Haomei supplies carbon coated aluminum foil for battery current collector applications, combining a thin aluminum foil substrate with a conductive carbon coating on one or both sides.
The carbon layer is applied to the aluminum surface to improve the interface between the current collector and electrode coating. Substrate alloy, foil thickness, coating side, coating thickness, finished width and roll configuration can be specified according to the electrode process and end-use requirements.
Haomei can supply the aluminum foil substrate and, subject to the project scope, provide carbon-coated foil in customized configurations.
What Is Carbon Coated Aluminum Foil?
Carbon coated aluminum foil is a functionalized aluminum current collector in which a thin conductive carbon layer is applied to the surface of aluminum foil.
Unlike conventional battery aluminum foil, which is used primarily as the metallic current-collecting substrate, carbon-coated foil adds a conductive surface layer between the aluminum substrate and the electrode coating.
The carbon layer can contain conductive carbon materials such as carbon black, graphite or other carbon-based conductive additives together with a suitable binder system.
The coating is applied through a controlled coating process so that the carbon material is distributed consistently across the required coating area.
Depending on the electrode design, the foil may be supplied with a single coated side or both sides coated.
Carbon coated aluminum foil is not exactly the same as plain battery aluminum foil. It is a deeper-processed current collector material consisting of an aluminum foil substrate with an additional conductive carbon coating.
Carbon Coated Aluminum Foil Specifications
| Aluminum Foil Substrate | 1060, 1070, 1080, 1100, 1235 and selected 1xxx-series aluminum grades. |
| Aluminum Purity | Typically ≥99.9% for selected high-purity substrates, subject to alloy. |
| Temper | According to the substrate specification and production requirements. Confirm the actual temper on the technical specification or material certificate. |
| Aluminum Foil Substrate Thickness | 16 μm available for specified configurations. Other thickness options can be discussed according to the coating process and electrode requirements. |
| Coating Material | Conductive carbon coating. |
| Conductive Phase | Carbon black, graphite and other carbon-based conductive materials. |
| Coating Configuration | Single-sided or double-sided coating. |
| Carbon Coating Thickness | Approximately 1 μm per coated side in a typical configuration. Final value depends on the coating specification. |
| Coating Binder | Water-based modified acrylic or other specified binder system, subject to formulation and project requirements. |
| Coating System | Water-based and other coating systems subject to formulation and project requirements. |
| Finished Width | Customizable according to the customer's coating, slitting and electrode manufacturing equipment. |
| Roll Dimensions | Core ID, roll OD, roll length, roll weight and other winding parameters can be specified according to the project. |
| Surface | Conductive carbon-coated aluminum surface according to the specified coating structure. |
Carbon Coated Aluminum Foil Structure
The aluminum substrate provides the mechanical carrier and conductive metallic path, while the carbon coating modifies the surface that contacts the electrode material.
Compared with uncoated aluminum foil, a properly selected carbon coating can provide several functional benefits.
- Improved adhesion between the current collector and electrode coating.
- Lower interfacial contact resistance.
- Better surface compatibility with selected cathode formulations.
- Additional protection of the aluminum surface against corrosion in demanding electrode processing conditions.
- More stable contact between the electrode layer and current collector during repeated cycling.
The actual improvement depends on the coating formulation, coating weight, electrode chemistry, drying conditions and cell design.
Double-sided structure
Typical Functional Structure
- Electrode Active Material
- Conductive Carbon Coating
- Aluminum Foil Substrate
- Conductive Carbon Coating
- Electrode Active Material
Aluminum Foil Substrate and Carbon Coating Options
Haomei can configure the product around the aluminum substrate and coating requirements of the application.
Aluminum Foil Substrate
Typical substrate options include 1060, 1070, 1080, 1100 and 1235 aluminum foil, together with selected grades according to the required foil properties.
Conductive Carbon Layer
The coating can use carbon black, graphite or other carbon-based conductive materials together with a suitable binder system.
The coating formulation should be matched to the intended electrode chemistry.
Coating Configuration
Single-sided and double-sided coating options are available according to the electrode construction and downstream coating process.
Coating thickness and finished roll dimensions are specified according to the project.
