a first step of supplying at least one sheet of anode current collecting substrate having slits, uncoated areas and areas coated with an anode layer, optionally coated with a layer of an electrolyte material or a separator layer, hereinafter referred to as anode foil, a second supply step at least one cathode current collector substrate sheet having slits, uncoated areas and areas coated with a cathode layer, optionally coated with a layer of a electrolyte material or of a separator layer, hereinafter called cathode sheet, a third step of producing an alternate stack of at least one anode sheet having slits, uncoated areas and coated areas and 'at least one cathode sheet having slits, uncoated areas and coated areas, so as to obtain at least one elementary cell comprising successively an anode current collector substrate, an anode layer, at least one layer of a electrolyte material or a separator, a cathode layer, and a cathode current collector substrate, and in such a way that in the first longitudinal direction of the battery, each anode current collector substrate protrudes with respect to both at each anode layer, at each layer of electrolyte material and / or separator layer, to each cathode layer as well as to each cathode current collector substrate layer, and o in the second longitudinal direction of the battery, opposite to said first longitudinal direction, each collector substrate cathode current protrudes from both each anode layer, each electrolyte material layer and / or separator layer, each cathode layer as well as each anode current collector substrate layer, a fourth step of carrying out a heat treatment and / or a mechanical compression of the stack of alternating sheets obtained in the third step, so as to form a consolidated stack, optionally, a fifth step of carrying out a first pair of cutouts making it possible to separate a given row of batteries from at least one other row of batteries formed from said consolidated stack, optionally a sixth printing step egnation of the consolidated stack obtained in the fourth step or the impregnation of the line of batteries obtained in the fifth step when this fifth step is carried out, with a phase carrying lithium ions such as liquid electrolytes or an ionic liquid containing lithium salts, so that said separator layer is impregnated with an electrolyte, optionally a seventh step of making a second pair of cutouts making it possible to expose

the anode edge of each anode current collector substrate protruding from both each anode layer, each layer of electrolyte material or separator layer, each cathode layer and each layer of cathode current collector substrate in the first longitudinal direction of the battery, each anode edge defining at least one anode connection zone, and

the cathode edge of each cathode current collector substrate protruding from both each anode layer, each layer of electrolyte material or separator layer, each cathode layer as well as each layer of anode current collector substrate in the second longitudinal direction of the battery, each cathode edge defining at least one cathodic connection area, said second pair of cutouts making it possible, when said fifth step is performed, to separate a given battery from at least one other battery formed from the row of batteries. In a particular embodiment of this method, one carries out, after the sixth step (if it is carried out), or if the sixth step is not carried out, after the fifth step (if it is carried out), or if the sixth step step and the fifth step are not carried out, after the fourth step, and before the seventh step, an eighth step of encapsulation of the consolidated stack or of the line of batteries, preferably, in which one covers, by a system encapsulation, at least partly the outer periphery of the stack or row of batteries, preferably the front faces of the stack or row of batteries, the side faces and at least partly the longitudinal faces so that only each anode edge of each anode current collector substrate protruding from both each anode layer, each electrolyte material layer or separator layer, each cathode layer as well as at each bed e of cathodic current collector substrate along the first longitudinal direction of the battery, is flush with a first longitudinal face, and that only each cathode edge of each cathode current collector substrate protrudes with respect to both each anode layer, at each layer of electrolyte material or separator layer, at each cathode layer as well as at each layer of anode current collector substrate in the second longitudinal direction of the battery, a second longitudinal face is flush with said second longitudinal face being preferably opposite and parallel to the first longitudinal face, it being understood that each anode edge defines an anode connection zone and that each cathode edge defines a cathode connection zone; said encapsulation system comprising, preferably, - optionally, at least one first covering layer, preferably chosen from parylene, type F parylene, polyimide, epoxy resins, silicone, polyamide, silica sol -gel, organic silica and / or a mixture of these, deposited on at least part of the outer periphery of the stack or of the line of batteries, - optionally a second covering layer composed of an electrically insulating material deposited by deposition of atomic layers,

- on at least part of the outer periphery of the stack or row of batteries,

- or on the first covering layer, and - at least a third waterproof covering layer, preferably having a water vapor permeance (WVTR) of less than 10 ⁵ g / m ² .d, this third covering layer being composed of a ceramic material and / or a glass with a low melting point, preferably a glass with a melting point of less than 600 ° C, deposited on at least part of the outer periphery of the stack or of the row of batteries, or of the first covering layer, it being understood that a sequence of at least a second covering layer and at least a third covering layer can be repeated z times with z ³ 1 and deposited at the outer periphery of at least the third cover layer, and that the last layer of the encapsulation system is a waterproof cover layer, preferably having a water vapor permeance (WVTR) of less than 10 ^-5 g / m ² .d and being composed of a ceramic material and / or a low melting point glass.

In another particular embodiment of the method according to the invention, which can be combined with the previous one, after the seventh step, at least the anode connection zone is covered, preferably at least the first longitudinal face comprising at least the zone of anodic connection, by an anodic contact member, capable of ensuring electrical contact between the stack and an external conductive element, and at least the cathodic connection zone, preferably at least the second longitudinal face comprising at least the cathodic connection zone, by a cathodic contact member, capable of ensuring electrical contact between the stack and an external conductive element, said embodiment of anodic and cathodic contact members comprising:

the deposition on at least the anode connection zone and on at least the cathodic connection zone, preferably on at least the first longitudinal face comprising at least the anode connection zone, and on at least the second longitudinal face comprising at least minus the cathodic connection area, of a first electrical connection layer of material charged with electrically conductive particles, said first layer preferably being formed of polymeric resin and / or of a material obtained by a sol-gel process charged with particles electrically conductive,

- optionally, when said first layer is formed of polymeric resin and / or of a material obtained by a sol-gel process loaded with electrically conductive particles, a drying step followed by a step of polymerization of said polymeric 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 comprising a metal foil arranged on the first electrical connection layer,

- optionally, the deposition on the second electrical connection layer, of a third electrical connection layer comprising a conductive ink.

Figures

The appended figures, given by way of non-limiting examples, represent different aspects and embodiments of the invention. [Fig. 1] is a perspective view of the anode and cathode sheets intended to form a stack according to the battery manufacturing process according to the invention, these anode and cathode sheets having elementary entities comprising uncoated areas, coated areas, and slits.

[Fig. 2] is a front view, illustrating one of the sheets, in particular an anode sheet of Figure 1.

[Fig. 3] is a front view, on a larger scale, illustrating an elementary entity, consisting of an uncoated area hereinafter referred to by the term "spare", a coated area, and a slot, provided in an anode sheet according to the invention or according to a variant of the invention. [Fig. 4] is a perspective view, also on a large scale, illustrating the uncoated or spared areas, the coated areas and the slits of these elementary entities provided in adjacent sheets.

[Fig. 5] is a top view, illustrating a cutting step performed on different elementary entities provided in the stack of the preceding figures. [Fig. 6] is a top view, illustrating on a larger scale the cuts made on the elementary entities.

[Fig. 7] is a sectional view, along section line VII-VII indicated in FIG. 6 illustrating the stack of elementary anode and cathode entities according to the invention or according to a variant of the invention, each of these elementary entities being consisting of an uncoated area, a coated area and a slot.

[Fig. 8] is a sectional view, along section line VII-VII indicated in FIG. 6, illustrating the stack of elementary entities encapsulated in an encapsulation system. [Fig. 9] is a sectional view, along section line VII-VII illustrating a battery according to the invention comprising an encapsulation system, which can be obtained in particular according to the method of the preceding figures.

[Fig. 10] is a perspective view illustrating a battery according to the invention comprising an encapsulation system, which can be obtained in particular according to the method of the preceding figures.

[Fig. 11] is a sectional view, along section line VII-VII illustrating a battery according to the invention comprising an encapsulation system and contact members, which can be obtained in particular according to the method of the preceding figures . [Fig. 12] is a perspective view illustrating a battery according to the prior art.

[Fig. 13] is a front view, illustrating one of the sheets according to a variant of the invention, in particular an anode sheet where the anodic savings are made in the form of a single savings strip.

[Fig. 14] is a top view, illustrating a cutting step performed on different elementary entities provided in the stack according to a variant of the invention.

[Fig. 15] is a top view, illustrating a cutting step performed on different elementary entities provided in the stack according to a variant of the invention and showing the batteries obtained according to this same variant.

[Fig. 16] is a top view, illustrating a line of batteries according to the invention. [Fig. 17] is a perspective view illustrating a line of batteries according to the invention comprising an encapsulation system, which can be obtained in particular according to the method of the preceding figures.

[Fig. 18] to [Fig. 20] are front views, illustrating successive steps in the production of a battery according to another embodiment of the invention, in which this battery comprises a single cell and each current collector forms a tab. [Fig. 21] is a front view, similar to FIG. 8, illustrating a battery according to a variant of this FIG. 8.

[Fig. 22] to [Fig. 24] are front views, similar to Figures 18 to 21, illustrating successive steps in producing a battery according to yet another embodiment of the invention, using an electrical connection support of the metal grid type.

[Fig. 25] is a front view, similar to FIG. 24, illustrating a variant of this FIG. 24. The following references are used in these figures and in the description which follows: 1000, 1000 'Battery according to the invention

1002 Anode connection area

1002 Anode edge of each anode current collector substrate

1006 Cathodic connection area

1006 ’Cathodic edge of each cathode current collector substrate

100, 100 ’, 100” Elementary cell 10 Anode current collector substrate 20 Anode layer

30 Layer of electrolyte material / Layer of electrolyte

31 Separator layer impregnated or subsequently impregnated with an electrolyte / Separator layer

40 Cathodic current collector substrate

50 Cathode layer

60 Elementary entity

60 ’Elementary anodic entity

60 ”Elementary cathode entity

70 I-shaped slits in cathode sheets, cathode slit

H 70 Total height of the cathode slit 70 I-shaped L70 Total width of the cathode slit 70 I-shaped

71 Coated area in the cathode foil

72 Saving / Uncoated area in cathode foil / Cathodic saving

L72 Total width of the spare / uncoated area 72 in the cathode sheet

H 72 Total height of the savings / uncoated area 72 in the cathode foil

L71 Total width of the coated area in the cathode foil

80 I-shaped slits in the anode sheets, anode slit

H 80 Total height of the anode slot 80 I-shaped Leo Total width of the anode slot 80 I-shaped

81 Coated area in the anode sheet

82 Saving / Uncoated area in the anode sheet / Anodic saving

82 Savings Band Lei Total width of the coated area in the anode sheet

Hbi Total height of the coated area in the anode sheet I - 82 Total width of the savings / uncoated area 82 H 82 Total height of the savings / uncoated area 82 90 Material waste

95 Encapsulation system 97 Contact member 97 'Anodic contact member 97'a Anodic contact member lug covering the ends of the faces F1, F2, F3, F5 to the longitudinal face F6

97 ”Cathodic contact organ

97 "a Cathodic contact member lug covering the ends of the faces F1, F2, F3, F5 adjacent to the longitudinal face F4

Dca Smallest distance between the first longitudinal face (F6) of a battery 1000 comprising at least one anode connection zone (1002) and the first end plane DY _a

Dec Smallest distance between the second longitudinal face (F4) of a battery 1000 comprising at least one cathodic connection zone (1006) and the second end plane DY ' _a Dca' Smallest distance between the first longitudinal face of a battery 1000 'comprising at least one anode connection zone and the first end plane defined by the first longitudinal ends of each anode layer, of each layer of electrolyte material or separator layer, of each cathode layer as well as each layer of cathode current collector substrate

Dec 'Smallest distance between the second longitudinal face of a battery 1000' comprising at least one cathodic connection zone and the second end plane defined by the first longitudinal ends of each anode layer, of each layer of material d 'electrolyte or separator layer, of each cathode layer as well as of each anode current collector substrate layer hooo Battery width

L1000 Battery length C1000 Battery center 1000

Z1000 Axis parallel to the frontal direction ZZ of the battery and passing through the center C1000 of the battery 1000.

