Hybrid solid-state cell with a sealed anode structure

A method for forming a three-dimensional (3D) porous anode for an electrochemical cell including a cathode, an anode, an electrolyte separator, comprised of a ceramic material, located between the cathode and the anode, and an anode current collector, wherein the anode comprising a 3D porous anode is located between the anode current collector and the electrolyte separator, the method comprising:

• mixing a first precursor material and a second precursor material together to form a mixture;
• depositing the mixture as a layer where the anode is to be formed;
• and
• sintering the mixture to form the 3D porous anode with ionically conducting electrolyte strands extending through the anode from the anode current collector to the electrolyte separator, pores extending through the anode from the anode current collector to the electrolyte separator, and an electronically conducting network extending on sidewall surfaces of the pores from the anode current collector to the electrolyte separator,
• wherein the second precursor material is a sacrificial material configured to decompose during formation of the pores by the sintering using the second precursor material, and the first precursor material is a material which forms a coating of the electronically conducting network on the sidewall surfaces of the pores formed by sintering the second precursor material.

A method for forming a 3D porous anode for an electrochemical cell including a cathode, an anode, an electrolyte separator, comprised of a ceramic material, located between the cathode and anode, and an anode current collector, wherein the anode comprising a three-dimensional (3D) porous anode is located between the anode current collector and the electrolyte separator, the method comprising:

• depositing the mixture of a powder of solid electrolyte material and a powder of a sacrificial pore forming material as a layer where the anode is to be formed;
• sintering the mixture to form pores to form the 3D porous anode;
• and
• infusing an electronically conducting material into the 3D porous anode after the sintering, to coat sidewall surfaces of the pores,
• wherein the electrochemical cell is configured to be used to form a lithium-ion battery, and wherein the electronically conducting material is comprised of a material which conducts electrons from the anode current collector along the sidewall surfaces of the pores to combine with lithium ions from the ionically conducting electrolyte strands at the sidewall surfaces of the pores to form lithium in the pores during charging of the lithium-ion battery.