CuO nanoparticles (NPs) are applied in various key technologies, such as catalysis, energy conversion, printable electronics and nanojoining. In this study, an economic, green and easy-scalable sol-gel synthesis method was adopted to produce submicron-sized nanoporous CuO NP aggregates with a specific surface area > 18 m²/g. To this end, a copper-carbonate containing precursor was precipitated from a mixed solution of copper acetate and ammonia carbonate and subsequently calcinated at T ≥ 250 °C. The thus obtained CuO nanopowder is composed of weakly-bounded agglomerates, which are constituted of aggregated CuO NPs with a tunable size in the range of 100–140 nm. The CuO aggregates, in turn, are composed of equi-axed primary crystallites with a tunable crystallite size in the range of 20–40 nm. The size and shape of the primary CuO crystallites, as well as the nanoporosity of their fused CuO aggregates, can be tuned by controlled variation of the degree of supersaturation of the solution via the pH and the carbonate concentration. The synthesized submicron-sized CuO aggregates can be more easily and safely processed in the form of a solution, dispersion or paste than individual NPs, while still offering the same enhanced reactivity due to their nanoporous architecture.

Electrophoretic deposition (EPD) of nanoporous oxide coatings is an interesting research avenue owing to the experimental simplicity and broad scope of applications and materials. In this study, the properties of concentrated (up to 5000 mg/L), non-aqueous CuO nanoparticle (NP) dispersions were tailored to produce micrometer thick, nanoporous CuO films by EPD. In particular, we performed a systematic investigation of the electrophoretic mobilities and size distributions of dispersed CuO aggregates and developing agglomerates in different organic solvents for concentrations ranging from 50 to 5000 mg/L with and without surfactant addition. Time-resolved DLS analyses showed that aggregate mobilities and agglomeration rates decrease with increasing hydrocarbon chain length of the organic solvent (from ethanol to hexanol) and thus with increasing viscosity. The highest electrophoretic mobility was obtained for CuO NP aggregates and agglomerates dispersed in ethanol as a solvent. However, the addition of  0.5 wt.% acetylacetone (AcAc) as a surfactant is required to stabilize these dispersions for subsequent EPD and at the same time introduce a net attractive (electrostatic) interaction between neighboring agglomerates on the substrate to promote layer formation during the EPD step. The produced micrometer thick nanoporous CuO coatings can serve as high-surface area nanostructured materials or nanoporous scaffolds in catalysis, combustion, propellants and nanojoining.

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