R 1000 Battery rotation 1000 around Z1000

I Stack of substrate sheets, covered with an electrode layer (anode or cathode) and an electrolyte sheet or a separator sheet impregnated or subsequently impregnated with an electrolyte / Stack of at least one elementary cell

2nd anode sheet presenting elementary entities

5th Cathode sheet presenting elementary entities

4 Perforated central zone of the anode sheet presenting elementary entities

6 Peripheral frame of the anode sheet presenting elementary entities

7 Perforations present at the four ends of the sheets of substrate, anode, cathode, electrolyte or separator impregnated or subsequently impregnated with an electrolyte

8 Material bridges between two lines

H ₈ Height of decks

9 Bands of material between two rows

L9 Band width

XX Longitudinal or horizontal direction of the stack / battery

YY Lateral or transverse direction of the stack / battery ZZ Front direction of the stack / battery

L, Ln, Ln-1, Ln + 1 Row of elementary entities / Row of batteries R, Rn, Rn-1, Rn + 1 Row of elementary entities DYn-1, DY'n-i, DYn, DY ' _n , DYn + i, DY ' _{n + 1} Cutouts

DXn-i, DX'n-1, DX _n , DX ' _n , DX _{n + i} , DX'n + i Cutouts DYa First end plane of a coil defined by the first longitudinal ends of each anode layer , each layer of electrolyte material or separator layer, each cathode layer as well as each cathode current collector substrate layer. DY'a Second end plane of a battery defined by the second longitudinal ends of each anode layer, each layer of electrolyte material or separator layer, each cathode layer as well as each substrate layer anode current collector

2000 Battery according to prior art

200, 200 ', 200 ”Elementary cell of a battery according to the prior art 2002 Anode connection zone of a battery according to the prior art 2006 Cathodic connection zone of a battery according to the prior art 295 encapsulation of a battery according to the prior art

YH Lateral median axis of elementary entities

F 1, F2 Front faces of stack (I) / battery (1000) F3, F5 Side faces of stack (I) / battery (1000) F4, F6 Longitudinal faces of stack (I ) / battery (1000) FF1. FF2 Front faces of the battery line (L _n ) FF3, FF5 Side faces of the battery line (L _n ) FF4, FF6 Side faces of the battery line (L _n )

Description of the invention

By convention, the following geometric names are associated with this battery: ZZ the so-called frontal direction, namely perpendicular to the plane of the various stacked layers;

XX the direction called longitudinal, which is included in the plane of the stacked layers and which is parallel to the largest dimension of these layers, in top view, namely in the front direction; YY the so-called lateral or transverse direction, which is included in the plane of the stacked layers and which is parallel to the smallest dimension of these layers, in top view.

Also by convention, the two directions associated with each of these three directions are given with reference to the plane of the sheet on which is reproduced in Figure 10.

For the XX direction, we therefore associate the direction towards the right and the direction towards the left, for the direction YY, we associate the direction towards the front and the direction towards the rear, and for the direction ZZ, we associate the upward and downward direction, with reference to the plane of the sheet on which is reproduced in Figure 10. Also by convention, a first longitudinal direction XX 'directed from right to left and a second longitudinal direction XX ”, opposite to the first longitudinal direction XX', namely directed from left to right, with reference to the plane of the sheet on which is reproduced in Figure 10. We define, still with reference to the plane of the sheet on which is reproduced Figure 10, a first lateral direction YY 'directed from front to rear, a second lateral direction YY ", opposite to first lateral direction, a first frontal direction ZZ 'directed from top to bottom, as well as a second frontal direction ZZ ”, opposite to the first frontal direction.

The method according to the invention firstly comprises a step in which a stack I of alternate sheets is produced, these sheets being referred to in what follows, as the case may be, "anode sheets" or "cathode sheets". As will be seen in more detail, each anode sheet is intended to form the anode of several batteries, and each cathode sheet is intended to form the cathode of several batteries. In the example illustrated in Figure 1. two cathode sheets have been shown having elementary entities 5e, as well as two anode sheets having elementary entities 2e. In practice, this stack is formed by a higher number of sheets, typically between ten and a thousand. The number of cathode sheets having elementary entities 5th is identical to the number of anode sheets presenting elementary entities 2e employed constituting the stack I of alternating sheets of opposite polarity.

In an advantageous embodiment, each of these sheets has perforations 7 at its four ends so that when these perforations 7 are superimposed, all the cathodes and all the anodes of these sheets are arranged according to the invention, like this will be explained in greater detail below (see Figures 1, 2 and 3). These perforations 7 at the four ends of the sheets can be produced by any suitable means, in particular on anode and cathode sheets after manufacture, or on substrate sheets 10,40 before manufacture of the anode and cathode sheets. Each anode sheet comprises an anode current collector substrate 10 coated at least partially with an active layer 20 of an anode material, hereinafter anode layer 20. Each cathode sheet comprises a cathode current collector substrate 40 coated. at least partially of an active layer 50 of a cathode material, hereinafter referred to as cathode layer 50. Each of these active layers can be solid, and more particularly of dense or porous nature. Furthermore, in order to avoid any electrical contact between two active layers of opposite polarities, a electrolyte layer 30 or a separator layer 31 subsequently impregnated with an electrolyte is placed on the active layer of at least one of these current-collecting substrates previously coated with the active layer, in contact with the active layer in look. The electrolyte layer 30 or the separator layer 31, can be arranged on the anode layer 20 and / or on the cathode layer 50; the electrolyte layer 30 or the separator layer 31 forms an integral part of the anode sheet and / or of the cathode sheet 1 or comprising it.

Advantageously, the two faces of the anode current collector substrate 10, respectively cathode 40, are at least partially coated with an anode layer 20, respectively with a cathode layer 50, and optionally with an electrolyte layer 30. or a separator layer 31, disposed on the anode layer 20, respectively on the cathode layer 50. In this case, the anode current collector substrate 10, respectively cathode 40, serves as a current collector for two cells. elementary adjacent 100, 100 '. The use of these substrates in batteries can increase the production efficiency of high energy density, high power density rechargeable batteries.

The mechanical structure of one of the anode sheets is described below, it being understood that the other anode sheets have an identical structure. Moreover, as will be seen in what follows, the cathode sheets have a structure similar to that of the anode sheets.

As can be seen in FIG. 2. the anode sheet 2e having elementary entities 60, 60 ’has the shape of a quadrilateral, substantially of the square type. It delimits a so-called perforated central zone 4, in which elementary entities are provided which will be described below. With reference to the positioning of these elementary entities, a so-called lateral or transverse direction YY of the sheet is defined, which corresponds to the lateral direction of these elementary entities, as well as a so-called horizontal direction XX of the sheet, perpendicular to the direction YY . The central zone 4 is bordered by a peripheral frame 6 which is solid, namely devoid of elementary entities. The function of this frame is in particular to ensure easy handling of each sheet.

The elementary entities 60, 60 ′ are distributed along lines Li to L _y , arranged one below the other, as well as along rows Ri to R _x provided one beside the other. By way of nonlimiting examples, in the context of the manufacture of micro-batteries of the surface mountable component type (hereinafter CMS), the anode and cathode sheets used can be plates of 100 mm × 100 mm. So Typically, the number of rows of these sheets is between 10 and 500, while the number of rows is between 10 and 500. Depending on the desired capacity of the battery, its dimensions may vary and the number of rows and rows. rows by anode and cathode sheets can be adapted accordingly. The dimensions of the anode and cathode sheets used can be modulated as required. As shown in FIG. 2, two adjacent lines can be separated by bridges of material 8, the height of which is denoted He, which is between 0.05 mm and 5 mm. Two adjacent rows can be separated by strips of material 9, the width of which is denoted Lg, which is between 0.05 mm and 5 mm. These bridges 8 and strips 9 of material of the anode and cathode sheets give these sheets sufficient mechanical rigidity so that they can be easily handled.

Elementary entities 60, 60 ’, 60” include spares, i.e. uncoated areas 72,82, coated areas 71,81, and slots 70,80 as will be seen in more detail, below. These slots 70, 80, preferably in the form of an I, are through, ie they open onto the opposite upper and lower faces of the sheet, respectively. These slots 70, 80 preferably have the shape of a quadrilateral, substantially of the rectangular type. These slots 70, 80 can be made in a manner known per se, directly on the current collector substrate, before any deposition of anode or cathode materials by chemical etching, by electroforming, by laser cutting, by microperforation or by stamping. These 70,80 slots can also be made:

- on current collecting substrates at least partially coated with a layer of anode or cathode material, or

- on current collecting substrates at least partially coated with a layer of anode or cathode materials, itself coated with an electrolyte layer or a separator layer, ie on anode sheets or cathode.

When the slits 70,80 are made on such at least partially coated substrates, the slits 70,80 can be produced in a manner known per se, for example by laser cutting (or laser ablation), by femtosecond laser cutting, by microperforation. or by stamping. The slits 70, made in all of the cathode sheets, are mutually superimposed. The slots 80, made in all of the anode sheets, are mutually superimposed.

We will now describe one of the elementary entities 60 as illustrated in FIG. 3, it being understood that the set of elementary entities 60.60 'of the anode sheet is identical and that all of the elementary entities 60.60 ”of the cathode sheet is identical. In FIG. 3 is shown an anode elementary entity 60.60 ′.

