METHOD AND APPARATUS FOR MANUFACTURING A BATTERY CELL

Abstract

Disclosed is a method and an apparatus for assembling battery cells, the method including forming electrode layers in a pasty state on electrically conductive supports, these electrode layers being mixtures of ion-conductive liquid electrolytes, monomer or polymer mixtures, and initiators of polymerisation or cross-linking of the monomer or polymer mixtures, the electrode layers being exposed to a radiation initiating their solidification then placed in contact with a separation layer in the liquid state before completion of their respective solidifications, in such a way as to obtain a solid electrolyte battery cell having properties close to those of liquid electrolyte battery cells.

Claims

1. A manufacturing method for an energy storage cell in electrochemical form, comprising the steps of: forming a first half-cell, comprising the following steps a1), a2), a3): a1) providing a first electrically conducting support; a2) depositing, on a surface of the first electrically conducting support, a cathode layer in a pasty state, comprising an active cathode material, carbonaceous electrically conducting fillers, a first liquid ion conducting electrolyte mixture, a first monomer or polymer mixture and a first polymerization or cross-linking initiator for the first monomer or polymer mixture; and a3) exposing the cathode layer in a pasty state by means of a first radiation suited to the first polymerization or cross-linking initiator for the first monomer mixture, so as to initiate a solidification of the cathode layer; forming a second half-cell, comprising the following steps b1), b2), b3): b1) providing a second electrically conducting support; b2) depositing, on a surface of the second electrically conducting support, an anode layer in a pasty state, comprising an active anode material, carbonaceous electrically conducting fillers, a second liquid ion conducting electrolyte mixture, a second monomer or polymer mixture and a second polymerization or cross-linking initiator for the second monomer or polymer mixture; and b3) exposing the anode layer in a pasty state by means of a second radiation suited to the second polymerization or cross-linking initiator for the second monomer mixture, so as to initiate a solidification of the anode layer; implementing at least one of the following steps a4), b4) and c4): a4) depositing and exposing, on the exposed cathode layer before complete solidification of the exposed cathode layer, a first separation layer formed of a first separation mixture in a liquid state, comprising a first ion conducting separation liquid electrolyte mixture, a first separation monomer or polymer mixture and a first polymerization or cross-linking initiator for the first separation monomer or polymer mixture; and c4) depositing and exposing, on an electrically insulating grid film, a third separation layer formed of a third separation mixture in a liquid state, comprising a third ion conducting separation liquid electrolyte mixture, a third separation monomer or polymer mixture and a third polymerization or cross-linking initiator for the third separation monomer or polymer mixture; b4) depositing and exposing, on the exposed anode layer before complete solidification of the exposed anode layer, a second separation layer formed of a second separation mixture in a liquid state, comprising a second ion conducting separation liquid electrolyte mixture, a second separation monomer or polymer mixture and a second polymerization or cross-linking initiator for the second separation monomer or polymer mixture; and where the exposures for steps a4), b4), and c4) were implemented by means of third radiations, suited for the polymerization or cross-linking initiators for the respective separation monomer or polymer mixtures and suited for initiating solidification of the first, second and third separation layers; assembling the first half-cell and the second half-cell by interposing between the two half-cells, at least one of the separation layers from steps a4), b4) and c4), where the assembly comprises one of the following steps d1), d2), d3) and d4): d1) bringing the exposed first separation layer into direct contact with the exposed second separation layer, d2) bringing the exposed first separation layer into direct contact with the exposed anode layer; and d3) bringing the exposed second separation layer into direct contact with the exposed cathode layer; and d4) enclosing the third exposed separation layer between the exposed cathode layer and the exposed anode layer, in which steps d1), d2), d3) and d4) the respective solidifications of the layers brought into contact are incomplete.

2. The method according to claim 1, comprising: sizing of the thickness of the cathode layer, respectively of the anode layer, before depositing the first separation layer, respectively before depositing the second separation layer; and/or sizing of the thickness of the first separation layer, respectively of the second separation layer before assembling the half-cells.

3. The method according to claim 1, wherein the first support and the second support are respectively a first support strip and a second support strip and wherein: supplying the first support and supplying the second support respectively comprises uncoiling the first support strip and uncoiling the second support strip respectively from a first uncoiling roller and a second uncoiling roller.

