Three-dimensional porous current collector with internal volume for active material particles

A method of manufacturing an electrode for a rechargeable battery cell, the method comprising:

• providing an electrode substrate;
• and
• fixing a current to the electrode substrate, wherein the collector has a three-dimensional (3D) porous structure defining void spaces configured to accommodate therein active material particles;
• and
• arranging active material particles within the void spaces;
• wherein charging the battery cell reversibly deposits transient ions onto the active material particles and expands the active material particles into the void spaces of the 3D porous structure and discharging the battery cell extracts the transient ions from the active material particles, such that the active material contracts out of the void spaces of the 3D porous structure.

An electrode for a lithium-ion rechargeable battery cell, comprising:

• an anode substrate;
• and
• an anode current collector fixed to the anode substrate and having a three-dimensional (3D) porous structure defining void spaces;
• wherein:
• the 3D porous structure includes nodes established by pore walls defining the void spaces and the 3D porous structure has a variable size porosity characterized by a porosity gradient defined by the pore walls gradually increasing in thickness with increasing proximity to the anode substrate and thereby configured to support comparatively higher energy density loading proximate the anode substrate;
• and
• active material particles arranged within the void spaces;
• wherein charging the battery cell reversibly deposits transient lithium ions onto the active material particles and expands the active material particles into the void spaces of the 3D porous structure and discharging the battery cell extracts the transient lithium ions from the active material particles, such that the active material contracts out of the void spaces of the 3D porous structure.