Single-Sided and Double-Sided Carbon Coated Aluminum Foil
The coating configuration is selected according to the electrode construction, surface requirements and converting process.
Single-Sided Coating
Single-sided carbon coating places the conductive layer on one side of the aluminum foil.
This configuration can be used when only one foil surface needs to contact the electrode material or when the opposite side serves another function.
Double-Sided Coating
Double-sided carbon coated aluminum foil has a conductive carbon layer applied to both sides of the aluminum substrate.
This configuration is commonly used for electrode structures in which both foil surfaces are coated with active material.
Properties of Carbon Coated Aluminum Foil Substrate
| Alloy | 1235 T | 1235 T3 | 1100 | 1060 |
| Tensile Strength Mpa | ≥200 | ≥240 | ≥240 | ≥200 |
| Elongation % | ≥2.0 | ≥2.5 | ≥3.0 | ≥3.0 |
| Surface Tension Mn/M | ≥31 | ≥31 | ≥31 | ≥31 |
| Thickness And Deviation Μm | 9-25;±4% | |||
| Width And Deviation Mm | 200-1400;±1 | |||
| Pinholes/M2 | Diameter 0.1-0.3mm; <3 | |||
| Plate Shape | With a flat sheet | |||
| Surface Quality | No oil, no roller marks, no oxidation, no foreign matter pressed in and other defects that affect use | |||
| End Surface Quality | No staggered layers, tower type, burrs ≤50µm, gaps ≤50µm | |||
| Weight Per Roll Kg | 50-500kg | |||
| Roll Diameter Mm | 76.2±1/152±1 | |||
| Environmental Requirements | Comply with ROHS standards | |||
Mechanical Properties of Carbon Coated Aluminum Foil Substrate
| Alloy | Temper | Thickness/mm | Room temperature tensile testing results | ||||
| Tensile strength (Rm) MPa | elongation after break (A100) % | elongation after break (A50) % | |||||
| Single side light aluminum foil | Double side light aluminum foil | Single side light aluminum foil | Double side light aluminum foil | ||||
| 1050 | H18 | >0.013-0.015 | - | - | - | - | - |
| 1050 | H18 | >0.015-0.020 | ≥185 | ≥2.0 | - | - | - |
| 1050/1060 | H18 | ≤0.010 | - | - | - | - | - |
| 1050/1060 | H18 | ≤0.010 | - | - | - | - | - |
| 1050/1060 | H18 | >0.010-0.013 | ≥190 | - | ≥2.5 | - | ≥3.0 |
| 1050/1060 | H18 | >0.013-0.015 | - | - | - | - | - |
| 1070 | H18 | ≤0.010 | ≥185 | - | ≥2.0 | - | - |
| 1070 | H18 | >0.010-0.013 | - | - | - | - | - |
| 1070 | H18 | >0.013-0.015 | ≥180 | - | - | - | - |
| 1070 | H18 | >0.015-0.020 | ≥175 | - | - | - | - |
| 1100 | H18 | ≤0.010 | ≥230 | ≥1.0 | ≥2.0 | - | ≥3.0 |
| 1100 | H18 | >0.010-0.013 | - | - | - | - | - |
| 1100 | H18 | >0.013-0.015 | ≥220 | - | - | - | - |
| 1100 | H18 | >0.015-0.020 | - | - | ≥2.0 | - | - |
| 1235 | H18 | ≤0.010 | - | - | - | - | - |
| 1235 | H18 | >0.010-0.013 | ≥180 | - | - | ≥2.0 | - |
| 1235 | H18 | >0.013-0.015 | ≥185 | - | - | - | - |
| 1235 | H18 | >0.015-0.020 | ≥175 | - | - | - | - |
Advantages Compared with Plain Aluminum Foil
Carbon coated foil can provide a modified surface for selected battery electrode applications.
Improved Adhesion
The carbon coating can improve bonding between the current collector and electrode coating, helping maintain contact during repeated charge-discharge cycles.
Lower Interfacial Resistance
A properly selected conductive coating can reduce interfacial contact resistance between the aluminum substrate and electrode layer.
Surface Protection
The carbon layer can act as an additional barrier to help protect the aluminum surface in selected electrode processing conditions.
Electrode Interface Stability
A suitable carbon coating can support more stable contact between the electrode layer and current collector during repeated cycling.