Each elementary entity 60, 60 ’, 60” comprises a through slot 80.70, preferably I-shaped, a spare, i.e. an uncoated area 82.72, and a coated area 81.71.

By coated zone 81 with an elementary anode entity 60 'is meant the zone of the anode sheet which is covered by an anode layer 20 or which is covered by an anode layer 20 and an electrolyte layer 30 or a separator layer 31. The term “spare or uncoated zone 82 of an elementary anode entity 60 ′” means the zone of the anode sheet which is not covered by an anode layer 20 or which is not covered by an anode layer 20 and an electrolyte layer 30 or a separator layer 31.

The anode spares 82 are areas free of any electrolyte or separator material and any anode material. When they are produced on the anode sheets, these anode spares 82 are carried out so as to remove or avoid the deposition of any electrolyte or separator material, of any anode material, and to leave at least part of the substrate anode current collector 10. So that, in a first longitudinal direction XX 'of the battery, each anode current collector substrate 10 protrudes with respect to both each anode layer 20, to each layer of material of electrolyte 30 or separator layer impregnated with an electrolyte 31. When the current collector substrates are fully covered with an anode layer 20, itself optionally covered with an electrolyte layer 30 or with a layer separator 31, the anode sparing 82 can be achieved by laser ablation in order to locally remove the anode layer 20 or the anode layer 20 coated with an electrolyte layer 30 or a separator layer 31. Savings a nodes 82 can also be produced, in a manner known per se, by local slot-die coating of the current collector substrate. The local slot-die coating of the current collector substrate makes it possible to carry out a local deposition on the substrate, in particular with an anode layer 20, optionally subsequently covered by the same process with an electrolyte layer 30 or d. a separator layer 31. Slot-die coating on the substrate with symmetry in the direction of travel of the substrate makes it possible to directly leave uncoated areas 82 on the substrate; this makes it possible to reduce the number of steps in the process for manufacturing the elementary entities on the anode sheets. The savings 82.72 on the one hand, and the slot 80.70 of the same elementary entity 60, 60 ', 60 ”on the other hand, are mutually symmetrical in top view, with respect to the median axis elementary entities 60, 60 ', 60 ”, which is denoted YH.

Each anode sparing 82 is produced in the extension of each cathode slot 70 and each cathode sparing 72 is produced in the extension of each anode slit 80.

The anode sheet obtained after making slits 80, coated areas 81 and savings 82, is hereinafter called anode sheet having elementary entities 2e.

We notice :

• Heo the height of the entire anode slot, which is typically between 0.25 mm and 10 mm;

• Leo its width, which is typically between 0.25 mm and 10 mm;

• H _b 2 the height of each anode spar, which is typically between 0.25 mm and 10 mm;

• L _S 2 the width of each anode spar, which is typically between 0.25 mm and 10 mm.

Similarly, each cathode sheet is also provided with different lines and rows of elementary cathode entities 60.60 ", provided in the same number as the elementary anode entities 60, 60".

As shown in particular in Figure 4, the structure of each elementary cathode entity 60 ”is substantially similar to that of each elementary anode entity 60 ', namely that this elementary cathode entity 60” comprises a spare or uncoated zone 72, a zone coated 71 and a slot 70.

The term “spare or uncoated zone 72 of an elementary cathode entity 60” is understood to mean the zone of the cathode sheet 5e which is not covered by a cathode layer 50 or which is not covered by a cathode layer 50. and an electrolyte layer 30 or a separator layer 31.

By coated zone 81 with an elementary cathode entity 60 ”is meant the zone of cathode sheet 5e which is covered by a cathode layer 50 or which is covered by a cathode layer 50 and by an electrolyte layer 30 or a separator layer 31.

The dimensions of the cathode spares 72 are identical to those of the anode slots 80 and, analogously, the dimensions of the anode spares 82 are analogous to those of the cathode slits 70. In top view, the cathode spares 72 are superimposed on the anode slots 80 and the anode spares 82 are superimposed on the cathode slots 70.

The only differences between the elementary anode 60 "and cathode 60" entities reside in the fact that on the one hand, the cathode spares 72 and the anode spares 82 are mutually reversed. On the other hand, the cathode slits 70 and the anode slits 80 are mutually reversed. In this way, in top view, each anode sparing 82 is produced in the extension of each cathode slot 70 and each cathode sparing 72 is produced in the extension of each anode slit 80.

Cathodic spares 72 are areas free of any electrolyte or separator material and any cathode material. When they are produced on the cathode sheets, these cathode spares 72 are carried out so as to remove or avoid the deposition of any electrolyte or separator material, of any cathode material, and to leave at least part of the collecting substrate of anode current 10. In this way, according to the second longitudinal direction XX ”of the battery, opposite to the first longitudinal direction XX ', each cathode current collector substrate 40 protrudes with respect to both each cathode layer 50, at each layer of electrolyte material 30 or separator layer impregnated with an electrolyte 31. When the current collector substrates are fully covered with a cathode layer 50, itself 50 optionally covered with an electrolyte layer 30 or of a separator layer 31, the cathodic spares 72 can be produced by laser ablation in order to locally remove the cathode layer 50 or the cathode layer 50 coated with a layer of el electrolyte 30 or a separator layer 31. Cathodic sparing 72 can also be achieved by local slot-die coating of the current collector substrate. The local slot-die coating of the current collector substrate makes it possible to carry out a local deposition on the substrate, in particular with a cathode layer 50, optionally subsequently covered by the same process with an electrolyte layer 30 or with a separator layer 31. Slot-die coating on the substrate with symmetry in the direction of travel of the substrate makes it possible to directly leave uncoated areas 72 on the substrate; this makes it possible to reduce the number of steps in the manufacturing process of the elementary entities on the cathode sheets.

The cathode sheet obtained after making slits 70, coated zones 71 and savings 72 is hereinafter called cathode sheet having elementary entities 5e. An alternating stack I is then produced of at least one anode sheet having elementary entities 2e and of at least one cathode sheet having elementary entities 5e, so as to obtain at least one elementary cell, each elementary cell successively comprising a substrate anode current collector 10, an anode layer 20, a layer of an electrolyte material 30 or a layer of a separator impregnated or subsequently impregnated with an electrolyte 31, a cathode layer 50, and a collector substrate cathode current 40.

Stack I comprises an alternating arrangement of at least one anode sheet 2e having slits 80, uncoated areas 82 and coated areas 81 and at least one cathode sheet 5e having slits 70, uncoated areas 72 and coated zones 71. At least one elementary cell 100 is thus obtained successively comprising an anode current collector substrate 10, an anode layer 20, a layer of an electrolyte material 30 and / or a separator layer 31. , a cathode layer 50, and a cathode current collector substrate 40.

This stack I is produced so that:

- According to the first longitudinal direction XX 'of the battery, each anode current collector substrate 10 protrudes with respect to both each anode layer 20, each layer of electrolyte material 30 and / or separator layer 31 , to each cathode layer 50 as well as to each cathode current collector substrate layer 40, and

- according to the second longitudinal direction XX ”of the battery, opposite to said first longitudinal direction XX ', each cathodic current collector substrate 40 protrudes with respect to both each anode layer 20, to each layer of electrolyte material 30 and / or separator layer 31, to each cathode layer 50 as well as to each anode current collector substrate layer 10.

In the case where said battery comprises a plurality of elementary cells 100, 100 ', 100 ”, said elementary cells 100, 100', 100” are arranged one below the other, namely superimposed in a frontal direction ZZ to the plane main battery as shown in Figure 10, so that, preferably: the anode current collector substrate 10 is the anode current collector substrate 10 of two elementary cells 100, 100 ', 100 ”adjacent, and in that o the cathode current collector substrate 40 is the cathode current collector substrate 40 of two elementary cells 100, 100 ', 100 ”adjacent. It is assumed that the stack, described above, is subjected to steps aimed at ensuring its overall mechanical stability. These steps, of a type known per se, include in particular the heat-pressing of the various layers. As will be seen below, this thus consolidated stack allows the formation of individual batteries, the number of which is equal to the product between the number of rows Y and the number of rows X.

To this end, with reference to FIG. 5, three lines L _n -i to L _{n + i} have been illustrated, as well as three rows R _n -i to R _{n + i} . In accordance with the invention, and when the stack I comprises several lines, ie at least two lines of elementary entities also called hereafter line of batteries L _n , a first pair of cutouts DX _n and DX ' _{n is produced} making it possible to separate a row L _n of batteries 1000 given vis-à-vis at least one other row L _n - 1, L _{n + i} of batteries formed from said consolidated stack, as shown in Figures 16 and 17. Each cutting, which is carried out through the way, namely that it extends over the entire height of the stack, is carried out in a manner known per se. By way of nonlimiting examples, mention will be made of cutting by sawing, in particular dicing, cutting by guillotine or even laser cutting. In addition, the areas 90 of the sheets of the stack, which do not form the batteries, have been illustrated with a filling in solid lines, while the volume of the slots is left in white and that of the savings in gray. As shown in particular in Figure 6, which is a view on a larger scale of one of the elementary entities 60,60 'of Figure 5, each cutout is made in the longitudinal direction of the battery, in the first longitudinal direction XX 'or the second longitudinal direction XX ”, regardless. The cutouts DX _n and DX ' _n are preferably mutually parallel and are preferably made perpendicular both to the alignment of the slots 80,70 and of the spares 72,82 of the elementary entities 60,60 ', 60 ”.

With reference again to FIG. 5, each final battery is delimited, at the front and at the rear, by the two cutouts DX _n and DX ' _n , preferably mutually parallel, and, on the right and on the left by a second pair of cuts DY _n and DY ' _n , preferably mutually parallel.

In this FIG. 5, the batteries 1000 have been shown hatched once they have been cut along the cutting lines D _n and D ' _n and along the _{cutting lines DY n} and DY'n.

Under these conditions, with reference to this FIG. 6, by way of nonlimiting examples, we note: the distance Dca which corresponds to the smallest distance between the first longitudinal face F6 of a battery comprising at least one anode connection zone 1002 and the first end plane DYa. This distance Dca is between 0.01 mm and 0.05 mm, it being understood that this distance Dca is less than or equal to Le _å / L70;

- the distance Dec which corresponds to the smallest distance between the second longitudinal face F4 of a battery comprising at least one cathodic connection zone 1006 and the second end plane DY'a. This distance Dec is between 0.01 mm and 0.05 mm, it being understood that this distance Dec is less than or equal to L72 / Leo;

Figure 7 is a sectional view, taken along section line VI I -VI I which extends through the battery. In Figure 7. there is shown the alternating arrangement of two anode sheets having elementary entities 2e and two cathode sheets having elementary entities 5th. In the same figure, the slots 70,80, the coated areas 71,81 and the spares 72,82 of the elementary entities 60,60 ', also illustrated in FIG. 6, are referenced, as well as the adjacent elementary cells according to a method of advantageous embodiment of the invention.

