How can a successfully lab-tested “copper foil surface roughening technology” be scaled up from a small experimental tank to a full production line? This summer, a dedicated research team from Jiangxi University of Science and Technology, led by faculty members Fan Xiaowei and Song Ning along with graduate students Huang Jian, Luo Yixin, and Huang Yanle, is tackling this very challenge in the sweltering workshop.
The microscopic “texture” formed on the copper foil acts like gripping teeth, essential for bonding the foil to circuit board substrates—a factor critically influencing the peel resistance of electronic products.
In the workshop, Huang Yanle carefully pours additive from a reagent bucket into the electrolytic tank. “The lab tank holds only 1 liter, while the production tank is 1.36 cubic meters—over a thousand times larger. You can’t just scale the additives linearly. Incorrect dosing could cause precipitation and ruin the roughening effect,” explains Luo Yixin, who continuously calculates and monitors the electrolyte concentration. “In a small tank, additives diffuse evenly, but large tanks may have dead zones.” It’s like stirring a spoon of sugar into a glass versus a whole bag into a tub: the mixing strategy must change.
To avoid local concentration spikes that cause precipitation, the team developed a “gradient dosing method”—first dissolving small amounts of additive in a limited volume of electrolyte before introducing it into the main tank.
Copper foil, often called the “blood vessel” of the electronics industry, is only microns thick yet must carry high-frequency signals reliably. Surface smoothness and mechanical properties are crucial. While lab conditions allow precise control over temperature and additive concentration, production environments are far less predictable. “Our first trial produced foil nothing like the lab samples,” recalls Fan Xiaowei. “The lab is ideal—the real test is on the production floor.”
To bridge the gap, Song Ning and Huang Jian compared data and surface morphologies between small and large tanks, eventually adjusting current density to replicate lab results while maintaining uniform appearance and avoiding powder residue.
“Professor Tang Yunzhi always reminds us: production isn’t lab experimentation. Our technology must withstand real-world tests of cost, efficiency, and environmental impact,” shares Luo Yixin.
With strong support from Jiangxi Copper Foil Technology Co., Ltd., the team successfully applied their novel composite additive system and current density adjustments to achieve a surface roughness below 2µm and peel strength exceeding 1N/mm—making the technology production-ready.
This breakthrough exemplifies how Jiangxi University of Science and Technology continues to drive the integration of innovation, education, and industry—transforming laboratory advances into real-world solutions.