Process Compatibility
The coating structure can be selected according to the customer's electrode formulation, coating equipment and converting process.
Material Optimization
The final coating design can be evaluated together with substrate thickness, coating weight and electrode chemistry to support the required cell design.
Haomei Carbon Coated Aluminum Foil Quality Control
Haomei focuses on substrate quality and finished-roll control, including the material and coating parameters defined in the production specification.
- Aluminum alloy and material identification
- Foil substrate thickness
- Finished width
- Surface condition
- Coating coverage
- Coating thickness
- Coating uniformity
- Roll edge condition
- Winding quality
- Core and roll dimensions
- Packing condition before shipment
Carbon Coated Aluminum Foil Applications
Carbon coated aluminum foil is mainly used where a conductive aluminum current collector with a modified electrode interface is required.
Lithium-Ion Battery Cathodes
Current collector applications for selected lithium-ion battery electrode structures.
Power Batteries
Conductive current collector material for selected power battery electrode designs.
Energy Storage Batteries
Coated current collector material for selected energy storage battery applications.
Lithium-Sulfur Battery R&D
Selected research and development applications requiring a modified conductive foil surface.
Supercapacitors
Selected electrochemical material applications requiring conductive aluminum foil.
Other Electrochemical Materials
Experimental and advanced electrode systems subject to application-specific material selection.
Carbon Coated Foil vs Plain Battery Aluminum Foil
| Item | Plain Battery Aluminum Foil | Carbon Coated Aluminum Foil |
| Main Structure | Aluminum foil substrate. | Aluminum foil plus conductive carbon layer. |
| Surface | Bare aluminum. | Functional carbon-coated surface. |
| Interface with Electrode | Direct aluminum/electrode contact. | Carbon-modified electrode interface. |
| Adhesion | Depends on electrode formulation and surface condition. | Can improve interfacial adhesion. |
| Corrosion Protection | Depends mainly on aluminum surface and process. | Carbon layer can provide an additional barrier. |
| Processing | Simpler foil supply. | Additional coating process and tighter surface control. |
| Typical Selection | Standard current collector applications. | Applications requiring enhanced interface performance. |
For conventional aluminum battery foil specifications, see our Battery Aluminum Foil page.
Why Source Carbon Coated Foil from Haomei?
We can work around the customer's required combination of aluminum grade, substrate thickness, coating configuration and finished roll dimensions.
For projects that involve converting, slitting or roll-to-roll electrode coating, the supply specification can be discussed before production so that the delivered roll matches the intended processing route.
Haomei Supply Scope
- Aluminum foil substrate selection.
- Substrate thickness and alloy configuration.
- Single-sided or double-sided coating configuration.
- Coating thickness and coating system discussion.
- Finished width and roll specification.
- Slitting and winding requirements.
- Inspection and material documentation.
- Packing requirements before shipment.
FAQ – Carbon Coated Aluminum Foil
What is the difference between carbon coated foil and battery aluminum foil?
Battery aluminum foil is the aluminum substrate used as the current collector. Carbon coated foil adds a conductive carbon layer to the aluminum surface, creating a modified interface between the substrate and electrode material.
What aluminum alloys can be used as the substrate?
Typical substrate options include 1060, 1070, 1080, 1100 and 1235, subject to the required foil properties and production specification.
How thick is the carbon coating?
A typical configuration can use approximately 1 μm of carbon coating on each coated side. The final coating thickness should be confirmed according to the formulation and application.
Can the width and roll dimensions be customized?
Yes. Finished width and roll configuration can be specified according to the customer's coating, slitting and electrode manufacturing equipment.
What information is needed for a carbon coated foil quotation?
Please provide the alloy, substrate thickness, coating side, coating thickness, finished width, roll weight or length, core ID, roll OD, coating system and application requirements.
Can both sides be coated?
Yes, the product can be specified with single- or double-sided coating. For double-sided material, define the coating requirement for each face and identify any uncoated margins.
Will carbon coated aluminum foil improve battery cycle life?
It may support cycling performance when contact resistance or adhesion is a limiting factor. There is no universal improvement figure: the result depends on the electrode, electrolyte, cell design and test conditions.