The anode sheet having elementary entities 2e comprises an anode current collector substrate 10 coated with an anode layer 20, itself optionally coated with an electrolyte layer 30 or with a separator layer 31 subsequently impregnated with 'an electrolyte. Each cathode sheet having elementary entities 5e comprises a cathode current collector substrate 40 coated with an active layer of a cathode material 50, itself optionally coated with an electrolyte layer 30 or with a separator layer. 31 subsequently impregnated with an electrolyte. In order to avoid any electrical contact between two active layers of opposite polarity, ie between the anode layer 20 and the cathode layer 50, at least one electrolyte layer 30 and / or at least one separator layer is arranged. 31 impregnated or subsequently impregnated with an electrolyte. In Figure 7 is shown an elementary cell 100 comprising successively an anode current collector substrate 10, an anode layer 20, at least one layer of an electrolyte material 30 or a separator layer 31 impregnated or subsequently impregnated with 'an electrolyte, a cathode layer 50, and a cathode current collector substrate 40. Advantageously, the anode current collector substrate 10 of an elementary cell 100' can be attached to the anode current collector substrate 10 of the adjacent elementary cell 100 ”. Similarly, the current collector substrate cathode 40 of an elementary cell 100 can be attached to the cathode current collector substrate 40 of the adjacent elementary cell 100 '.

In an advantageous embodiment, the anode current collector substrate 10, respectively cathode 40, can serve as a current collector for two adjacent elementary cells, as illustrated in particular in FIG. 7. As explained previously, the two faces of the collector substrate current 10, respectively cathode 40, are coated with an anode layer 20, respectively a cathode layer 50, and optionally an electrolyte layer 30 or a separator layer 31, arranged on the anode layer 20, respectively on the cathode layer 50. This makes it possible to increase the production efficiency of the batteries. As shown in FIG. 7, each anode sheet exhibiting elementary 2e and cathode entities exhibiting elementary entities 5e are arranged so that each cathode sparing 72 is produced in the extension of each anode slot 80 and so that each anode sparing 82 or made in the extension of each cathode slit 70.

According to the first longitudinal direction XX ', each anode current collector substrate 10 protrudes relative to a first end plane DYa, this first plane being defined by the first longitudinal ends of each anode layer 20, of each layer of electrolyte material 30 or separator layer 31, each cathode layer 50 as well as each cathode current collector substrate layer 40.

According to the second longitudinal direction XX ”of the battery, opposite to said first longitudinal direction XX ', each cathodic current collector substrate 40 protrudes with respect to both each anode layer 20 and each layer of electrolyte material 30 or separator layer 31 impregnated or subsequently impregnated with an electrolyte, to each cathode layer 50 as well as to each anode current collector substrate layer 10.

This is a particularly advantageous characteristic of the invention, since it makes it possible to avoid the presence of a short-circuit at the level of the lateral edges of the battery, to avoid the presence of leakage current, and to facilitate the electrical contact sockets at the anode 1002 and cathode 1006 connection zones.

In sectional view, the cathode spares 72 are superimposed on the anode slots 80 and the anode spares 82 are superimposed on the cathode slots 70.

Advantageously, after producing the stack of anode sheets having elementary 2e and cathode entities having elementary entities 5e, it is consolidates the stack I by thermal and / or mechanical treatment (this treatment can be a thermocompression treatment, comprising the simultaneous application of a pressure and a high temperature). The heat treatment of the stack allowing the battery to be assembled is advantageously carried out at a temperature between 50 ° C and 500 ° C, preferably at a temperature below 350 ° C. The mechanical compression of the stack of anode sheets having elementary entities 2e and cathode sheets having elementary entities 5e to be assembled is carried out at a pressure of between 10 MPa and 100 MPa, preferably between 20 MPa and 50 MPa.

We have just described the production of the consolidated stack of the layers which constitute the battery. It is then possible, when the stack I comprises several lines, ie at least two lines of elementary entities also called hereinafter lines of banks L _n , make a first pair of cuts DX _n and DX ' _n making it possible to separate a line L _n of batteries 1000 given vis-à-vis at least one other row L _n -i, L _{n + i} of batteries formed from said consolidated stack. Each cutout, which is carried out through the way, namely that it extends over the entire height of the stack, is made in a manner known per se, as indicated above. As shown in Figure 17, the row of batteries L _n has six faces, namely:

- two so-called front faces FF1, FF2 mutually opposite, in particular mutually parallel, generally parallel to the anode current collector substrate (s) 10, to the anode layer (s) 20, to the layer (s) electrolyte material 30 or electrolyte impregnated separator layer (s) 31, cathode layer (s) 50, and substrate (s) cathode current collector 40,

- two so-called side faces FF3, FF5 mutually opposed, in particular mutually parallel and parallel to the side faces F3, F5 of the battery 1000,

- and two so-called longitudinal faces FF4, FF6, mutually opposite, in particular mutually parallel and parallel to the longitudinal faces F4, F6 of the battery

1000.

When a separator is used as a host matrix for an electrolyte, the previously obtained consolidated stack or the row L _n of batteries 1000 can be impregnated when the initial stack I comprises several rows of batteries L _n and a first pair of cuts (DXn, DX'n) was carried out in order to separate the row (L _n ) of batteries (1000) given with respect to at least one other row (L _n -i, L _{n + i} ) of batteries (1000) formed from said consolidated stack. The impregnation of the consolidated stack obtained previously or of the line L _n of batteries 1000 can be carried out, with a phase carrying lithium ions such as liquid electrolytes or an ionic liquid containing lithium salts, so that said separator (31) is impregnated with an electrolyte.

After the production of a consolidated stack I, and possibly impregnated with a phase carrying lithium ions, this stack or the line L _n of batteries 1000 is encapsulated by depositing an encapsulation system 95 to ensure the protection of the cell. of the battery vis-à-vis the atmosphere, as shown in FIG. 8. The encapsulation system should advantageously be chemically stable, withstand high temperature and be impermeable to the atmosphere in order to perform its function as a layer. fence. The stack can be covered with an encapsulation system comprising: optionally a first dense and insulating covering layer, preferably chosen from parylene, type F parylene, polyimide, epoxy resins, silicone, polyamide , sol-gel silica, organic silica and / or a mixture thereof, deposited on the stack of anode and cathode sheets; and - optionally a second covering layer composed of an electrically insulating material, deposited by depositing atomic layers on the stack of anode and cathode sheets or on said first covering layer; and particularly advantageously, at least a third waterproof covering layer, preferably having a water vapor permeance (WVTR) of less than 10 ⁵ g / m ² .d, this third covering layer being composed of a ceramic material and / or a low melting point glass, preferably a glass with a melting point below 600 ° C, deposited at the outer periphery of the stack of anode and cathode sheets or of the first covering layer, it being understood that this sequence of at least one second covering layer and at least one third covering layer can be repeated z times with z ³ 1 and deposited on the outer periphery of at least the third cover layer, and that the last layer of the encapsulation system is a waterproof cover layer, preferably having a water vapor permeance (WVTR) of less than 10 ^-5 g / m ² .d which is composed of '' a ceramic material and / or a low point glass fusion. This sequence can be repeated z times with z ³ 1. It has a barrier effect, which is all the more important as the value of z is high.

A rigid and sealed encapsulation is thus obtained, which in particular prevents the passage of water vapor at the level of the interface between the encapsulation system and the contact members (see interface A in Figure 11).

For the purposes of the invention, a waterproof layer is defined as having a water vapor permeance (WVTR) of less than 10 ⁵ g / m ² .d. The water vapor permeance can be measured using a method which is the subject of US Pat. No. 7,624,621 and which 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.

Typically, the first covering layer, which is optional, is selected from the group formed by: silicones (deposited for example by impregnation or by plasma-assisted chemical vapor deposition from hexamethyldisiloxane (HMDSO)), resins epoxy, polyimide, polyamide, poly-para-xylylene (also called poly (p-xylylene), but better known by the term parylene), and / or a mixture thereof. When a first covering layer is deposited, it protects the sensitive parts of the battery from its environment. The thickness of said first cover layer is preferably between 0.5 µm and 3 µm. This first covering layer is useful especially when the electrolyte and electrode layers of the battery have porosities: it acts as a planarization layer, which also has a barrier effect. For example, this first layer is capable of lining the surface of the microporosities emerging on the surface of the layer, to close access to them. In this first cover layer, different variants of parylene can be used. It can be 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 parylene. or F. Parylene is a dielectric, transparent, semi-crystalline material which exhibits high thermodynamic stability, excellent resistance to solvents and very low permeability. Parylene also has barrier properties. In the context of the present invention, type F parylene is preferred.

This first covering layer is advantageously obtained from the condensation of gaseous monomers deposited by chemical vapor deposition (CVD) on the surfaces of the stack of the battery, which makes it possible to have a conformal, thin and uniform covering. of all the accessible surfaces of stacking. This first covering layer is advantageously rigid; it cannot be considered as a soft surface.

The second cover layer, which is also optional, is composed of an electrically insulating material, preferably inorganic. It is deposited by atomic layer deposition (ALD), by PECVD, by HDPCVD (in English "High Density Plasma Chemical Vapor Deposition") or by ICPCVD (Inductively Coupled Plasma Chemical Vapor Deposition) , so as to obtain a conformal covering of all the accessible surfaces of the stack previously covered with the first covering layer. The layers deposited by ALD are very fragile mechanically and require a rigid support surface to ensure their protective role. The deposition of a fragile layer on a flexible surface would lead to the formation of cracks, causing a loss of integrity of this protective layer. Furthermore, the growth of the layer deposited by ALD is influenced by the nature of the substrate. A layer deposited by ALD on a substrate exhibiting zones of different chemical natures will have inhomogeneous growth, which may lead to a loss of integrity of this protective layer. For this reason, it is preferable for this second optional layer, if it is present, to bear on said first optional layer, which ensures a chemically homogeneous growth substrate. ALD deposition techniques are particularly well suited for covering surfaces with high roughness in a completely sealed and compliant manner. They make it possible to produce conformal layers, free of defects, such as holes (so-called “pinhole free” layers, i.e. free of holes) and represent very good barriers. Their WVTR coefficient is extremely low. The Water Vapor Transmission Rate (WVTR) is used to assess the water vapor permeance of the encapsulation system. The lower the WVTR coefficient, the more watertight the encapsulation system. The thickness of this second layer is advantageously chosen according to the desired level of gas tightness, i.e. the desired WVTR coefficient and depends on the deposition technique used, in particular from among ALD, PECVD, HDPCVD and HDCVDICPCVD.

