Carbon Foam Based Three-Dimensional Batteries and Methods

A method of making a three-dimensional battery comprising:

• attaching an anode current collector to a region of a three-dimensional porous carbon foam base;
• immersing the three-dimensional porous carbon foam base in an electrolyte to form an electrolyte layer over the three-dimensional porous carbon foam base;
• forming a layer of polyphenyl oxide formed over the electrolyte layer using an electropolymerization process;
• infiltrating the three-dimensional porous carbon foam base with a carbon slurry;
• and
• attaching a cathode current collector to a second region of the three-dimensional porous carbon foam base.

A method of making a three-dimensional battery comprising:

• forming a three-dimensional base from a porous carbon foam having a predetermined geometric structure;
• bonding an anode current collector to a region of the three-dimensional base;
• forming a thin film layer of an electrolyte over the three-dimensional base;
• forming a layer of polyphenyl oxide formed over the electrolyte layer;
• infiltrating the three-dimensional base with a carbon slurry;
• bonding the cathode current collector to a second region of the three-dimensional base.

A three-dimensional battery comprising:

• a three-dimensional porous anode foam base;
• an anode current collector bonded to and in electrical communication with a first region of the base;
• a separator layer disposed over the three-dimensional porous anode foam base;
• and
• a cathode current collector bonded to and in electrical communication with a second region of the three-dimensional porous anode foam base.