Composite material and current collector for battery

Abstract

A composite material including a first carbon foam structure including a network of pores and a second carbon foam structure including a network of pores. An intermediate bonding structure is disposed at least in part between the first and second carbon foam structures.

1 . A composite material, comprising: 
 a first carbon foam structure including a network of pores;    a second carbon foam structure including a network of pores; and    an intermediate bonding structure disposed at least in part between the first and second carbon foam structures.    
     
     
         2 . The composite material of  claim 1 , wherein the intermediate bonding structure permeates at least some of the pores of the first carbon foam structure and at least some of the pores of the second carbon foam structure.  
     
     
         3 . The composite material of  claim 2 , wherein the intermediate bonding structure permeates the pores of the first carbon foam structure by a depth equal to or greater than an average pore size of the first carbon foam structure.  
     
     
         4 . The composite material of  claim 2 , wherein the intermediate bonding structure permeates the pores of the second carbon foam structure by a depth equal to or greater than an average pore size of the second carbon foam structure.  
     
     
         5 . The composite material of  claim 1 , wherein the intermediate bonding structure comprises a polymer.  
     
     
         6 . The composite material of  claim 5 , wherein the intermediate bonding structure comprises polypropylene.  
     
     
         7 . The composite material of  claim 1 , wherein the intermediate bonding structure comprises a metal.  
     
     
         8 . The composite material of  claim 1 , wherein the intermediate bonding structure comprises an electrically conductive material.  
     
     
         9 . The composite material of  claim 1 , wherein at least one of the first and second carbon foam structures is graphite foam.  
     
     
         10 . The composite material of  claim 1 , wherein at least one of the first and second carbon foam structures has a total porosity value of at least about 60%.  
     
     
         11 . The composite material of  claim 1 , wherein at least one of the first and second carbon foam structures has an open porosity value of at least about 90%.  
     
     
         12 . The composite material of  claim 1 , wherein each of the first and second carbon foam structures has an average pore size of between about 0.25 mm and about 2.0 mm.  
     
     
         13 . A method of making a composite material, comprising: 
 providing a first carbon foam element including a network of pores;    applying bonding material to the first carbon foam element; and    placing a second carbon foam element, which includes a network of pores, on the bonding material.    
     
     
         14 . The method of  claim 13 , wherein applying the bonding material and placing the second carbon foam element forms a stacked structure, and wherein the method further comprises applying heat to the stacked structure.  
     
     
         15 . The method of  claim 14  further comprising applying pressure to the stacked structure.  
     
     
         16 . The method of  claim 15 , wherein the steps of applying pressure and applying heat are at least in part performed substantially simultaneously.  
     
     
         17 . The method of  claim 13 , further including forming a current collector for a battery by coupling a first electrical connection element with the first carbon foam element.  
     
     
         18 . The method of  claim 17 , wherein the layer of bonding material comprises an insulating material.  
     
     
         19 . The method of  claim 18 , further comprising coupling a second electrical connection element with the bonding material.  
     
     
         20 - 40 . (canceled)