Said second covering layer may be made of a ceramic material, of a vitreous material or of a glass-ceramic material, for example in the form of an oxide, of the _{Al 2} O _{3 type} , of Ta 2 C> 5, of nitride, of phosphates, of oxynitride, or siloxane. This second covering layer preferably has a thickness of between 10 nm and 10 μm, preferably between 10 nm and 50 nm. This second covering layer deposited by ALD, by PECVD, by HDPCVD (in English “High Density Plasma Chemical Vapor Déposition”) or by ICPCVD (Inductively Coupled Plasma Chemical Vapor Déposition in English) on the first covering layer allows on the one hand , to ensure the watertightness of the structure, ie to prevent the migration of water inside the object and on the other hand to protect the first covering layer, preferably of type F parylene, of the atmosphere, in particular air and humidity, thermal exposures in order to avoid its degradation. This second covering layer thus improves the life of the encapsulated battery. Said second covering layer can also be deposited directly on the stack of anode and cathode sheets, that is to say in a case where said first covering layer has not been deposited.

The third covering layer must be waterproof and preferably has a water vapor permeance (WVTR) of less than 10 ⁵ g / m ² .d. This third covering layer is composed of a ceramic material and / or of a low-melting point glass, preferably of a glass whose melting point is less than 600 ° C, deposited at the outer periphery of the glass. stacking of anode and cathode sheets or of the first covering layer. The ceramic and / or glass material used in this third layer is advantageously chosen from: a glass with a low melting point (typically <600 ° C.), preferably S1O2-B2O3; B12O3-

B2O3, Z ^h O-Bΐ2q3-B2q3, Te02-V20s, Pb0-Si02,

- oxides, nitrides, oxynitrides, Si _x N _y , S1O2, SiON, amorphous silicon or SiC.

These glasses can be deposited by molding or by dip-coating. The ceramic materials are advantageously deposited by PECVD or preferably by HDPCVD or by ICP CVD at low temperature; these methods make it possible to deposit a layer having good sealing properties.

As described above, the battery according to the invention comprises an encapsulation system which, advantageously, is produced in the form of a succession of layers. This allows the realization of a very tight encapsulation on all sides of the battery. Furthermore, this encapsulation has a very small footprint, which allows the miniaturization necessary for the production of microbatteries.

The description of the encapsulation system above illustrates a significant difference, accompanied by its technical effects, with regard to the teaching of the Suzuki document US 2018/212210. In this prior battery, the resin in contact with the cells does not provide a sealed encapsulation function. Indeed, this resin does not have the permeance characteristics described above.

Furthermore, this Suzuki document concerns a solid battery. On the contrary, the battery according to the invention may not be entirely solid. In this case, the longitudinal ends of this battery are of the “open” type. However, as shown in particular in Figure 9, the sealed encapsulation system is advantageously placed in direct contact with the ends of the electrolyte layer 30 or separator 31, at the level of the opposite longitudinal faces F4 and F6. Consequently, this encapsulation system is capable of "closing" the pores of the layer 30, respectively 31, which makes it possible to maintain satisfactorily in particular the nanoconfined electrolytes inside the cell. As a variant not shown, it may optionally be provided that this encapsulation system is not in contact with the other layers. However, it is preferred that this encapsulation comes into direct contact with all of the components of the cell, with the exception of the protruding substrate, on the opposite longitudinal sides of the stack.

Furthermore, advantageously, the battery encapsulation system according to the invention is electrically insulating. For the purposes of the invention, this means that the conductivity of this encapsulation system is advantageously less than 10 ^{e 11} S.nr ¹ , in particular less than 10 ^{e 12} S. nr ¹ . Such a characteristic is advantageous, since it avoids short circuits, while allowing resumption of the opposite positive and negative connections with a view to compatibility with a machine for placing electronic components, of the “pick and place” type. This characteristic can be compared with the teaching of the Suzuki document above, in which the seal is provided by an outer casing of a metallic nature.

The stack thus coated is then cut by any suitable means along the cutting lines DYn and DY'n so as to expose the areas of anode 1002 and cathode 1006 connections and to obtain unit batteries as shown in FIG. 9. .

As shown in Figures 9 and 10, the cuts of the consolidated and encapsulated stack along the cut lines DYn and DY'n are made so that:

- only each anode edge 1002 'of each anode current collector substrate 10 protrudes relative to the first end plane DY _a , this first plane being defined by the first longitudinal ends of each anode layer 20, of each layer of electrolyte material 30 and / or separator layer 31, of each cathode layer 50 as well as of each cathode current collector substrate layer 40 along the first longitudinal direction XX 'of the battery, is flush with a first longitudinal face F6, and that - only each cathode edge 1006' of each collector substrate of cathode current 40 protrudes from the second end plane (DY ' _a ), this second plane being defined by the second longitudinal ends of each anode layer 20, of each layer of electrolyte material 30 and / or layer separator 31, each cathode layer 50 as well as each anode current collector substrate layer 10 along the second longitudinal direction XX ”of the battery, is flush with a second longitudinal face F4, said second longitudinal face F4 preferably being opposite and parallel to the first longitudinal face F6, it being understood that each anode edge 1002 'defines an anode connection zone 1002 and that each cathode edge 1006' defines a cathodic connection area

1006.

Contact members 97.97 ’, 97” (electrical contacts) are added at the level where the cathodic connection areas 1006, respectively anodic 1002 are visible. These contact areas are preferably disposed on opposite sides of the battery stack to collect current (side current collectors). The contact members 97, 97 ', 97 ”are arranged on at least the cathodic connection zone 1006 and on at least the anode connection zone 1002, preferably on the face of the coated and cut stack comprising at least the zone of cathodic connection 1006 and on the face of the coated and cut stack comprising at least the anode connection zone 1002 (cf. FIG. 11).

Thus, at least the anode connection zone 1002 is covered, preferably at least the first longitudinal face F6 comprising at least the anode connection zone 1002, and more preferably the first longitudinal face F6 comprising at least the anode connection zone 1002, and the ends 97'a of the faces F1, F2, F3, F5 to this first longitudinal face F6, by an anode contact member 97 ', capable of ensuring electrical contact between the stack I and an external conductive element. Furthermore, at least the cathodic connection zone 1006 is covered, preferably at least the second longitudinal face F4 comprising at least the cathodic connection zone 1006, and more preferably the second longitudinal face F4 comprising at least the cathodic connection zone 1006 , and the ends 97 ”has faces F1, F2, F3, F5 adjacent to this second longitudinal face F4, by a cathodic contact member 97”, capable of ensuring electrical contact between the stack I and an external conductive element.

Preferably, the contact members 97, 97 ′, 97 ”are formed, near the cathodic 1006 and anode 1002 connection areas, of a stack I of layers successively comprising a first electrical connection layer comprising a material loaded with particles. electrically conductive, preferably a polymeric resin and / or a material obtained by a sol-gel process, loaded with electrically conductive particles and even more preferably a polymeric resin loaded with graphite, and a second layer consisting of a metal foil arranged on the first layer.

The first electrical connection layer makes it possible to fix the second subsequent electrical connection layer while providing “flexibility” to the connection without breaking the electrical contact when the electrical circuit is subjected to thermal and / or vibratory stresses.

The second layer of electrical connection is a metal foil. This second layer of electrical connection is used to permanently protect the batteries from humidity. In general, for a given thickness of material, metals make it possible to produce very waterproof films, more waterproof than those based on ceramics and even more waterproof than those based on polymers which are generally not very hermetic to the passage of molecules. of water. It increases the calendar life of the battery by reducing the WVTR at the contact members.

Advantageously, a third electrical connection layer comprising a conductive ink can be deposited on the second electrical connection layer; it is used to reduce WVTR, which increases battery life.

The contact members 97,97 ’, 97” make it possible to take up the alternately positive and negative electrical connections on each end. These contact members 97.97 ’, 97” make it possible to make the electrical connections in parallel between the different battery cells. For this, only the cathode connections come out on one end, and the anode connections are available on another end.

Application WO 2016/001584 describes stacks of several elementary cells, consisting of anode and cathode sheets stacked alternately and laterally offset (cf. FIG. 121. encapsulated in an encapsulation system 295 for ensure the protection of the cell of the battery 2000 vis-à-vis the atmosphere. The cutting of these encapsulated stacks making it possible to obtain unit batteries, with areas of bare anode 2002 and cathode 2006 connections, is carried out according to a section plane crossing an alternating succession of electrode and encapsulation system. Due to the difference in density existing between the electrode and the encapsulation system of the battery of the prior art, the cut made according to this cutting plane induces a risk of the encapsulation system tearing off in the vicinity of the plane of cut, and thus the creation of short circuits. In application WO 2016/001584, during encapsulation, the encapsulation layer fills the interstices of the stack of sheets bearing U-shaped cutouts. This encapsulation layer introduced at these interstices is thick and does not adhere very well to the stack, inducing this risk of tearing of the encapsulation system 2095 during subsequent cutting. According to the present invention, this risk is eliminated with the use of sheets carrying elementary entities where:

- According to the first longitudinal direction XX ', each anode current collector substrate 10 protrudes relative to the first end plane DYa, this first plane being defined by the first longitudinal ends of each anode layer 20, of each layer of electrolyte material 30 or separator layer 31, each cathode layer 50 as well as each cathode current collector substrate layer 40, and

- according to the second longitudinal direction XX ”of the battery, opposite to said first longitudinal direction XX ', each cathodic current collector substrate 40 protrudes with respect to both each anode layer 20, to each layer of electrolyte material 30 or separator layer 31 impregnated or subsequently impregnated with an electrolyte, to each cathode layer 50 as well as to each anode current collector substrate layer 10.

The heat-pressed mechanical structure of elementary entities is extremely rigid around the cutout, due to the alternate superposition of cathode and anode sheets. The use of such a rigid structure, with the use of sheets carrying elementary entities, makes it possible to reduce the number of defects during cutting, to increase the cutting speed and thus to improve the production efficiency of the batteries. .

According to the invention, the cuts DY ' _n and DY _n are made through anode sheets having elementary entities 2e and cathode sheets having elementary entities 5e of comparable density inducing a clean cut of best quality. In addition, near the section planes DY ' _n and DY _n, the presence along the first longitudinal direction XX' of anode current collector substrate 10 free of any anode material, electrolyte, separator impregnated or not with 'an electrolyte, cathode and cathodic current collector substrate as well as the presence, along the second longitudinal direction XX ”, of cathodic current collector substrate 40 free of any anode material, electrolyte, impregnated separator or not an electrolyte, cathode and anode current collector substrate, prevents any risk of short circuit and leakage current, and facilitates electrical contact at the connection areas 1002,1006. The anode connection areas 1002 and the cathode connection areas 1006 are preferably laterally opposed.

