Precision Conductive Coating for Copper Foil

Cheersonic UAM6000S Ultrasonic Spraying: Preparation Solution for Precision Conductive Coating for Copper Foil

Abstract

This article focuses on the Cheersonic UAM6000S ultrasonic spraying equipment, systematically elucidating its technical principles, core advantages, process implementation, and application value in the preparation of microporous carbon coated copper foil conductive coatings. This equipment, with its non-contact precision atomization, high uniformity, high material utilization, and precisely controllable microporous structure, perfectly solves the pain points of traditional coating processes in the preparation of ultra-thin, porous copper foil carbon coatings, such as poor uniformity, difficult porosity control, and material waste. It provides a high-performance, low-cost, and scalable coating solution for new energy fields such as lithium batteries and supercapacitors.

Keywords: Cheersonic UAM6000S; ultrasonic spraying; microporous carbon-coated copper foil; conductive coating; new energy current collector; precision coating

I. Introduction: Industry Demand and Process Challenges of Microporous Carbon-Coated Copper Foil

In the fields of new energy batteries (especially lithium batteries and solid-state batteries) and supercapacitors, microporous carbon-coated copper foil serves as a key negative electrode current collector. The quality of its conductive carbon coating directly determines the battery’s rate performance, cycle life, and safety. An ideal carbon coating must meet the following requirements: ultra-thin and uniform (50–500 nm), three-dimensional interconnected microporous structure, highly conductive network, strong adhesion to copper foil, and high material utilization.

Traditional coating processes (blade coating, roller coating, magnetron sputtering, etc.) suffer from numerous bottlenecks:

• Mechanical contact easily damages ultra-thin/porous copper foil (<6 μm); – Poor coating uniformity (CV>5%), with significant edge effects and streak defects;
• Uncontrollable porosity, making it difficult to form efficient ion transport channels;
• Low material utilization (<60%), resulting in significant waste of high-cost carbon materials (graphene, carbon nanotubes).
• The Cheersonic UAM6000S ultrasonic spraying equipment, with non-contact precision atomization as its core, provides a revolutionary technological path for the industrial production of microporous carbon-coated copper foil.

Cheersonic UAM6000S: Core Technology and Equipment Parameters

2.1 Equipment Positioning and Core Positioning
The UAM6000S is a high-precision ultrasonic spraying system designed by Cheersonic Ultrasonic specifically for pilot-scale research and development and small-batch mass production. It focuses on precision thin-film coating of planar substrates, and is particularly suitable for the preparation of carbon-based conductive coatings on ultra-thin and porous copper foils.

2.2 Core Technology Principles The equipment is based on Cheersonic’s patented ultrasonic atomization technology. The core process is as follows:

• High-Frequency Vibration Atomization: A built-in piezoelectric ceramic transducer converts electrical energy into 50–120 kHz high-frequency mechanical vibration, which acts on the carbon-based slurry at the nozzle tip. Through capillary wave fragmentation, the slurry is broken into uniform microdroplets of 10–40 μm, with an extremely narrow droplet size distribution (CV < 5%).
• Low-Speed ​​Gentle Deposition: No high-pressure airflow is required. Guided by only a very small amount of carrier gas (0.05–0.3 MPa), the droplets gently settle onto the copper foil surface at a low speed of <1 m/s. This non-contact coating completely avoids mechanical damage to the substrate.
• Precise Flow Control: Equipped with a 0.01 ml/min precision flow pump, it achieves ultra-low flow continuous/intermittent spraying, precisely controlling the coating’s surface density and thickness.
• In-situ Formation of Microporous Structure: Droplets spread and fuse uniformly on the copper foil surface, then solidify via gradient heating, spontaneously forming a three-dimensional interconnected microporous network. Porosity and pore size can be precisely controlled through process parameters.

III. Preparation of Microporous Carbon-Coated Copper Foil with UAM6000S: Complete Process Flow

3.1 Carbon-Based Slurry Preparation (Adapted for Ultrasonic Spraying)

• Formulation Design: Conductive phase (graphene/carbon nanotubes/conductive carbon black) + binder (water-based/solvent-based) + dispersant, solid content controlled at 10–30%, viscosity <20 cps, ensuring good atomization.
• Dispersion Process: Three-roll milling + vacuum degassing, fineness ≤5 μm, no agglomerated particles, avoiding nozzle clogging.

