Rechargeable battery having permeable anode current collector

A rechargeable battery comprising:

• (a) a casing;
• (b) a battery cell at least partially enclosed by the casing, the battery cell comprising:
• (1) a substrate,
• (2) a cathode and cathode current collector on the substrate, the cathode being electrically coupled to the cathode current collector,
• (3) an electrolyte electrically coupled to the cathode or the cathode current collector, and
• (4) a permeable anode current collector having a first surface electrically coupled to the electrolyte and an opposing second surface, the permeable anode current collector comprising a grid having perforations that allow cathode material to pass through the perforations to form an anode on the second surface or in the perforations when the battery cell is electrically charged;
• and
• (c) positive and negative terminals that electrically connect to the battery cell.

A method of forming a rechargeable battery, the method comprising:

• (a) forming a battery cell by the steps of:
• (1) forming a substrate,
• (2) forming a cathode and cathode current collector on the substrate, the cathode being electrically coupled to the cathode current collector,
• (3) forming an electrolyte electrically coupled to the cathode or the cathode current collector, and
• (4) forming a permeable anode current collector having a first surface electrically coupled to the electrolyte and an opposing second surface, the permeable anode current collector having (1) a thickness that is less than about 1000 Å and that is sufficiently small to allow cathode material to permeate therethrough to form an anode on the second surface of the permeable anode current collector, and (2) absent an overlayer on the second opposing surface when the battery cell is electrically charged;
• (b) connecting positive and negative terminals to the battery cell;
• and
• (c) enclosing the battery cell at least partially within a casing.

A method of forming a rechargeable battery, the method comprising:

• (a) forming a battery cell by the steps of:
• (1) forming a substrate,
• (2) forming a cathode and cathode current collector on the substrate, the cathode being electrically coupled to the cathode current collector,
• (3) forming an electrolyte electrically coupled to the cathode or the cathode current collector, and
• (4) forming a permeable anode current collector having a first surface electrically coupled to the electrolyte and a second opposing surface, the permeable anode current collector comprising a grid having perforations that allow cathode material to pass through the perforations to form an anode on the second surface of the anode current collector or in the perforations when the battery cell is electrically charged;
• (b) connecting positive and negative terminals to the battery cell;
• and
• (c) enclosing the battery cell at least partially within a casing.