The unique structure of the battery according to the invention makes it possible to avoid the presence of a short circuit at the level of the longitudinal faces F4, F6 of the battery, to avoid the presence of leakage current and to facilitate the electrical contact points. level of the anode 1002 and cathode 1006 connection zones. Indeed, the absence of electrode materials and electrolyte materials on the longitudinal faces F4, F6 of the battery including the anode and cathode connection zones, prevents leakage lateral lithium ions and facilitates battery balancing; the effective surfaces of the electrodes in contact with each other, and delimited by the first and second end planes DYa, DY'a are substantially identical as shown in Figures 7 to 10.

Alternatively, and as shown in Figure 5 and Figure 16, 1000 ’batteries can be obtained according to the invention. These 1000 ’batteries correspond to 1000 batteries having undergone a rotation of 180 ° around the Z1000 axis which is an axis parallel to the front ZZ axis passing through the C1000 center of the battery. The 1000 ’and 1000’ batteries can have the same dimensions. The 1000 and 1000 ’batteries may have mutually identical or different longitudinal dimensions. The realization of the batteries 1000 and 1000 ’on the same stack allows to optimize the production efficiency of the batteries while minimizing the waste of materials 90.

The batteries according to the invention can be produced from elementary entities according to different variants of the invention. By way of non-limiting example, as shown in FIG. 13, the coated areas 71, 81 of the elementary entities can be produced by slot-die coating on the current collector substrate 40, 10 with symmetry in the direction of travel of the substrate. This makes it possible to leave uncoated areas 72, 82 directly on the substrate and thus to reduce the number of steps in the process for manufacturing the elementary entities on the cathode and anode sheets. The savings of each elementary entity of the same row R can be common and form a band of savings 82 ′ (cf. FIGS. 13 & 14).

As shown in Figure 15, additional batteries 1000 can be obtained according to the invention and according to this same variant of the invention. These 1000 batteries correspond to 1000 batteries having undergone a rotation of 180 ° around the Z1000 axis which is an axis parallel to the front ZZ direction passing through the C1000 center of the battery. The realization of batteries 1000 and 1000 on the same stack makes it possible to optimize the production efficiency of the batteries while minimizing waste 90

As an alternative not shown, the savings of each elementary entity of a row R _n can be made from a strip of savings common to each elementary entity of the same row R _n , which makes it possible to optimizing the production efficiency of the batteries while avoiding the presence of waste material 90. The central part 4 of the stack of alternating sheets is then entirely used for the manufacture of batteries according to the invention.

Figures 18 to 20 illustrate a further embodiment of the invention. In these figures, the constituent elements similar to those of the first embodiment are assigned the same reference numbers, increased by the number 300.

Battery 1300, illustrated in FIG. 20, differs from that 1000 above, in particular in that it comprises a single elementary cell 400 covered with an encapsulation system 395. This single cell comprises successively, from top to bottom in FIG. 20: an anode current collector substrate 310 an anode layer 320 a separator layer impregnated with an electrolyte 331, which can be replaced by a layer of an electrolyte material as seen above above a cathode layer 350, and a cathode current collector substrate 340.

With reference to this FIG. 18, the various constituents of the cell are first of all placed on top of each other. This architecture is generally obtained by producing a localized deposit on the substrate. Part of the current collector is not covered by the deposit. The current collecting substrates 310 and 340, provided on the opposite end faces F1 F2, are arranged so that their opposite ends protrude from the other layers, on the opposite longitudinal faces F4 F6. Then, as shown in Figure 19, these components are covered by means of the encapsulation system 395. Cutouts are then carried out, along the vertical lines 392 and 393 which are visible in this FIG. 19. As shown in FIG. 20, the aforementioned cuts make it possible to expose the edges 311 and 341 of the respective current collecting substrates 310 and 340. It will be noted that these slices are covered by zones 394 and 396 of the encapsulation system 395, which protrude in the longitudinal direction XX, in the two opposite directions.

Figure 21 illustrates yet another embodiment of the invention. In these figures, the constituent elements similar to those of the first embodiment are assigned the same reference numbers, increased by the number 400. The battery 1400 of this FIG. 21 comprises, like the battery 1000, several elementary cells 500 arranged one after the other. below the others, in the frontal direction ZZ. Unlike this battery 1000, battery 1400 has an encapsulation system 495, which is analogous to that 395 immediately described above. In particular, this system 495 has several projecting zones 494 and 496 in the direction XX. Just as for the battery 1300, these zones 494 and 496 are formed by making cutouts 492 493, materialized by vertical dashed lines in FIG. 21. These cutouts make it possible to expose the slices 411 and 441, belonging to the different substrates. current collectors 410 and 440.

Figures 22 to 24 illustrate a further embodiment of the invention, which is to be compared to that shown in Figures 18 to 20. In these Figures 22 to 24 the constituent elements, similar to those of the embodiment of Figures 18 to 20, are assigned the same reference numbers increased by the number 200.

Similar to battery 1300, battery 1500 illustrated in FIG. 24 comprises a single elementary cell 600, covered with an encapsulation system 595. This single cell comprises successively, from top to bottom in FIG. 24: a substrate anode current collector 510 an anode layer 520 a separator layer impregnated with an electrolyte 531, which can be replaced by a layer of an electrolyte material as seen above - a cathode layer 550, and a cathode current collector substrate 540.

However, the battery 1500 differs from that 1300, first of all in that the current collecting substrates 510 and 540 do not protrude in the longitudinal direction XX, relative to the other layers. Furthermore, this battery 1500 is equipped with two additional components, namely electrical connection members 560 and 570, provided on the opposite end faces of the cell 600. These connection members, which are in particular mutually identical, each have a thickness typically less than 300 μm, preferably less than 100 μm.

Each connection member is advantageously made of an electrically conductive material, in particular a metallic material. These are in particular aluminum, copper, or even stainless steel. In order to improve their weldability property, these materials can be coated with a thin layer of gold, nickel or tin.

We will now describe the means of securing between, on the one hand the connection member 560 and the current collector 510 and, on the other hand, the connection member 570 and the current collector 540. These securing means are typically formed by a conductive glue, in particular a graphite glue, or else an glue loaded with metallic nanoparticles of copper or aluminum. This layer of conductive adhesive, which is not shown in Figure 24, has a typical thickness of 0.1 micrometers to a few micrometers. As a variant, provision can be made to replace this layer of conductive adhesive with a solder.

As shown in FIG. 22, each connection member 560 570 is placed on its respective collecting substrate 510 540 in an offset manner, in the longitudinal direction. More precisely, the first ends of these connection members define tongues 562 572, projecting in two opposite directions with respect to the longitudinal faces F4 and F6 of the cell. Furthermore, at their end opposite to these tabs, each connection member is set back relative to the cell, so as to define a respective shoulder 564 574. This arrangement, which constitutes an advantageous option, makes it possible to visually distinguish between them better. connecting members with respect to other layers. Then the cell 600, equipped with connection members, is covered by means of the encapsulation system. As shown in FIG. 23, the longitudinal and lateral faces of the cell are first of all covered, as well as the shoulders 564 and 574, by means of a partial encapsulation system 595 ′. Then, with reference to FIG. 24, the front faces of the connection members are covered in order to form the final encapsulation system 595. Finally, cuts are made, which are not shown but are similar to those 392 393 of the FIG. 19. This makes it possible to expose the sections 566 and 576 of the connection members. In the present example, the encapsulation system is reported in two successive steps, it being understood that a single step can be provided. Figure 25 illustrates a variant of the embodiment of Figures 22 to 24. In this Figure 25 the constituent elements, similar to those of Figures 22 to 24, are assigned the same reference numbers increased by the number 100. As seen below- above, the electrical connection members 560 and 570 protrude from the cell, in the two opposite directions of the longitudinal direction. On the other hand, the electrical connection members 660 and 670 of the battery 1600, illustrated in FIG. 25, both protrude in the same direction, namely to the right in this figure.

The embodiments of Figures 18 to 20, as well as 22 to 25, have specific advantages. Indeed, they relate to "single cell" type batteries which are well suited to certain applications requiring a high energy density. Moreover, such an architecture easily lends itself to encapsulation operations. Finally, the embodiments of Figures 22 to 25, relating to the use of electrical connection members, also have specific advantages. This avoids having to make localized deposits on the substrate, so that this current-collecting substrate can be coated over its entire surface with electrode material. As the lateral offset is achieved at the level of the connection members, it is no longer necessary to make localized deposits on the current collectors, as is the case in particular in the embodiment of Figures 18, 19 and 20.

With reference to these embodiments of FIGS. 22 to 25, the invention also relates to a battery (1500) comprising a stack formed by at least one elementary cell, in particular by a single elementary cell (600), each elementary cell successively comprising a anode current collector substrate (510), an anode layer (520), at least one layer of an electrolyte material (530) and / or at least one layer of separator impregnated with an electrolyte (531), a cathode layer (550) and a cathode current collector substrate (540), said stack and said battery having six faces, namely two so-called front faces (F1, F2) mutually opposite, generally parallel to said layers as well as to said current collecting substrates - two mutually opposed so-called longitudinal faces (F4, F6), comprising respectively anodic and cathodic connection zones two mutually opposed so-called lateral faces the battery being charac terized in that it further comprises two electrical connection members (560,570), provided on the opposite end faces of the stack, a first end (562,572) of each electrical connection member projecting, in the longitudinal direction (XX), beyond a respective longitudinal face (F4, F6) of the stack.

According to other characteristics of this battery in accordance with this additional object of the invention: the first end (562) of a connection member (560) projects in a first direction, beyond a first longitudinal face ( F4), while the first end (572) of the other connection member (570) protrudes, in the opposite direction, at the level of the other longitudinal face (F6). the first end (662, 672) of the two connection members (660, 670) protrudes in the same direction, beyond the same longitudinal face (F4). each electrical connection member is secured to a respective current collector substrate, in particular by means of a conductive adhesive. none of the current-collecting substrates, as well as the anode, cathode and separator layers, protrude beyond the longitudinal faces of the stack. - Opposite the projecting end, each electrical connection member defines a shoulder (564, 574) with said stack.

The process according to the invention is particularly suitable for the manufacture of fully solid batteries, i.e. batteries whose electrodes and electrolyte are solid and do not include a liquid phase, even impregnated in the solid phase. The method according to the invention is particularly suitable for the manufacture of batteries considered to be quasi-solid comprising at least one separator 31 impregnated with an electrolyte. The separator is preferably a porous inorganic layer having: a porosity, preferably a mesoporous porosity, greater than 30%, preferably between 35% and 50%, and even more preferably between 40

% and 50%, pores with an average diameter D50 less than 50 nm.