4. The method according to claim 1, comprising the steps of: applying electrically insulating film to the first support or the second support after assembling the first half-cell and the second half-cell; and coiling, around the coiling roller, the assembled first half-cell and second half-cell and the electrically insulating film applied to the first support or the second support.

5. The method according to claim 3, wherein depositing the cathode layer, and depositing the anode layer may take place continuously by passage of the first strip and the second strip respectively in front of a first depositing head for the first mixture and a second depositing head for the second mixture.

6. The method according to claim 3, wherein: depositing the first separation layer and depositing the second separation layer take place continuously by passage of the first strip and the second strip respectively in front of a third electrolyte depositing head and in front of a fourth electrolyte depositing head.

7. The method according to claim 3, wherein: exposing the cathode layer and exposing the anode layer take place by passage respectively of the first strip and the second strip respectively in front of at least one first source of radiation and at least one second source of radiation.

8. The method according to claim 3, wherein, exposing the first separation layer and exposing the second separation layer takes place by passage respectively of the first strip and of the second strip in front of a third radiation source and a fourth radiation source.

9. The method according to claim 2, wherein the first support and the second support are respectively a first support strip and a second support strip and wherein: sizing of the thickness of the cathode layer, respectively sizing of the anode layer, takes place by passage of the first support strip, provided with the cathode layer respectively of the second support strip provided with the anode layer through a first pair of sizing rollers and a second pair of sizing rollers.

10. The method according to claim 2, wherein sizing of the thickness of the first separation layer, respectively sizing of the second separation layer, takes place by passage of the first half-cell, respectively of the second half-cell, through a third pair of sizing rollers and a fourth pair of sizing rollers.

11. The method according to claim 1, comprising implementation of steps a4) and b4) and comprising placing an electrically insulating grid separator film between the separation layers during assembly of the first half-cell and the second half-cell.

12. The method according to claim 1, comprising, subsequent to assembly of the half-cells, an operation of formatting the cell comprising cutting of the battery cell into formatted cells.

13. The method according to claim 12, comprising placing a protective coating of electrically insulating material over at least one side edge of the formatted battery cell.

14. The method according to claim 1, wherein the first liquid electrolyte mixture of the cathode layer, the second liquid electrolyte mixture of the anode layer, the first liquid electrolyte mixture of the first separation layer, the second liquid electrolyte mixture of the second separation layer and the third liquid electrolyte mixture of the third separation layer are identical.

15. A method for manufacturing a battery comprising the manufacturing a plurality of battery cells according to the method claim 11, and the formation of a stack of battery cells, where the formation of the stack comprises placing a free conducting surface of the first support of a formatted battery cell into contact with a free conducting surface of the second support of a following formatted battery cell of the stack.

16. An apparatus for manufacturing a battery cell according to claim 1, comprising: a first manufacturing line for manufacturing a first half-cell; a second manufacturing line for manufacturing a second half-cell; a pair of assembly rollers for the assembly of the first half-cell formed on the first manufacturing line and a second half-cell formed on the second manufacturing line; a battery-cell coiling roller placed downstream from the pair of assembly rollers; wherein at least one of the first manufacturing line and the second manufacturing line comprise: an uncoiling roller for uncoiling a support strip; and, in order between the uncoiling roller and the pair of assembly rollers; a first coating module for forming a cathode layer, respectively an anode layer; a first rolling module; a second coating module for forming a separation layer; and a second rolling module, wherein the first and second rolling module comprise respectively a pair of sizing rollers and a thickness sensor associated respectively with the pair of sizing rulers, and wherein the first coating module and the second coating module respectively comprise a depositing head and at least one radiation source associated with the depositing head.

17. The apparatus according to claim 16 wherein the coiling roller is a driving roller.

18. (canceled)

19. The apparatus according to claim 16, wherein the uncoiling roller is a braking roller.

20. (canceled)

21. (canceled)

22. The apparatus according to claim 16, comprising a driver unit for at least one among the coiling roller, the first coating module, the second coating module, the first rolling module and the second rolling module.

