Copper Foam 50–98% Porosity ≥98% Through-Hole ATOMFAIR®

COPPER FOAM 50-98% POROSITY ≥98% THROUGH-HOLE THERMAL EMI FILTER

ADVANCED POROUS METAL MATERIAL

Copper Foam

Copper foam features high porosity (50%-98%), excellent thermal and electrical conductivity. With 0.1-10mm pore size (5-120ppi) and ≥98% through-hole rate, it is widely used for battery electrodes, heat dissipation, EMI shielding, filtration and catalysis. Custom sizes available.

I. Pore Characteristics and Bulk Density

Parameter	Specification
Pore Size	0.1mm-10mm (5-120ppi)
Porosity	50%-98%
Through-hole Rate	≥98%
Bulk Density	0.1-0.8 g/cm³

II. Main Features

Copper foam has excellent thermal conductivity and can be widely used for heat conduction and dissipation in motors, electrical appliances and electronic components.
Due to its superior electrical conductivity, copper foam is gaining industry attention for applications as electrode materials in nickel-zinc batteries and electric double-layer capacitors.
Thanks to its structural characteristics and human-friendly properties, copper foam is also an excellent filtration material and water purification filter medium.

III. 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 be promoted as a current collector for electric double-layer capacitor electrodes. Moreover, copper foam used as an electrode material for electrolytic recovery of copper-containing wastewater shows very broad prospects.
Catalysts: In many organic chemical reactions, people attempt to directly use copper foam with large specific surface area to replace punched copper plates as chemical reaction catalysts. Copper foam as a carrier for photocatalytic air purification has also been successfully applied.
Thermal Conduction Materials: Copper foam has excellent thermal conductivity, making it a superior flame-retardant material applied in many advanced fire-fighting equipment overseas, especially as a flame isolation device with outstanding effects. Additionally, using its excellent thermal conductivity and apparent permeability, copper foam is made into heat dissipation materials for motors and electrical appliances.
Sound Absorption and Shielding Materials: Sound waves undergo diffuse reflection on the surface of copper foam, achieving noise reduction through expansion silencing and micro-pore sound absorption principles. The shielding performance of copper is close to silver, making it an excellent electromagnetic shielding material.
Filter Materials: With excellent structural characteristics and human-friendly properties, copper foam metal products have been successfully applied as filter materials. Copper foam also shows good prospects in water purification device applications.
Fluid Pressure Buffering Materials: The dispersion and buffering effect of copper foam on fluids makes it 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 trade-off between porosity and mechanical integrity affect copper foam performance in electrode applications?

Higher porosity (up to 98%) maximizes surface area for electrochemical reactions and reduces bulk density to as low as 0.1 g/cm³, but it also decreases the foam's mechanical strength and structural integrity. For electrode applications in nickel-zinc batteries or electric double-layer capacitors, the ≥98% through-hole rate ensures ionic transport, but the optimal porosity must balance active material loading with sufficient mechanical support to prevent collapse during cycling. The source specifies a porosity range of 50%–98% and pore sizes from 0.1 mm to 10 mm (5–120 ppi), allowing engineers to select a grade that meets both conductivity and durability requirements.

Can copper foam be directly integrated as a current collector in electric double-layer capacitors without additional surface treatments?

Yes, copper foam's superior electrical conductivity and high through-hole porosity (≥98%) make it suitable as a skeletal electrode material or current collector for electric double-layer capacitors, as stated in the application areas. However, the source notes that it has been trialed and put into batch use by nickel-zinc battery manufacturers, while its use as a current collector for capacitor electrodes is still under promotion. Engineers should verify compatibility with the specific electrolyte system and consider potential corrosion issues in aqueous electrolytes, as copper may require protective coatings or alloying for long-term stability.

What handling and storage precautions are required to prevent oxidation and maintain the thermal and electrical conductivity of copper foam?

Copper foam is susceptible to surface oxidation when exposed to air, which can degrade its thermal and electrical conductivity. The source does not specify explicit storage conditions, but standard practice for high-purity copper materials dictates storage in a dry, inert atmosphere (e.g., nitrogen or argon) or vacuum-sealed packaging to minimize oxidation. For laboratory use, handling with clean gloves and avoiding contact with moisture or acidic vapors is recommended. The product's high surface area (due to 50%–98% porosity) accelerates oxidation rates, so immediate use after opening or re-storage under desiccant is advised.

Assessment

Copper foam with 50-98% porosity and ≥98% through-hole rate provides high surface area and excellent thermal/electrical conductivity, making it suitable for battery electrodes, heat sinks, EMI shielding, and filtration. Custom sizes are available for tailored integration.

Positive

High porosity and through-hole rate: Porosity ranges from 50% to 98% with a through-hole rate ≥98%, ensuring effective fluid flow and large surface area for catalysis, filtration, and electrode applications.
Excellent thermal and electrical conductivity: Copper's high conductivity enables efficient heat dissipation in electronics and serves as a current collector in battery electrodes, as explicitly stated in the product description.

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).