The thickness of the separator is advantageously less than 10 μm, and preferably between 2.5 μm and 4.5 μm, so as to reduce the final thickness of the battery without reducing its properties. The pores of the separator are impregnated with an electrolyte, preferably, by a phase carrying lithium ions such as liquid electrolytes or an ionic liquid containing lithium salts. The “nanoconfined” or “nanopiégé” liquid in the porosities, and in particular in the mesoporosities, can no longer come out. It is linked by a phenomenon called here "absorption in the mesoporous structure" (which does not seem to have been described in the literature in the context of lithium ion batteries) and it can no longer come out even when the cell is switched on. under a vacuum. The battery is then considered to be quasi-solid.

The battery according to the invention can be a lithium ion microbattery, a lithium ion mini battery, or even a high power lithium ion battery. In particular, it can be designed and dimensioned so as to have a capacity less than or equal to approximately 1 mA h (commonly called a “microbattery”), so as to have a power greater than approximately 1 mA h up to approximately 1 A h ( commonly referred to as a “mini-battery”), or even so as to have a capacity greater than approximately 1 A h (commonly referred to as a “power battery”). Typically, microbatteries are designed to be compatible with microelectronics manufacturing processes.

The batteries of each of these three power ranges can be realized:

- either with "all solid" type layers, i.e. devoid of impregnated liquid or pasty phases (said liquid or pasty phases possibly being a conductive medium of lithium ions, capable of acting as an electrolyte),

- either with mesoporous “all solid” type layers, impregnated with a liquid or pasty phase, typically a conductive medium of lithium ions, which spontaneously enters the interior of the layer and which no longer emerges from this layer, so that this layer can be considered as quasi-solid,

- or with impregnated porous layers (i.e. layers having a network of open pores which can be impregnated with a liquid or pasty phase, and which gives these layers wet properties).

Claims

1. Battery (1000) comprising at least one elementary cell (100), each elementary cell (100) successively comprises an anode current collector substrate (10), an anode layer (20), at least one layer of a electrolyte material (30) and / or at least a separator layer impregnated with an electrolyte (31), a cathode layer (50), and a cathodic current collector substrate (40), knowing that in the case where said battery comprises a plurality of elementary cells (100, 100 ', 100 ”), said elementary cells (100, 100', 100”) are arranged one below the other, namely superimposed in a frontal direction (ZZ) at the main plane of the battery, so that, preferably: o the anode current collector substrate (10) is the anode current collector substrate (10) of two adjacent elementary cells (100, 100 ', 100 ”), and in that the cathode current collector substrate (40) is the ac current collector substrate thodic (40) of two adjacent elementary cells (100, 100 ', 100 ”), said at least elementary cell or said elementary cells (100, 100', 100”) define a stack (I), said stack (I) and said battery having six faces, namely

- two so-called front faces (F1, F2) mutually opposite, in particular mutually parallel, generally parallel to the anode current collector substrate (s) (10), to the anode layer (s) (20) , to the layer (s) of an electrolyte material (30) or to the separator layer (s) impregnated with an electrolyte (31), to the cathode layer (s) ( 50), and to the cathodic current collector substrate (s) (40),

- two so-called lateral faces (F3, F5) mutually opposite, in particular mutually parallel,

- and two so-called longitudinal faces (F4, F6), mutually opposite, in particular mutually parallel, it being understood that the first longitudinal face (F6) of the battery comprises at least one anode connection zone (1002) and that a second face longitudinal (F4) of the battery comprises at least one cathodic connection zone (1006), said anodic (1002) and cathodic (1006) connection zones being laterally opposed, characterized in that

- in a first longitudinal direction (XX ') of the battery, each anode current collector substrate (10) protrudes with respect to both each anode layer (20) and each layer of electrolyte material (30 ) or separator layer impregnated with an electrolyte (31), to each cathode layer (50) as well as to each cathode current collector substrate layer (40), and

- in a second longitudinal direction (XX ”) of the battery, opposite to said first longitudinal direction (XX '), each cathodic current collector substrate (40) protrudes with respect to both each anode layer (20), to each layer of electrolyte material (30) or separator layer impregnated with an electrolyte (31), to each cathode layer (50) as well as to each layer of anode current collector substrate (10).

2. Battery according to claim 1, characterized in that each anode current collector substrate (10) protrudes relative to a first end plane (DY _a ), this first plane being defined by the first longitudinal ends of each layer. anode, each electrolyte material layer or separator layer, each cathode layer as well as each cathode current collector substrate layer.

3. Battery according to claim 1 or 2, characterized in that each cathode current collector substrate (40) protrudes relative to a second end plane (DY ' _a ), this second plane being defined by the second longitudinal ends. each anode layer, each electrolyte material layer or separator layer, each cathode layer as well as each anode current collector substrate layer.

4. Battery according to one of claims 1 to 3, characterized in that it comprises an encapsulation system at least partially covering the outer periphery of the stack (I), said encapsulation system comprising at least one waterproof covering layer, having a water vapor permeance (WVTR) of less than 10 ⁵ g / m ² .d, this encapsulation system being in direct contact at least with said layer of electrolyte material (30) and / or with said separator layer impregnated with an electrolyte (31), at each longitudinal face (F4, F6).

5. Battery according to the preceding claim, characterized in that the encapsulation system is in direct contact, at each longitudinal face (F4, F6), also with the anode layer, the cathode layer, as well as the current collector substrate that does not protrude.

6. Battery according to one of claims 4 or 5, characterized in that the encapsulation system is electrically insulating, the conductivity of this encapsulation system being advantageously less than 10 ^{e 11} S.nr ¹ , in particular less than 10 ^{e 12} S. nr ¹ .

7. Battery according to one of claims 4 to 6, characterized in that said encapsulation system (95) covers the front faces of the stack (F1, F2), the side faces (F3, F5) and at least in part the longitudinal faces (F4, F6) so that

- only each anode edge (1002 ') of each anode current collector substrate (10) projecting with respect to both each anode layer (20), each layer of electrolyte material (30) or layer of separator (31), at each cathode layer (50) as well as at each cathodic current collector substrate layer (40) along the first longitudinal direction (XX ') of the battery, is flush with a first longitudinal face (F6), and that - only each cathode edge (1006 ') of each cathode current collector substrate (40) projecting with respect to both each anode layer (20), each layer of electrolyte material (30) or separator layer (31), at each cathode layer (50) as well as at each layer of anode current collector substrate (20) along the second longitudinal direction (XX ”) of the battery, is flush with a second longitudinal face (F4 ), said second longitudinal face (F4) preferably being opposite and parallel to the first fac e longitudinal (F6), it being understood that each anode edge (1002 ’) defines an anode connection area (1002) and that each cathode edge (1006’) defines a cathode connection area (1006).

8. Battery according to one of claims 4 to 7, characterized in that the encapsulation system (95) comprises:

- optionally, a first covering layer, preferably chosen from parylene, type F parylene, polyimide, epoxy resins, silicone, polyamide, sol-gel silica, organic silica and / or a mixture of these, deposited on at least part of the outer periphery of the stack (I),

- optionally a second covering layer composed of an electrically insulating material deposited by deposition of atomic layers, on at least partly the outer periphery of the stack (I), or on the first covering layer,

- at least a third waterproof covering layer, preferably having a water vapor permeance (WVTR) of less than 10 ⁵ g / m ² .d, this third covering layer being composed of a ceramic material and / or a low-melting point glass, preferably a glass whose melting point is less than 600 ° C, deposited on at least part of the outer periphery of the stack (I), or on the first layer covering, it being understood that when said second covering layer is present, a succession of said second covering layer and said third covering layer can be repeated z times with z ³ 1 and deposited at the outer periphery of at least the third cover layer, and the last layer of the encapsulation system being a waterproof cover layer, preferably having a water vapor permeance (WVTR) of less than 10 ^-5 g / m ² .d and being composed of d 'a ceramic material and / or glass with low po merge int.

9. Battery according to any one of the preceding claims, characterized in that at least the anode connection zone (1002), preferably the first longitudinal face (F6) comprising at least the anode connection zone (1002), is covered by an anodic contact member (97 '), and in that at least the cathodic connection zone (1006), preferably the second longitudinal face (F4) comprising at least the cathodic connection zone (1006), is covered by a cathodic contact member (97 ”), it being understood that said anodic (97 ') and cathodic (97”) contact members are able to ensure electrical contact between the stack (I) and an external conductive element.

10. Battery according to the preceding claim, characterized in that each of the anode (97 ') and cathode (97 ”) contact members comprises: - a first electrical connection layer, arranged on at least the anode connection zone (1002) and at least the cathode connection zone (1006), preferably on the first longitudinal face (F6) comprising at least the cathode connection zone (1002) and on the second longitudinal face (F4) comprising at least the cathodic connection zone (1006), this first layer comprising a material loaded with electrically conductive particles, preferably a polymeric resin and / or a material obtained by a process sol-gel, charged with electrically conductive particles and even more preferably a polymeric resin charged with graphite,

11. Battery according to any one of the preceding claims, characterized in that the smallest distance (Dca) between the first longitudinal face (F6) comprising at least one anode connection zone (1002) and the first end plane ( DY _a ) defined by the first longitudinal ends of each anode layer (20), of each layer of electrolyte material (30) and / or separator layer (31), of each cathode layer (50) as well as of each cathode current collector substrate layer (40) is between 0.01 mm and 0.5 mm, and / or in that the smallest distance (Dec) between the second longitudinal face (F4) comprising at least one cathodic connection area (1006) and the second end plane (DY ' _a ) defined by the second longitudinal ends of each anode layer (20), of each layer of electrolyte material (30) and / or layer separator (31), each cathode layer (50) as well as each collecting substrate layer. r of anode current (10) is between 0.01 mm and 0.5 mm.