23. The apparatus according to claim 16, wherein the depositing head of the first coating module is a cathode layer depositing head, depositing head of the second coding module is an anode layer depositing head; at least one radiation source is associated with the cathode layer depositing head and at least one radiation source is associated with the anode layer depositing head.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0188] FIG. 1 is a schematic representation of various members of the manufacturing apparatus for a cell conforming to the invention. It also indicates the various steps of a manufacturing method for the cell.

[0189] FIG. 2 is a schematic representation of a manufacturing line for a manufacturing apparatus for cells comparable to those from FIG. 1 and shows an organization into modules of the members of the apparatus.

[0190] FIG. 3 is a schematic view along a principal surface of a formatted battery cell manufactured conforming to the invention.

[0191] FIG. 4 is a schematic section of a part of a stack of manufactured formatted cells conforming to the invention and making up a storage battery.

[0192] The figures are shown at arbitrary scale.

DETAILED DESCRIPTION OF THE INVENTION

[0193] In the following description, identical, similar or equivalent parts from different figures are referenced with the same reference sign so as to be able to refer from one figure to another.

[0194] FIG. 1 shows apparatus 100 for manufacturing a battery cell 10 conforming to the invention.

[0195] The apparatus 100 is provided with two manufacturing lines 110a, 110b, comprising the same members and which are intended to simultaneously form two half-cells 10a, 10b. The manufacturing lines 110a, 110b come together in a pair of assembly rollers 142 intended to form a battery cell 10 from half cells 10a, 10b. The two manufacturing lines 110a, 110b are configured for forming respectively a half-cell 10a with a positive electrode (cathode) and a half-cell 10b with a negative electrode (anode).

[0196] However, the choice of forming a half-cell with a positive or negative electrode does not depend on the apparatus but on the materials used, such that the nature of the half-cell made, with a positive or negative electrode, does not depend on the manufacturing line. It would therefore be possible to implement a half-cell with a positive electrode on the second manufacturing line 110b and a cell with a negative electrode of the first manufacturing line 110a.

[0197] Each manufacturing line 110a, 110b comprises an uncoiling roller intended to provide an electrically conducting support serving to collect current from the half-cell in question.

[0198] A first uncoiling roller 112a thus delivers a first support strip 14a and a second uncoiling roller 112b delivers a second support strip 14b. The operation supplying a first support 14a and supplying a second support 14b are symbolically shown by arrows, with references 214a, 214b respectively.

[0199] For simplification, the first support and the second support, and also the strips that form them respectively, are referenced with the same reference signs 14a, 14b. The support strips 14a, 14b are intended to form the current collectors of the battery cell 10. They may be metal films, for example copper, aluminum, stainless steel, nickel, and also conducting polymer films, webs of conducting fibers, or may comprise several layers of material providing functions of mechanical strength and electrical conduction. The thickness of the support strips may be of order 10 to 200 μm.

[0200] The strips may be long, for example, several hundreds of meters. It is not limited by the size of the rollers. Further, in the implementation example described, the width of the support strips is 1200 mm. Other widths, larger or smaller may be selected.

[0201] Downstream from the uncoiling rollers 112a, 112b each manufacturing line may comprise a set of return idlers, not shown, serving to control the tension of the support strip 14a, 14b delivered by the roller, and also a thickness sensor 118a, 118b.

[0202] Other conveyor rollers, not shown, may be provided for supporting the support strips along the manufacturing line.

[0203] Conveyor tables, covered with stainless steel or PVC type polymer sheets, may also be provided for supporting the support strips.

[0204] The support strips 14a, 14b respectively join a first depositing head 120a and a second depositing head 120b respectively of the first and second manufacturing line.

[0205] These depositing heads are respectively supplied with a first mixture comprising a cathode active material, carbonaceous electrically conducting fillers, an electrolyte in liquid state and with a second mixture comprising an anode active material, carbonaceous electrically conducting fillers and an electrolyte in liquid state.

[0206] Also, as the first support strip 14a passes in front of the first depositing head 120a and the second support strip 14b passes in front of the second depositing head 120b, a first layer of first mixture comprising the cathode active material is deposited in step on the first support strip 14a: this is the cathode layer 16a.

[0207] In the same way, a second layer of second mixture comprising the anode active material is deposited in step on the second support strip 14b: this is the anode layer 16b. The layers are not shown in detail in FIG. 1, but can be seen on FIG. 4.

