Copper Foam Electrode 60–98% Porosity 5–130 PPI ATOMFAIR®

COPPER FOAM 60-98% POROSITY THERMAL CONDUCTIVE EMI SHIELDING ELECTRODE

ADVANCED POROUS METAL MATERIAL

Copper Foam

Copper foam features 60-98% porosity, 5-130PPI, ≥98% through-hole rate, and excellent thermal conductivity (>6W/(m²·K)). With superior electrical conductivity and mechanical strength (≥2.5MPa), it is widely used for LED/CPU cooling, battery electrodes, EMI shielding, filtration and catalysis. Custom sizes available.

Copper Foam Performance Parameters

Parameter	Specification
Heat Transfer Coefficient	>6 W/(m²·K)
Mechanical Strength	≥2.5 MPa
Tensile Strength	5–18 KPa
Pore Size	0.1–10 mm
Porosity	60–98%
Through-hole Rate	≥98%
Bulk Density	0.5–1.5 g/cm³
PPI (Pores Per Inch)	5–130 PPI

Application Directions

Heat dissipation materials, heat absorption materials, chemical catalyst carriers, electromagnetic shielding materials, filter materials, damping materials, battery electrode materials, sound-absorbing materials, decorative materials.

Thermal Dissipation Material Application

With the rapid development of electronic products, heat dissipation issues have gained increasing attention, especially for high-power LED lighting and CPU cooling, which have become key challenges for the industry. Small vapor chambers and heat pipe systems made from copper foam can effectively balance cost, volume and cooling efficiency, making them a key research direction in the high-power LED thermal management field. Once thermal issues are resolved, LEDs will see broader application in public lighting, harsh environment lighting and other scenarios.

Main Features

Copper foam has excellent thermal conductivity and can be widely used for heat conduction and dissipation in motors, electrical appliances and various electronic components.
Copper foam has superior electrical conductivity, and its application as electrode material in nickel-zinc batteries and electric double-layer capacitors is gaining significant industry attention.
Thanks to its unique structural characteristics and good biocompatibility, copper foam is also an outstanding filtration and water purification filter material.

Application Areas

Electrode Materials: The excellent electrical conductivity allows copper foam to be widely used as skeletal electrode material for new-type batteries such as nickel-zinc batteries and electric double-layer capacitors. It has been trialed and put into batch use by several nickel-zinc battery manufacturers. It is also expected to achieve large-scale promotion as a current collector for electric double-layer capacitor electrodes, with broad prospects in electrolytic recovery of copper-containing wastewater.
Catalysts: In many organic chemical reactions, copper foam with large specific surface area can replace punched copper plates as chemical reaction catalysts. Copper foam as a carrier for photocatalytic air purification has achieved mature application.
Thermal Conduction Materials: Copper foam has outstanding thermal conductivity, making it an excellent flame-retardant material suitable for various high-end fire-fighting equipment, especially effective in flame isolation. Additionally, leveraging its excellent thermal conductivity and apparent permeability, copper foam can be used to manufacture heat dissipation components for motors and electrical appliances.
Sound Absorption and Shielding Materials: Sound waves undergo diffuse reflection on the copper foam surface, achieving noise reduction through expansion silencing and micro-pore sound absorption principles. The electromagnetic shielding performance of copper is close to silver, making copper foam an excellent EMI shielding material.
Filter Materials: With excellent structural properties and good biocompatibility, copper foam has been successfully applied as filter material and shows promising prospects in water purification equipment.
Fluid Pressure Buffering Materials: Copper foam provides dispersion and buffering effects on fluids, serving as an effective pressure reduction protection device for various pressure instruments.

Sizes can be customized. For any questions or specific customization requirements, please feel free to contact us at inquiry@atomfair.com

TAILORED SOLUTIONS FOR RESEARCH

Contact our engineering team for technical support or official quotations.

EMAIL: inquiry@atomfair.com

Manufacturer: Atomfair LLC

Brand: ATOMFAIR®

How does the porosity level (60-98%) affect the thermal conductivity and mechanical strength of copper foam?

Higher porosity reduces bulk density (0.5–1.5 g/cm³) and mechanical strength, but the copper foam maintains a thermal conductivity >6 W/(m²·K) and mechanical strength ≥2.5 MPa across the full porosity range. The through-hole rate remains ≥98%, ensuring open-cell structure for fluid flow. This trade-off allows engineers to select porosity based on application requirements for heat transfer versus structural support.

Can copper foam be directly integrated into existing nickel-zinc battery electrode designs without compatibility issues?

Yes, copper foam has superior electrical conductivity and is already used as a skeletal electrode material in nickel-zinc batteries, with trialed and batch use by several manufacturers. However, compatibility depends on the specific electrochemical environment; copper's stability differs from nickel. The source confirms application as an electrode material and current collector for electric double-layer capacitors, indicating broad electrochemical compatibility.

What handling precautions are necessary when cutting or shaping copper foam to prevent structural damage?

Copper foam has a tensile strength of only 5–18 KPa, making it fragile under tension. Care must be taken to avoid tearing during cutting or machining. Sharp tools or laser cutting are recommended to minimize edge deformation. The mechanical strength (≥2.5 MPa) provides compressive stability, but the material is delicate in tensile loading.

Assessment

This copper foam product offers a tunable porous structure with 60-98% porosity and 5-130 PPI, providing high thermal conductivity (>6 W/(m²·K)) and electrical conductivity for applications in heat dissipation, battery electrodes, and EMI shielding. Its low tensile strength (5-18 KPa) necessitates careful handling and integration into supporting structures.

Positive

High porosity and through-hole rate: Porosity of 60-98% with ≥98% through-hole rate enables excellent fluid permeability and large surface area, ideal for catalysis, filtration, and electrode applications.
Broad PPI range and custom sizes: PPI range of 5-130 and customizable dimensions allow tailoring of pore structure and form factor to meet specific thermal management, electrochemical, or shielding requirements.

Trade-offs

Low tensile strength limits handling: Tensile strength of 5-18 KPa is very low, requiring careful handling during integration and precluding standalone structural use without reinforcing support.

Quality Standards & Performance Verification

Every advanced material, component, equipment, and instrument in our catalog is backed by rigorous testing. We maintain strict internal quality management frameworks and align with CE conformity metrics to deliver transparent, reproducible performance data via our public open-science repository.

To request raw batch performance data, submit formal vendor registration paperwork, or execute a fast-turnaround R&D manufacturing loop, contact us at inquiry@atomfair.com.

Shipping & Returns

Item is dispatched under the Atomfair Shipping & Delivery Framework (Free worldwide shipping on orders over $59 USD excl. heavy equipment). Return is governed by the Atomfair Return & Refund Policy (7-day technical return window).