AC6766 Hard Carbon Double Side Coated Aluminum Foil

Hard Carbon Double Side Coated Aluminum Foil Description

Hard Carbon Double Side Coated Aluminum Foil is an advanced anode material primarily used in sodium-ion batteries, featuring hard carbon coatings on both sides of a lightweight aluminum foil substrate. This double-sided coating increases the active material loading per unit area, resulting in higher overall energy density without significantly increasing the electrode’s thickness or weight. Hard carbon is a non-graphitizable carbon characterized by a disordered microstructure consisting of randomly oriented graphitic layers and nanopores, which provide abundant sites for sodium-ion storage through intercalation and pore-filling mechanisms.

The disordered structure enables a high reversible capacity, typically ranging from 250 to 350 mAh/g, with excellent rate capability and cycling stability. Unlike graphite, which performs poorly in sodium-ion systems, hard carbon maintains stable performance over many charge-discharge cycles due to its minimal volume expansion and strong structural integrity. The use of aluminum foil as the current collector offers advantages such as low density, corrosion resistance, and good electrical conductivity, which contribute to improved overall electrode efficiency.

Electrochemically, this material exhibits a low operating voltage plateau and low initial irreversible capacity loss, enhancing battery safety and energy efficiency. The double-side coating design further optimizes electrode packing density in battery cells, making it suitable for large-scale energy storage applications, electric mobility solutions, and renewable energy integration. The combination of high capacity, stable cycling, and scalable manufacturing processes positions Hard Carbon Double Side Coated Aluminum Foil as a promising material for next-generation sodium-ion battery technologies.

Hard Carbon Double Side Coated Aluminum Foil Applications

Hard Carbon Double Side Coated Aluminum Foil is widely used as an anode material in sodium-ion batteries, which are increasingly adopted for grid-scale energy storage, renewable energy integration, and backup power systems due to their cost-effectiveness and abundant raw materials. It is also suitable for electric two-wheelers, low-speed electric vehicles, and portable energy storage devices where long cycle life, safety, and stable performance are essential. Additionally, this material is being explored for use in flexible and solid-state batteries, supporting the development of next-generation energy storage technologies that require high capacity and durability.

Hard Carbon Double Side Coated Aluminum Foil Packaging

Our products are packaged in customized cartons of various sizes based on the material dimensions. Small items are securely packed in PP boxes, while larger items are placed in custom wooden crates. We ensure strict adherence to packaging customization and the use of appropriate cushioning materials to provide optimal protection during transportation.

Packaging: Carton, Wooden Box, or Customized.

Kindly review the packaging details provided for your reference.

Manufacturing Process

1.       Testing Method

(1)    Chemical Composition Analysis - Verified using techniques such as GDMS or XRF to ensure compliance with purity requirements.

(2)    Mechanical Properties Testing - Includes tensile strength, yield strength, and elongation tests to assess material performance.

(3)    Dimensional Inspection - Measures thickness, width, and length to ensure adherence to specified tolerances.

(4)    Surface Quality Inspection - Checks for defects such as scratches, cracks, or inclusions through visual and ultrasonic examination.

(5)    Hardness Testing - Determines material hardness to confirm uniformity and mechanical reliability.

Please refer to the SAM testing procedures for detailed information.

Hard Carbon Double Side Coated Aluminum Foil FAQs

Q1. What is Hard Carbon Double Side Coated Aluminum Foil?

It is an anode material used mainly in sodium-ion batteries, consisting of aluminum foil coated with hard carbon on both sides to increase active material loading and improve battery performance.

Q2. Why is hard carbon preferred over graphite for sodium-ion batteries?

Hard carbon has a disordered structure that efficiently stores sodium ions, while graphite struggles with sodium intercalation due to ion size and structure incompatibility.

Q3. What capacity can I expect from this anode material?

Typical reversible capacity ranges from 250 to 350 mAh/g, depending on synthesis and battery conditions.

Related Information

1.       Common Preparation Methods

The preparation of Hard Carbon Double Side Coated Aluminum Foil involves first synthesizing hard carbon by pyrolyzing organic precursors such as phenolic resins, cellulose, or pitch at temperatures between 1000°C and 1300°C in an inert atmosphere to produce a disordered carbon structure suitable for sodium-ion storage. The hard carbon powder is then mixed with conductive additives and a binder like polyvinylidene fluoride (PVDF) dissolved in a solvent such as N-methyl-2-pyrrolidone (NMP) to create a uniform slurry. This slurry is coated evenly on both sides of an aluminum foil substrate using coating methods such as doctor blade or slot-die coating. After coating, the foil is dried at elevated temperatures to remove residual solvents and calendared to improve the coating’s uniformity, adhesion, and electrode density. Finally, the double side coated foil is cut or punched into the desired shapes and sizes, resulting in an anode material with high mechanical strength, excellent electrical conductivity, and superior electrochemical performance for use in sodium-ion batteries.