[0208] It can be noted that a return idler for strip 122a, 122b faces respectively each depositing head 120a, 120b so as to guarantee a good hold of the support strip 14a, 14b at the time of coating thereof.

[0209] The first mixture and the second mixture, which form the cathode and anode layers, leave the depositing heads with a pasty consistency. In addition to active material and possible carbonaceous electrically conducting fillers previously mentioned, they each comprise a liquid state electrolyte which could be solidified.

[0210] The thickness of the cathode layer and the thickness of the anode layer may be of order 50 to 300 μm.

[0211] Operations of depositing the cathode layer and the anode layer are symbolically indicated by arrows 220a, 220b. The depositing may be done over the full width of the support strips. However, in the example described, the depositing is limited to a width of 1160 mm, while leaving the edges of the strips 14a, 14b free.

[0212] In this way, a possible risk of overflow of liquid mixture onto the lateral edges of the strips can be avoided.

[0213] On both sides of the first depositing head 120a, first UV radiation sources 124a are found in order to apply radiation to the cathode layer 16a in order to initiate solidification of this layer. In the implementation example from FIG. 1, it involves separated radiation sources with which to expose both surfaces the cathode layer 16a.

[0214] The solidification of the layers 16a is due to the solidification of the solidifiable liquid electrolyte that it contains. The electrolyte is in fact provided with a photoinitiator compatible with the radiation from the first radiation sources 124a.

[0215] Similarly, on the second manufacturing line 110b second UV radiation sources 124b are arranged on both sides of the second depositing head 120b in order to initiate solidification of the anode layer 16b.

[0216] Operations of exposing cathode layer 16a and anode layer 16b to radiation initiating solidification thereof are indicated by arrows 224a and 224b.

[0217] Interestingly, in the implementation example described, it may be noted that the irradiation of the layers takes place at the same moment as depositing thereof onto the support strips or immediately after this deposit.

[0218] Exposure after depositing is also conceivable, but it does not allow exposure on both surfaces of the deposited layers.

[0219] After these operations, the strips from the two manufacturing lines 110a, 110b pass respectively between a first pair of sizing rollers 126a and a second pair of sizing rollers 126b.

[0220] Strips provided with the layer thereof containing the active electrode material, meaning respectively the cathode layer and the anode layer, undergo calendering aiming to size the thickness of the mixture layers and avoid porosities.

[0221] The thickness of the sheets provided with the electrode layer thereof is measured at the output from the sizing rollers by means of thickness sensors 128a, 128b. The thickness sensors are, for example, triangulated light beam sensors.

[0222] By differentiation of the measurements made with the thickness sensors 128a, 128b at the outlet of the sizing rollers and the measurements made by the thickness sensors 118a, 118b at the outlet of the uncoiling rollers 112a, 112b, it is possible to know the thickness of the mixture layers.

[0223] This thickness may be compared to a preplanned thickness in order to perform a control coupled to the separation of the pairs of sizing rollers 126a, 126b and the depositing heads 120a, 120b.

[0224] The thickness of the layer forming the positive electrode (cathode) and also the thickness of the layer forming the negative electrode may be included between 60 and 300 μm.

[0225] Operations of calibrating the thickness of the cathode layer 16a and the anode layer 16b are indicated by the arrows 226a, 226b.

[0226] After this first thickness sizing, the support strips 14a, 14b provided with cathode 16a and anode 16b layers comprising active electrode material, pass respectively in front of a third depositing head 130a and a fourth depositing head 130b. The third depositing head 130a is part of the first manufacturing line 110a fourth depositing head 130b is part of the second manufacturing line 110b. These depositing heads respectively deposit a first separation layer 18a in the form of an electrolyte without active material onto the cathode layer 16a of the first support strip 14a and a second separation layer 18b in the form of an electrolyte without active material onto the anode layer 16b of the second support strip 14b.

[0227] Operations of depositing the separation layers 18a and 18b, formed of electrolyte, are respectively indicated by the arrows 230a, 230b. The electrolyte is deposited in liquid form, preferably over an area equal to that of the cathode layer 16a and the anode layer 16b. A single solidifiable liquid electrolyte may be used for the depositing of the separation layers 18a, 18b on both manufacturing lines 110a, 110b. It may involve in particular solidifiable liquid electrolyte entering in the composition of the underlying cathode layer 16a and anode layer 16b. The electrolyte contains a photoinitiator with which to initiate the solidification of the electrolyte under the effect of light radiation. It may be ultraviolet, visible or near infrared radiation, for example.

