Battery including carbon foam current collectors

Abstract

A battery having a current collector constructed of carbon foam. The carbon foam includes a network of pores into which a chemically active material is disposed to create either a positive or negative plate for the battery. The carbon foam resists corrosion and exhibits a large amount of surface area. The invention includes a method for making the disclosed carbon foam current collector used in the battery.

1 . An electrode plate for a battery, comprising: 
 a carbon foam current collector including a network of pores, and    a chemically active paste disposed on the carbon foam current collector such that the chemically active paste penetrates into the network of pores.    
     
     
         2 . The electrode plate of  claim 1 , wherein the chemically active paste includes at least one of an oxide of lead, nickel hydroxide, cadmium hydroxide, lanthanum nickel, zinc hydroxide, and iron hydroxide.  
     
     
         3 . The electrode plate of  claim 1 , wherein the carbon foam current collector has a total porosity value of at least 60%.  
     
     
         4 . The electrode plate of  claim 1 , wherein the carbon foam current collector has an open porosity value of at least 90%.  
     
     
         5 . The electrode plate of  claim 1 , wherein the carbon foam current collector has an electrical resistivity value of less than about 1 Ω-cm.  
     
     
         6 . The electrode plate of  claim 1 , wherein the carbon foam current collector comprises graphite foam.  
     
     
         7 . The electrode plate of  claim 6 , wherein the graphite foam current collector has an electrical resistivity value of between about 100 Ω-cm and about 2500 Ω-cm.  
     
     
         8 . The electrode plate of  claim 1 , wherein the carbon foam current collector has a density of less than about 0.6 g/cm 3 .  
     
     
         9 . The electrode plate of  claim 1 , wherein the carbon foam current collector has an average pore size of at least about 200 μm.  
     
     
         10 . The electrode plate of  claim 1 , wherein the carbon foam current collector has an average pore size of at least about 40 μm.  
     
     
         11 . The electrode plate of  claim 1 , wherein the carbon foam current collector has an average pore size of at least about 20 μm.  
     
     
         12 . The electrode plate of  claim 1 , wherein the carbon foam current collector comprises carbonized wood.  
     
     
         13 . The electrode plate of  claim 1 , wherein the carbon foam current collector comprises graphitized wood.  
     
     
         14 - 35 . (canceled)  
     
     
         36 . The electrode plate of  claim 1 , wherein the chemically active paste includes an oxide of lead.  
     
     
         37 . The electrode plate of  claim 1 , wherein the chemically active paste includes lead.  
     
     
         38 . An electrode plate for a battery, comprising: 
 a carbon foam current collector including a network of pores, and    a chemically active paste disposed on the carbon foam current collector such that the chemically active paste penetrates into the network of pores,    wherein the carbon foam current collector has a total porosity value of at least 60% and an open porosity value of at least 90%.    
     
     
         39 . The electrode plate of  claim 38 , wherein the chemically active paste includes lead.  
     
     
         40 . The electrode plate of  claim 38 , wherein the carbon foam current collector has an electrical resistivity value of less than about 1 Ω-cm.  
     
     
         41 . An electrode plate for a battery, comprising: 
 a carbon foam current collector including a network of pores, and    a chemically active paste disposed on the carbon foam current collector such that the chemically active paste penetrates into the network of pores,    wherein the carbon foam current collector comprises carbonized wood and has a total porosity value of at least 60%.    
     
     
         42 . The electrode plate of  claim 41 , wherein the carbon foam current collector has an electrical resistivity value of less than about 1 Ω-cm.