Reticulated electrode structure and method of making the same

1. A method of forming an electrode in an electrochemical battery comprising:

applying a conductive coating to a reticulated substrate, the reticulated substrate having a plurality of interconnecting openings, wherein applying the conductive coating to the reticulated substrate comprises:

immersion dipping the reticulated substrate, wherein immersion dipping comprises immersing the reticulated substrate in an ultrasonic tank containing the conductive coating, wherein the conductive coating is a water-soluble conductive liquid; and

applying ultrasonic wave to break down a surface tension at the boundary layer of the reticulated substrate to allow the water-soluble conductive liquid to flow through the openings and permeate an interior of the reticulated substrate to increase a reactive surface area of the reticulated substrate and promote adhesion of the conductive material within the interior of the reticulated substrate;

curing the reticulated substrate coated with the conductive material; and

electroplating the reticulated substrate coated with the conductive material with a desired metal material.

2. The method of generating signals in the ultrasonic tank having an ultrasonic frequency in a range of 28-48 kHz.

3. The method of claim 1 , wherein the conductive liquid is a water-soluble conductive ink having conductive carbon materials.

4. The method of claim 1 , wherein the conductive liquid is a water-soluble conductive ink having conductive carbon materials, wherein the conductive carbon materials are a combination of graphene and graphite.

5. The method of claim 4 , wherein the graphene is approximately 2-25 micron in linear dimensions.

6. The method of claim 1 , wherein the reticulated substrate is a reticulated open-cell polymer foam.

7. The method of claim 6 , comprising removing the reticulated open-cell polymer foam after electroplating.

8. The method of claim 7 , wherein removing the reticulated open-cell polymer foam comprises removing the reticulated open-cell polymer foam through controlled combustion.

9. The method of claim 1 , wherein the reticulated substrate is one of a reticulated open-cell polymer foam or a reticulated ceramic.

10. The method of claim 1 , wherein the reticulated substrate is an open cell foam having a plurality of interconnected tubes the ultrasonic wave breaking down the surface tension at a boundary layer of the open cell foam to allow the water-soluble conductive ink to flow through the plurality of interconnecting tubes.

11. The method of claim 1 , wherein the reticulated substrate is a reticulated ceramic substrate having a honeycomb structure, the ultrasonic wave breaking down the surface tension at a boundary layer of the reticulated ceramic substrate to allow the water-soluble conductive ink to flow through an interior of the honeycomb structure.

12. A method of forming an electrode in an electrochemical battery comprising:

applying a conductive coating to a reticulated open-cell polymer foam substrate by immersion dipping the reticulated open-cell polymer foam substrate in an ultrasonic tank containing the conductive coating, wherein the conductive coating is a water-soluble conductive ink having conductive carbon materials, the reticulated open-cell polymer foam substrate having a plurality of interconnecting tubes formed therein;

applying ultrasonic wave to break down a surface tension at the boundary layer of the reticulated open-cell polymer foam substrate to allow the water-soluble conductive ink to flow through the plurality of interconnecting tubes and permeate an interior of the reticulated open-cell polymer foam substrate to increase a reactive surface area of the reticulated open-cell polymer foam substrate and promote adhesion of the conductive material to the interior of the reticulated open-cell polymer foam;

curing the reticulated open-cell polymer foam substrate coated with the conductive carbon materials; and

electroplating the reticulated open-cell polymer foam substrate coated with the conductive carbon material with a desired metal material.

13. The method of claim 12 , wherein the conductive carbon materials are a combination of graphene and graphite.

14. The method of claim 13 , wherein the graphene is approximately 2-25 micron in linear dimensions.

15. The method of 12 , comprising removing the reticulated open-cell polymer foam substrate after electroplating through controlled combustion.

16. A method of forming an electrode in an electrochemical battery comprising:

applying a conductive coating to a reticulated ceramic substrate having a honeycomb structure, wherein applying the conductive coating to the reticulated ceramic substrate comprises:

immersion dipping the reticulated ceramic substrate in an ultrasonic tank containing the conductive coating, wherein the conductive coating is a water-soluble conductive ink having conductive carbon materials;

applying ultrasonic wave to break down a surface tension at the boundary layer of the reticulated ceramic substrate to allow the water-soluble conductive ink to flow through the honeycomb structure and permeate an interior of the reticulated ceramic substrate to increase a reactive surface area of the reticulated ceramic substrate and promote adhesion of the conductive material;

curing the reticulated ceramic substrate coated with the conductive carbon materials; and

electroplating the reticulated ceramic substrate coated with the conductive carbon material with a desired metal material.