[0228] The thickness of the electrolyte layers without active material is, for example, of order 10 to 60 μm.

[0229] The distance between the first and third depositing head on the one hand, and the distance between the second and fourth depositing head on the other hand, is sufficiently short, and the passage speed of the support strips is sufficiently high for depositing separation layers 18a and 18b before complete solidification of the underlying cathode 16a and anode 16b layers. The solidification of the layers may take place in a few seconds corresponding to a forward motion of the strips along the manufacturing lines 110a, 110b of a few meters.

[0230] Initiation the solidification of the separation layers 18a, 18b takes place right after depositing thereof, by a new exposure to light radiation. The strips pass in front of a third UV radiation source 134a and a fourth UV radiation source 134b arranged respectively after the third and fourth depositing head 130a, 130b.

[0231] Exposing the separation layers 18a, 18b is indicated by the arrows 234a, 234b. The effect of this exposure is to initiate solidification of the separation layers 18a, 18b.

[0232] At the outcome of these operations, the first support strip 14a and the second support strip 14b, provided with the aforementioned layers, again pass by sizing rollers. More precisely it involves a third pair of sizing rollers 136a and a fourth pair of sizing rollers 136b, respectively.

[0233] Just like the first and second pair of sizing rollers, the third pair of sizing rollers and the fourth pair of sizing rollers are followed by thickness sensors 138a, 138b. The measurements from these thickness sensors compared to the measurements from the sensors 128a, 128b associated with the first and second sizing rollers serve to set the thickness of the separation layers 18a and 18b and to adjust the separation of the sizing rollers as needed.

[0234] Operations of sizing the thickness of the separation layers 18a, 18b are indicated by the arrows 236a and 236b respectively. The final thickness may be included, for example between 10 and 60 μm. Preferably, it may be 30 μm.

[0235] After the sizing, the support strips 14a, 14b, respectively provided with layers 16a, 16b comprising active electrode material and separation layers 18a, 18b form half-cells 10a, 10b.

[0236] After this operation, the half-cells 10a, 10b in strips reach the pair of assembly rollers 142, already discussed. The half-cells are assembled by placing the respective separation layers 18a, 18b thereof into contact. The assembly may be a direct assembly or an assembly accompanied by interposition of a layer of an additional electrically insulating grid separator film 20, coming from an uncoiling roller 112c. It may involve, for example, a grid of electrically insulating polymer wire. The operation for assembly of the half-cells is indicated with an arrow 242. The interposition of the film 20 must not prevent direct contact between the separation layers 18a and 18b in order to assure a good contact interface between these layers.

[0237] Optionally, it is possible to proceed with an operation of depositing a separation layer 18c on the electrically insulating separator film 20, as indicated by the arrow 230c. The electrolyte is deposited in liquid form by a fifth depositing head 130c on the film 20 while passing in front of the fifth depositing head, preferably over a width equal to that of the electrically insulating grid separator film 20 and so as to fully soak the latter. The same liquid electrolyte may be used as for depositing the separation layers 18a, 18b and similarly to the operations these layers underwent, and an initiation of the solidification of the film 20 takes place right after depositing thereof, by exposure to light radiation. The film 20 passes in front of a fifth UV radiation source 134c arranged after the fifth depositing head 130c, in order to be exposed to radiation during an exposure operation indicated by the arrow 234c.

[0238] The distance separating the assembly rollers 142 respectively from the third, fourth and fifth radiation sources is sufficiently small and the passage speed of the strips is sufficiently high, that the assembly of the half-cells takes place before complete solidification of the separation layers 18a, 18b and possibly 18c. In that way the solidification continues for several moments after assembly of the cells.

[0239] It should be noted that the separation layers 18a, 18b and 18c may each be used alone or in combination with one or another of the two other separation layers. Thus, two layers 18a and 18b together in direct contact, the layers 18a, 18b and 18c alone, the layer 18c in combination with one or the other of the layers 18a and 18b or in combination with both layers 18a and 18b may be used. What is important is to assure both the presence of a separation layer (which could be made up of an arbitrary combination of layers 18a, 18b and 18c) between the cathode 16a and anode 16b layers, and also a close contact between these layers in order to assure a good continuity in the movement of ions between the cathode and anode.