12. A method of manufacturing at least one battery (1000), each battery comprising at least one elementary cell (100), each elementary cell (100) successively comprises an anode current collector substrate (10), an anode layer. (20), at least one layer of an electrolyte material (30) and / or at least one layer of a separator (31) impregnated with a electrolyte, a cathode layer (50), and a cathodic current collector substrate (40), knowing that in the case where said battery (1000) comprises a plurality of elementary cells (100, 100 ', 100 ”), said cells elements (100, 100 ', 100 ”) are arranged one below the other, namely superimposed in a frontal direction (ZZ) on the main plane of the battery, so that, preferably: o the current collector substrate anode (10) is the anode current collector substrate (10) of two adjacent elementary cells (100, 100 '), and in that o the cathode current collector substrate (40) is the cathode current collector substrate (40) of two adjacent elementary cells (100, 100 '), said at least elementary cell (100) or said elementary cells (100, 100', 100 ”) define a stack (I), said stack (I) and said battery (1000 ) having six faces, namely,

- two so-called front faces (F1, F2) mutually opposite, in particular mutually parallel, generally parallel to the anode current collector substrate (s) (10), to the anode layer (s) (20) , to the layer (s) of an electrolyte material (30) or to the separator layer (s) (31) impregnated with an electrolyte, to the cathode layer (s) ( 50), and to the cathodic current collector substrate (s) (40), - two so-called lateral faces (F3, F5) mutually opposite, in particular mutually parallel,

- and two so-called longitudinal faces (F4, F6), mutually opposite, in particular mutually parallel, it being understood that the first longitudinal face (F6) of the battery comprises at least one anode connection zone (1002) and that a second face longitudinal (F4) of the battery comprises at least one cathodic connection zone (1006), said anodic (1002) and cathodic (1006) connection zones being laterally opposed, so that - in a first longitudinal direction (XX ') of battery, each anode current collector substrate (10) protrudes from both each anode layer (20), each layer of electrolyte material (30) or separator layer (31) impregnated with an electrolyte, to each cathode layer (50) as well as to each cathode current collector substrate layer (40), and according to a second longitudinal direction (XX ”) of the battery, opposite to said first longitudinal direction (XX '), each cathodic current collector substrate (40) protrudes with respect to both each anode layer (20), to each layer of electrolyte material (30) or separator layer (31) impregnated with an electrolyte, to each cathode layer (50) as well as to each anode current collector substrate layer (10), said method of manufacturing including:

(i) supplying at least one sheet of anode current collector substrate (10) having slits (80), uncoated areas (82) and areas coated (81) with an anode layer ( 20), optionally coated with a layer of an electrolyte material (30) or a separator layer (31), hereinafter called anode sheet (2e),

(ii) supplying at least one sheet of cathode current collector substrate (40) having slits (70), uncoated areas (72) and areas coated (71) with a cathode layer (50). ), optionally coated with a layer of an electrolyte material (30) or with a separator layer (31), hereinafter called cathode sheet (5e),

(iii) producing an alternate stack (I) of at least one anode sheet (2e) having slits (80), uncoated areas (82) and coated areas (81) and at least one cathode sheet (5e) having slits (70), uncoated areas (72) and coated areas (71), so as to obtain at least one elementary cell comprising successively an anode current collecting substrate (10), a layer anode (20), at least one layer of an electrolyte (30) or separator (31) material, a cathode layer (50), and a cathode current collector substrate (40), and so that in the first longitudinal direction (XX ') of the battery, each anode current collector substrate (10) protrudes with respect to both each anode layer (20) and each layer of material electrolyte (30) and / or separator layer (31), to each cathode layer (50) as well as to each cathode current collector substrate layer (40), and o according to the second longitudinal direction (XX ”) of the battery, opposite to said first longitudinal direction (XX '), each cathodic current collector substrate (40) protrudes with respect to both each anode layer (20), to each layer of electrolyte material (31) and / or separator layer (31), to each cathode layer (50) as well as each anode current collector substrate layer (10),

(iv) carrying out a heat treatment and / or mechanical compression of the stack (I) of alternating sheets obtained in step (iii), so as to form a consolidated stack,

(v) optionally, making a first pair of cuts (DXn, DX'n) making it possible to separate a given row (L _n ) of batteries (1000) from at least one other row (L _n -i, L _{n + i} ) of batteries (1000) formed from said consolidated stack, (vi) optionally, the impregnation of the consolidated stack obtained in step (iv) or the impregnation of the line ( L _n ) of batteries (1000) obtained in step (v) when step (v) is carried out, by a phase carrying lithium ions such as liquid electrolytes or an ionic liquid containing lithium salts, so that said separator layer (31) is impregnated with an electrolyte, (vii) making a second pair of cutouts (DYn, DY'n) making it possible to expose

• the anode edge (1002 ') of each anode current collector substrate (10) protruding from both each anode layer (20), each layer of electrolyte material (30) or separator layer (31), to each cathode layer (50) as well as to each cathode current collector substrate layer (40) along the first longitudinal direction (XX ') of the battery, each anode edge (1002') defining at least an anode connection zone (1002), and

• the cathode edge (1006 ’) of each cathode current collector substrate (40) protruding from both each anode layer

(20), to each layer of electrolyte material (30) or separator layer (31), to each cathode layer (50) as well as to each layer of anode current collector substrate (10) in the second direction longitudinal (XX ”) of the battery, each cathode edge (1006 ') defining at least one cathodic connection zone (1006), said second pair of cutouts (DYn, DY'n) allowing, when step (v) is carried out, to separate a given battery vis-à-vis at least one other battery formed from the line (L _n ) of batteries (1000).

13. Method according to the preceding claim, characterized in that one carries out, after step (vi) if it is carried out, or if step (vi) is not carried out, after step (v) if step (v) is performed, or if steps (vi) and (v) are not performed, after step (iv), and before step (vii), an encapsulation step (viii) of the consolidated stack or of the line (L _n ) of batteries (1000), preferably in which the outer periphery of the stack (I ) or of the row (L _n ) of batteries (1000), preferably the front faces of the stack (F1, F2) or of the row (L _n ) of batteries (FF1, FF2), the side faces ( F3, F5, FF3, FF5) and at least partly the longitudinal faces (F4, F6, FF4, FF6) so that o only each anode edge (1002 ') of each anode current collector substrate (10) protruding through to each layer of anode (20), to each layer of material iau electrolyte (30) or separator layer (31), to each cathode layer (50) as well as to each cathode current collector substrate layer (40) along the first longitudinal direction (XX ') of the battery , is flush with a first longitudinal face (F6, FF6), and that o only each cathode edge (1006 ') of each cathode current collector substrate (40) protruding from both each anode layer (20), to each layer of electrolyte material (30) or separator layer (31), to each cathode layer (50) as well as to each anode current collector substrate layer (10) along the second longitudinal direction (XX ” ) of the battery, is flush with a second longitudinal face (F4, FF4), said second longitudinal face (F4, FF4) preferably being opposite and parallel to the first longitudinal face (F6, FF6), it being understood that each anode edge (1002 ') defines an anode connection zone (1002) and that each cathode edge (1006') defines u n cathodic connection area (1006); said encapsulation system (95) preferably comprising

- optionally, 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 of these, deposited on at least in part the outer periphery of the stack (I) or of the row (L _n ) of batteries (1000), - optionally a second covering layer composed of an electrically insulating material deposited by deposition of atomic layers,

- on at least partly the outer periphery of the stack (I) or of the row (L _n ) of batteries (1000) - or on the first covering layer, and

- at least a third waterproof covering layer, preferably having a water vapor permeance (WVTR) of less than 10 ⁵ g / m ² .d, this third covering layer being composed of a ceramic material and / or a low-melting point glass, preferably a glass whose melting point is less than 600 ° C, deposited on at least part of the outer periphery of the stack (I) or of the line (L _n ) batteries (1000), or the first cover layer, it being understood that a sequence of at least a second cover layer and at least a third cover layer can be repeated z times with z ³ 1 and deposited at the outer periphery of at least the third cover layer, and that the last layer of the encapsulation system is a tight cover layer, preferably having a water vapor permeance (WVTR) of less than 10 ⁵ g / m ² .d and being composed of a ceramic material and / or a low melting point glass not.

14. Method according to any one of claims 12 or 13, characterized in that after step (vii), at least the anode connection zone (1002) is covered, preferably at least the first longitudinal face (F6). ) comprising at least the anode connection zone (1002), by an anode contact member (97 '), capable of ensuring electrical contact between the stack (I) and an external conductive element, and in that one covers at least the cathodic connection zone (1006), preferably at least the second longitudinal face (F4) comprising at least the cathodic connection zone (1006), by a cathodic contact member (97 ”), capable of ensuring contact electrical connection between the stack (I) and an external conductive element, said embodiment of anodic (97 ') and cathodic (97 ”) contact members comprising:

- the deposition on at least the anode connection zone (1002) and on at least the cathode connection zone (1006), preferably, on at least the first longitudinal face (F6) comprising at least the anode connection zone (1002), and on at least the second longitudinal face (F4) comprising at least the cathodic connection zone (1006), of a first electrical connection layer of material charged with electrically conductive particles, said first layer preferably being formed 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 of a material obtained by a sol-gel process loaded with electrically conductive particles, a drying step followed by a step of polymerization of said polymeric 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 comprising a metal foil arranged on the first electrical connection layer, - optionally, the deposition on the second electrical connection layer, of a third connection layer electric comprising a conductive ink.

15. Method according to any one of claims 12 to 14, characterized in that the cuts made in step (v) when this step is performed, and / or in step (vii), are performed by laser ablation. , preferably in that all the cuts made in step (v) when this step is performed, and / or in step (vii) are performed by laser.

16. Battery (1500) comprising a stack formed by at least one elementary cell, in particular by a single elementary cell (600), each elementary cell successively comprising an anode current collector substrate (510), an anode layer (520). , at least one layer of an electrolyte material (530) and / or at least one layer of electrolyte impregnated separator (531), a cathode layer (550) and a cathode current collector substrate (540) , said stack and said battery having six faces, namely

• two so-called front faces (F1, F2) mutually opposite, generally parallel to said layers as well as to said current collecting substrates

• two so-called longitudinal faces (F4, F6) mutually opposite, comprising respectively anodic and cathodic connection zones · two mutually opposed so-called lateral faces • the battery being characterized in that it further comprises two electrical connection members (560,570), provided on the opposite end faces of the stack, a first end (562,572) of each protruding electrical connection member, according to the longitudinal direction (XX), beyond a respective longitudinal face (F4, F6) of the stack.

17. Battery according to the preceding claim, characterized in that the first end (562) of a connection member (560) projects in a first direction, beyond a first longitudinal face (F4), while the first end (572) of the other connection member (570) protrudes, in the opposite direction, at the level of the other longitudinal face (F6).

18. Battery according to claim 16, characterized in that the first end (662, 672) of the two connection members (660, 670) projects in the same direction, beyond the same longitudinal face (F4).

19. Battery according to one of claims 16 to 18, characterized in that each electrical connection member is secured to a respective current collector substrate, in particular by means of a conductive adhesive.

20. Battery according to one of claims 16 to 19, characterized in that none of the current collecting substrates, as well as the anode, cathode and separator layers, protrudes beyond the longitudinal faces of stacking.

21. Battery according to one of claims 16 to 20, characterized in that, opposite the projecting end, each electrical connection member defines a shoulder (564, 574) with said stack.