Ultrasonic Spraying for Film Production

Ultrasonic Spraying for Film Production – Anti Reflective Coating – Cheersonic

Ultrasonic spraying is a highly advanced and precise coating technology that has revolutionized the production of thin films in multiple industries, particularly in the new generation of electronics and energy applications.

The main advantages of thin film production

This unique mechanism has significant advantages compared to traditional coating methods such as spin coating, slit coating, or traditional spray coating.

Advantage

• Extremely high uniformity: producing thin films with consistent thickness, density, and composition. This is crucial for the performance of electronic and optical devices.
• Accurate thickness control: It can prepare very thin films (ranging from nanometers to several micrometers) with excellent repeatability.
• Very few overspray and high material efficiency: material utilization rate of over 95%. It is crucial when using expensive materials such as conductive ink, perovskite, and carbon nanotubes.
• Low speed “soft spray”: prevent damage to fragile substrates (e.g., pre patterned circuits, flexible plastics, aerogels), and eliminate “bounce” leading to defects.
• Excellent conformal coating capability: It can uniformly coat complex, three-dimensional, or porous surfaces, not just flat substrates.
• Accurate patterning and control: The nozzle can be controlled by robots to coat specific areas, create gradients or multi-layer structures without the need for masks.
• Low blockage rate: Large openings and ultrasonic atomization can better handle suspensions and particles than pressure based nozzles.
• Scalability: Easy to expand from research and development using a single nozzle to industrial production using multiple nozzle arrays for coating large-area products (such as solar panels, roll to roll flexible electronics).

Key applications in film production

Ultrasonic spraying performs well in applications where precision, material cost, and film quality are crucial.

1. Electronics and Optoelectronics

• Printed electronics: Spray conductive ink (silver, copper, graphene) for flexible circuits, antennas, and sensors.
• Transparent conductive film: Deposition of silver nanowires, carbon nanotubes, PEDOT: PSS and other materials as alternatives to ITO.
• Thin film transistor: precise deposition of semiconductor and dielectric layers.

2. Photovoltaic (solar cell)

• Perovskite solar cells: Ideal for depositing perovskite absorber layers, electron transport layers, and hole transport layers, their high uniformity is crucial for efficiency and stability.
• Dye sensitized solar cells: spraying TiO ₂ photoanode and electrolyte layer.
• Organic photovoltaics: deposition of active layer and buffer layer.
• Anti reflective coating: used for silicon solar cells and cover glass.

3. Energy storage

• Battery electrode: Precisely coat the anode and cathode slurry onto the current collector (foil). It can achieve thinner and more uniform electrodes, thereby improving performance and accelerating charging speed.
• Fuel cell&electrolytic cell catalyst: Spray catalyst ink (such as Pt/C) onto proton exchange membrane or gas diffusion layer to manufacture catalyst coating membrane.

4. Function and protective coating

• Hydrophobic/oleophobic coating: For example, spray coating without PFAS or silica based coating, used for waterproofing and anti fouling.
• Anti corrosion coating: Apply a thin and conformal protective layer.
• Antibacterial coating: Deposition of silver or copper ion based coatings on medical devices.

Ultrasonic spraying has become a key enabling technology for advanced thin film manufacturing. The unique combination of precision, efficiency, and versatility makes it the preferred method for developing and producing next-generation electronic, energy, and functional devices, especially in areas where traditional coating methods are inadequate. It bridges the gap between laboratory scale discoveries and industrial scale production, especially for complex, multi material, and high-value products.

About Cheersonic

Cheersonic is the leading developer and manufacturer of ultrasonic coating systems for applying precise, thin film coatings to protect, strengthen or smooth surfaces on parts and components for the microelectronics/electronics, alternative energy, medical and industrial markets, including specialized glass applications in construction and automotive.

Our coating solutions are environmentally-friendly, efficient and highly reliable, and enable dramatic reductions in overspray, savings in raw material, water and energy usage and provide improved process repeatability, transfer efficiency, high uniformity and reduced emissions.

Chinese Website: Cheersonic Provides Professional Coating Solutions