[0240] The separation layers may have the same composition or different compositions, but each comprises a solidifiable liquid electrolyte mixture comprising an ion conducting separation liquid electrolyte, a separation monomer or polymer mixture and a polymerization or cross-linking initiator for the first separation monomer or polymer mixture. As with the cathode and anode layers, the presence of monomer or polymer along with the polymerization or cross-linking initiator for this monomer or this polymer assures the solidifiability of the separation layers.

[0241] A thickness sensor 144 which follows the assembly rollers 142 serves to measure the thickness of the assembled cell and adjust as needed the separation of the assembly rollers 142.

[0242] An electrically insulating film 30 provided by an unwinding roller 160 may be applied to the first support or the second support after assembly of the first half-cell with the second half-cell; and the assembled first half-cell and second half-cell and the electrically insulating film applied to the first support or the second support, so as to insulate themselves from each other, may be coiled around the coiling roller 150. This is particularly advantageous when the batteries are sodium sulfide or lithium sulfide type, since they are electrically charged during manufacturing thereof and it is then preferable to insulate them from each other in order to prevent possible electrical discharges.

[0243] After assembly of the half-cells 10a, 10b, the cell 10 goes by a tool 140 for edge cutting. It involves a tool with rotating blades or laser heads. The cutting, indicated on the figure with an arrow 238, is done on the lateral edges of the cell, so as to set the width thereof. It serves to eliminate lateral edges of the support strips 14a, 14b which might not have received active electrode material, and/or electrolyte, in order to only keep a central part where the cell is complete and free of rough edges.

[0244] The cell 10, now assembled, is finally coiled on a coiling roller 150. The coiling roller 150 has several functions. A first function is to coil the assembled battery cell. Another function is a driving function. In fact, the rotation of the coiling roller 150 has the effect of exerting traction on the assembled battery cell and consequently on the half-cells, on the support strips and, as applicable, on the electrically insulating grid separator film 20. Thus, the forward motion of the on-strip components along manufacturing lines is assured by rotating the coiling roller.

[0245] The uncoiling rollers may be driven and/or braked rollers, or freely rotating rollers. In the case of freely rotating rollers, the uncoiling simply results from the traction exerted by the driving coiling roller 150. When the uncoiling rollers are braked or driven, the braking or driving may be bound to the rotation of the driving coiling roller 150 so as to adjust the tension of the support strips and on-strip components passing along the manufacturing lines.

[0246] A driver unit 101 for the apparatus may be provided for coordinating various parameters such as the coiling speed, the tension of the support strips, but also the coating of the support strips or the calendering operations previously described. The driver unit thus controls at least one among the coiling roller, the first coating module, the second coating module, the first rolling module and the second rolling module.

[0247] The driver unit controls for example, the driving coiling roller 150 by acting on a speed setting for the drive motor M thereof.

[0248] Thus, during a step 248 indicated by an arrow on FIG. 1, the driver unit 101 controls the passage speed of the support strips by the control of the coiling speed of the driving coiling roller 150, and therefore controls the time interval separating the application of two consecutive operations of the manufacturing method at given locations of the support strips.

[0249] By controlling the time interval separating (i) the exposures of two liquid layers to radiation initiating solidification of these layers, and (ii) bringing these two layers into contact, a liquid interface between these two layers can be assured with placement thereof into contact occurring before complete respective solidification thereof.