3.2 Copper Foil Substrate Pretreatment

• Plasma/Corona Cleaning: Removes surface oil and oxide layer, improving coating adhesion.
• Preheating to 60–80℃: Promotes droplet spreading and reduces coating defects.

3.3 Ultrasonic Spraying Core Process (UAM6000S)

•  Parameter Settings: Ultrasonic power, spraying speed (50–500 mm/s), nozzle height (30–100 mm), flow rate (0.1–5 ml/min), carrier gas pressure (0.1–0.3 MPa).
• Continuous/Intermittent Spraying: Roll-to-roll or sheet-to-sheet mode for large-area uniform coating.
• Gradient Curing: 80℃ (pre-drying) → 120℃ (curing) → 90℃ (holding), total time <1 min, forming a stable microporous structure.
• Post-treatment and Inspection
  – Cooling and winding;
  – Inspection Indicators: Coating thickness (ellipsometry), uniformity (area density scanning), sheet resistance (four-probe), porosity (mercury porosimetry), adhesion (cross-cut adhesion test).

IV. Summary of Core Advantages of Ultrasonic Spraying:

1. Extremely Uniform: Droplet uniformity >95%, coating without streaks or pinholes, sheet resistance deviation <5%, ensuring battery consistency.

2. Controllable Micropores: Unique deposition method forms three-dimensional interconnected micropores, increasing specific surface area by >30%, accelerating electrolyte penetration and ion transport.

3. Cost Revolution: Material utilization rate >90%, saving 30-50% of carbon material costs compared to traditional processes, especially suitable for high-value graphene/carbon nanotube slurries.

4. Flexible Adaptability: Perfectly compatible with ultra-thin copper foil below 6 μm and porous copper foil, without mechanical damage, improving yield.

5. Flexible Process: Quickly switch between different carbon-based formulations, supporting seamless integration of R&D and mass production.

V. Application Scenarios and Industry Value

5.1 Core Application Areas

• Lithium-ion Battery Anode Current Collector: Microporous carbon-coated copper foil significantly reduces interfacial impedance, improving fast charging capability (charging time reduced by >30%) and cycle life (>1200 cycles).
• Solid-State Battery Interface Layer: Ultra-thin, high-porosity carbon coating serves as a transition layer between the solid electrolyte and copper foil, improving interfacial contact and enhancing ionic conductivity.
• Supercapacitor Current Collector: High specific surface area microporous carbon coating improves energy density and power density.
• Flexible Electronic Devices: Adapted to flexible copper foil, enabling the fabrication of bendable and foldable flexible electrodes.

5.2 Industry Value

• Technological Upgrade: Driving the iteration of carbon-coated copper foil from “traditional coating” to “precision ultrasonic spraying,” leading to a new level of product performance.
• Cost Optimization: In large-scale production, material costs are reduced by more than 30%, and equipment maintenance costs are reduced by 50%.
• Green Manufacturing: Reducing organic solvent volatilization and waste emissions, aligning with environmentally friendly production trends.

VI. Conclusion and Outlook

The Cheersonic UAM6000S ultrasonic spraying equipment, with its core technological barriers of precision atomization, non-contact operation, high uniformity, high utilization rate, and controllable micropores, provides a complete, efficient, and low-cost solution for the industrial-scale preparation of conductive coatings on microporous carbon copper foil. It not only overcomes the technical bottlenecks of traditional processes but also, through performance improvements and cost optimization, helps the new energy battery industry develop towards higher energy density, longer lifespan, faster charging, and lower costs.

Looking to the future, with the continuous iteration of ultrasonic spraying technology (such as multi-nozzle parallel operation, higher frequency atomization, and online closed-loop detection), the UAM6000S series equipment will further expand its applications in ultra-thin functional coatings, nanomaterial coatings, and other fields, becoming a benchmark equipment for precision coating in high-end manufacturing.

About Cheersonic

Cheersonic is the leading developer and manufacturer of ultrasonic coating systems for applying precise, thin film coatings to protect, strengthen or smooth surfaces on parts and components for the microelectronics/electronics, alternative energy, medical and industrial markets, including specialized glass applications in construction and automotive.

Our coating solutions are environmentally-friendly, efficient and highly reliable, and enable dramatic reductions in overspray, savings in raw material, water and energy usage and provide improved process repeatability, transfer efficiency, high uniformity and reduced emissions.

If you have any technical questions, customization demands, or procurement inquiries about ultrasonic atomization nozzles, feel free to contact our professional sales and technical team for detailed parameters, customized solutions, and industry application support.
Email: market2@cheersonic.com