What Are The Effects Of 100kHz Ultrasonic Atomization Spraying?

100kHz ultrasonic atomization spraying is a non-contact, high-precision thin-film coating technology. Its core function is to use 100kHz high-frequency ultrasonic vibration to atomize liquid materials into micron-sized uniform droplets, which are then precisely deposited onto the target substrate surface to form a coating with controllable thickness and strong adhesion.

 

Compared to traditional spraying methods (such as air pressure spraying and brushing), it offers significant advantages in fine coating, material utilization, and process compatibility. Its specific functions and applications are as follows:

 

1. Core Technology Role

Micron-level Uniform Atomization

High-frequency vibration at 100kHz can break liquids into tiny droplets of 1–50μm, with a narrow and highly uniform droplet size distribution. This characteristic enables ultra-thin, uniform coating deposition, with coating thickness precisely controlled from the nanometer to the micrometer level, avoiding problems such as "sagging," "pinholes," and "edge buildup" common in traditional spraying.

 

1.2Non-contact coating protects sensitive substrates.

There is no high-pressure airflow impact or mechanical contact during the spraying process, so it will not damage flexible substrates (such as films and fabrics), precision electronic components (such as chips and sensors) or fragile biological materials (such as cell carriers), making it suitable for scenarios with stringent requirements for substrate surface.

 

1.3 High material utilization rate, reduced costs.

Traditional air pressure spraying has a material utilization rate of only 30%–50%, while 100kHz ultrasonic atomization spraying can achieve a material utilization rate of 80%–95%. Directional droplet deposition reduces splashing and waste, making it particularly suitable for coating expensive materials such as precious metal solutions (e.g., silver paste, palladium solution) and high-concentration suspensions (e.g., ceramic slurries).

 

1.4 Compatible with multiple types of liquid materials.

It can atomize various systems such as aqueous solutions, organic solvents, suspensions, sol-gels, and biological liquids (e.g., protein solutions) without the need for additional diluents, preserving the original properties of the materials.

 

2. Typical Industry Applications

2.1 Electronics Industry: Functional Thin Film Preparation

Used for coating semiconductor chips (such as insulating layers, passivation layers), conductive coatings on flexible printed circuit boards (FPCs) (such as silver nanowire coatings), and antireflective coatings on solar cells, improving the insulation, conductivity, or optical performance of electronic components.

Advantages: Coating uniformity directly affects the performance stability of electronic components; 100kHz atomization can avoid short circuits or failures caused by coating defects.

 

2.2 New Energy Industry: Battery electrode coating

Is used in the preparation of electrodes for lithium batteries and fuel cells. It involves uniformly coating positive/negative electrode slurries (such as lithium iron phosphate or graphite slurries) onto a copper/aluminum foil substrate to form an electrode layer of uniform thickness.

Advantages: Improves battery energy density, cycle life, and charge/discharge efficiency; reduces the risk of electrode coating cracking.

 

2.3 Biopharmaceutical Industry: Precision Drug Delivery and Biocoatings

Used in medical implant coatings (such as antibacterial coatings for artificial joints and drug-releasing coatings for cardiovascular stents), precise drug loading and slow release are achieved by controlling droplet deposition.

Atomized cell culture media can be used to prepare cell coatings on the surface of bio-scaffolds for tissue engineering research.