[0250] In particular, during step 248 the following steps can be implemented by means of the driver unit 101: [0251] d1) placing the first separation layer (18a) into direct contact with the second separation layer (18b) and controlling (248): a first time interval separating (i) exposing the cathode layer in step a3) and (ii) depositing the first separation layer in step a4), such that the solidification of the cathode layer is not complete at the moment of depositing the first separation layer, and a second time interval separating (i) exposing the anode layer in step b3), and (ii) depositing the second separation layer in step b4) such that the solidification of the anode layer is not complete at the time of depositing the second separation layer, a third time interval separating (i) exposing the first separation layer in step a4) and (ii) placement in contact in step d1) and a fourth time interval separating (i) exposing the second separation layer in step b4) and (ii) placement in contact in step d1), such that the respective solidifications of the first and second separation layers are not complete at the moment of placement in contact in step d1); [0252] d2) placing the first separation layer (18a) into direct contact with the anode layer (16b) and controlling (248): a first time interval separating (i) exposing the cathode layer in step a3) and (ii) depositing the first separation layer in step a4), such that the solidification of the cathode layer is not complete at the moment of depositing the first separation layer, a second time interval separating (i) exposing the first separation layer in step a4) and (ii) placement in contact in step d2) and a third time interval separating (i) exposing the anode layer in step b3) and (ii) placement in contact in step d2), such that the solidification of the first separation layer is not complete at the moment of placement in contact in step d2); [0253] d3) placing the second separation layer (18b) into direct contact with the cathode layer (16a) and controlling (248): a first time interval separating (i) exposing the anode layer in step b3), and (ii) depositing the second separation layer in step b4), such that the solidification of the anode layer is not complete at the time of depositing the second separation layer, a second time interval separating (i) exposing the second separation layer in step b4) and (ii) placement in contact in step d3) and a third time interval separating (i) exposing the cathode layer in step a3) and (ii) placement in contact in step d3), such that the solidification of the second separation layer is not complete at the moment of placement in contact in step d3); and [0254] d4) enclosing the third separation layer (18c) between the cathode layer (16a) and the anode layer (16b) and placing the third separation layer into contact with the cathode layer and the anode layer and controlling (248): a first time interval separating (i) exposing the cathode layer in step a3) and (ii) placement in contact in step d4), a second time interval separating (i) exposing the anode layer in step b3) and (ii) placement in contact in step d4), and a third time interval separating (i) exposing the third separation layer in step c4) and (ii) placement in contact in step d4), such that the respective solidifications of the cathode layer, anode layer and third solidification layer are not yet complete at the moment of placement in contact in step d4).

[0255] Preferably, all of the manufacturing apparatus may be installed in a room with an anhydrous atmosphere avoiding any reaction of the still liquid electrolyte with moisture in the air which could lead to a breakdown of the cell.

[0256] The various members described with reference to FIG. 1 may be grouped in several independent modules whose positioning and separation on the manufacturing lines may be changed as needed.

[0257] The modules are indicated in FIG. 2 which shows one of the manufacturing lines 110a, 110b corresponding in some way to a half-manufacturing machine for half-cells. Because of the symmetry of the apparatus and the large similarity of the two manufacturing lines, the references for the two manufacturing lines 110a, 110b are shown on the same figure, FIG. 2. It is understood that one manufacturing line according to FIG. 2 may be used for manufacturing the half-cell comprising a cathode and for the half-cell comprising an anode.

[0258] Between the uncoiling roller 112a, 112b and the assembly rollers 142, only one of which is visible in FIG. 2, the strip passes through several modules. In order, there are a first coating module 320a, 320b, a first rolling module 326a, 326b, a second coating module 330a, 330b and a second rolling module 336a, 336b. The first coating module 320a, 320b comprises the first coating head 120a or the second coating head 120b described with reference to FIG. 1 and also the radiation sources 124a, 124b which are associated with them. It may be noted that the radiation source associated with the coating head for the first module is split. The use of a single radiation source is also conceivable.

[0259] The second coating module 330a, 330b comprises the third coating head 130a or the fourth coating head 130b described with reference to FIG. 1 and the radiation source 134a, 134b which is associated with it.

[0260] The first rolling module 326a, 326b comprises the sizing rollers 126a, 126b intended to set the thickness of the anode layer or the cathode layer, according to the manufacturing line involved. The first rolling module also comprises a thickness sensor 128a, 128b placed after the sizing rollers, in order to measure the thickness of the half-cell during manufacturing at the output of the sizing rollers.

[0261] The second rolling module 336a, 336b comprises sizing rollers 136a, 136b intended to set the thickness of the half-cells during manufacturing after depositing an electrolyte layer without active material. Like the first rolling module, the second rolling module comprises a thickness sensor 138a, 138b place just after the sizing rollers. The thickness sensor serves to measure the thickness of the half-cells immediately before the assembly thereof.

