Processing of strong and highly conductive carbon foams as electrode

Porous carbons were processed by the foaming of two-part polymer precursors with pre-loaded carbon powder (graphitic or amorphous), and then resin impregnation and carbonization to control both porosity and mechanical strength of the resulting foam. Electrical conductivity of the foams was improved by nickel-catalyzed graphitization. Different levels of graphitization were obtained for varied concentrations of nickel to the amorphous carbon foams. The presence of graphitic carbon improves the electrical conductivity by a factor of 50, compared to the amorphous counterparts. Electrochemical studies showed that graphitization of the amorphous structures increased the specific electrochemical surface area and electron transfer rate of the carbon electrodes.