3D self-assembled multi-modal carbon-based particles integrated into a continuous electrode film layer

An electrochemical cell comprising:

• an anode containing an anode active material,
• a cathode containing a cathode active material,
• a porous separator disposed between the anode and the cathode, and
• a liquid electrolyte in contact with the anode active material and the cathode active material, at least one of the anode or the cathode comprising:
• an electrically conductive substrate;
• a first contiguous film deposited on the electrically conductive substrate, the first contiguous film consisting of a first concentration of three-dimensional (3D) self-assembled binder-less multi-modal mesoporous carbon-based particles in contact with each other that collectively define a first electrical conductivity for the first contiguous film, each 3D self-assembled binder-less multi-modal mesoporous carbon-based particle comprising:
• a plurality of electrically conductive 3D aggregates formed of graphene sheets randomly sintered together to form a 3D hierarchical open porous structure including mesoscale structuring in combination with micron-scale fractal structuring, the plurality of electrically conductive 3D aggregates configured to provide electrical conduction between contact points of the graphene sheets;
• and
• a porous arrangement defining a plurality of interconnected porous channels formed in the 3D hierarchical open porous structure, the porous arrangement containing the liquid electrolyte and configured to facilitate ion transport through at least some interconnected porous channels;
• and
• a second contiguous film deposited on the first contiguous film, the second contiguous film consisting of a second concentration of 3D self-assembled binder-less multi-modal mesoporous carbon-based particles in contact with each other that collectively define a second electrical conductivity for the second contiguous film, wherein the second electrical conductivity of the second contiguous film is lower than the first electrical conductivity of the first contiguous film.