[0262] The various modules 320a, 320b, 326a, 326b, 330a, 330b, 336a, 336b, and also the uncoiling rollers 112a, 112b and the coiling roller 150 are connected to a driver unit 101, shown schematically, which serves to synchronize the various members.

[0263] As previously indicated, an implementation of the invention is possible by covering only one of the anode layer and the cathode layer with an electrolyte layer without active material. In this case, one of the second coating modules 330a, 330b and one of the second rolling modules 336a, 336b may be omitted.

[0264] The coiling roller 150 is a driving roller moved by a motor M indicated symbolically.

[0265] Some number of optional members described with reference to FIG. 1 are not shown in FIG. 2 for reasons of simplification.

[0266] FIG. 3 shows a formatted battery cell 1010. The formatted cell is obtained from the cell 10, in strip, from FIG. 1 at the end of the formatting operation indicated symbolically with reference 250. This operation comprises in particular, in the example shown by FIG. 3, the cutting of the peripheral edges of the formatted cell 1010. The cell is cut, from side to side, meaning through the entire thickness of the cell, which is of order a few hundreds of microns.

[0267] The cutting may advantageously be done on a laser cutting table. Cutting by knives is also conceivable.

[0268] In the example shown in FIG. 3, the formatted cell 1010 is shown with rectangular shape principal surfaces and with rounded corners. Cutting according to another, more complex pattern is entirely possible which may improve the ability to house the cell in a space dedicated to apparatus, for example.

[0269] Since the cell does not contain liquid, and in particular liquid electrolyte, the cutting operation does not require specific precautions. The electrically conducting supports serving as current collector remain electrically insulated, meaning insulated against conduction by an electron current because of the presence of solid electrolyte layers. In this respect, the cutting may preferably be done after complete solidification of the layers.

[0270] In the implementation example from FIG. 3, the peripheral edge of the formatted cell 1010, resulting from cutting, is covered with an electrically insulating protective coating 1024, for example varnish. This varnish may be reinforced with glass or basalt fibers, for example. The protective coating may be preferably formed after having stacked a plurality of identical formatted cells 1010 so as to cover the sides of the stack.

[0271] FIG. 4 shows a part of a stack of a plurality of formatted cells 1011, 1012, 1013, 1014, 1015, identical to the cell 1010 visible in FIG. 3. Each of the formatted cells may be cut into a strip battery cell 10 such as discussed with reference to FIG. 1. The stacking from FIG. 4 makes up a storage battery 1000.

[0272] For several formatted cells, FIG. 4 shows the first and second electrically conducting supports 14a, 14b, the cathode layer 16a and the anode layer 16b, the first separation layer 18a and the second separation layer 18b.

[0273] The layers making up each formatted cell are substantially identical and indicated with the same references. However, it can be seen that the first electrically conducting support 14a of the first formatted cell 1011 of the stack and the second electrically conducting support 14b of the last formatted cell 1015 at the stack are thicker than the other conducting supports. These thicker conducting supports are formed of several conducting sub-layers. They have a greater mechanical strength, which is suited to the function thereof as outer envelope of the battery 1000. The thicker conducting supports for the first and last cell of the stack also constitute exterior electrical connection terminals for the battery 1000.

[0274] In the stack, the cathode and anode layers, meaning the positive and negative electrodes of the various formatted cells, are alternated. Each cell of the stack is thus connected in series with the other cells of the stack via conducting supports 14a, 14b which form the current collectors thereof. The voltage at the terminals of the conducting layers 14a, 14b of the end cells 1011 1015 is equal to the sum of the voltage of the individual cells and corresponds to the battery voltage 1000.

[0275] It should be specified that other connections of formatted cells are possible and in particular connections in parallel, or series/parallel or parallel/series combinations. In this case, additional electrical conductors may be provided for connecting the current collectors of the individual formatted cells.

[0276] The embodiment detailed above is of roll-to-roll type implementing a continuous passage method. Alternatively, it is possible to implement a sequential manufacturing by manufacturing of individual plates. The handling of the plates may be done by conventional methods, for example by robotic arms provided with grasping means. In this case, control of the time is assured by control the moments of handling the plates.

[0277] The present invention can in no way be limited to the embodiment disclosed above, which could undergo modifications without thereby going outside the scope of the invention.