Application of Ultrasonic Sprayer in Carbon Felt Spraying

In today’s modern industrial process driven by science and technology, every technological innovation and breakthrough injects new vitality into industrial development. As an advanced spraying equipment, ultrasonic sprayer is deeply integrated into the carbon felt spraying process, bringing unprecedented changes to this field.

1. Principle and characteristics of ultrasonic sprayer
The ultrasonic sprayer relies on cutting-edge ultrasonic atomization technology, and its working principle is like a precise “dance” in the microscopic world. The ultrasonic generator inside the equipment produces high-frequency vibrations, and the frequency can usually reach tens of kilohertz or even higher. Under the action of this high-frequency vibration, the paint liquid is instantly “torn” into extremely small droplets. Compared with traditional spraying technology, the droplet size of ultrasonic spraying can be precisely controlled in a very small range, generally as low as micron level.

This unique atomization method shows extraordinary value in carbon felt spraying. First, it can achieve extremely uniform droplet distribution. Carbon felt has a complex and special microstructure. From a microscopic perspective, its internal fibers are interwoven to form numerous pores and gullies. Uniform droplet distribution ensures that the coating can be evenly covered on every microstructure of the carbon felt, which is of great significance for maintaining the performance stability and consistency of the carbon felt in subsequent applications. For example, in the carbon felt electrode used in energy storage batteries, the uniform coating can ensure the uniform electrochemical reaction on the electrode surface, improving the battery charging and discharging efficiency and service life.

Second, the ultrasonic atomization process is very gentle. In traditional spraying methods, such as high-pressure air spraying, the paint impacts the carbon felt surface at high speed under the action of high-pressure airflow, which may cause physical damage to the carbon felt fibers. During ultrasonic spraying, the droplets are attached to the carbon felt in a gentle manner, effectively avoiding damage to the fiber structure. It should be noted that the fiber structure of carbon felt is the cornerstone of its excellent performance. Once the fiber is broken or deformed, the mechanical strength, electrical conductivity and thermal conductivity of the carbon felt will be greatly reduced.

2. Characteristics and spraying requirements of carbon felt
As a porous material carefully woven from carbon fibers, carbon felt is like a “super sponge” in the microscopic world, with many remarkable characteristics. Its density is extremely low, but it has an ultra-high specific surface area, just like a “porous net” with a huge area but extremely light weight. At the same time, carbon felt performs well in electrical and thermal conductivity, which makes it very useful in many fields such as aerospace, energy storage, and environmental protection.

In the field of aerospace, some key components of aircraft need to work in extremely high temperature and high pressure environments. Carbon felt has become an ideal material due to its high temperature resistance and high strength. However, in order to further improve its performance in complex environments, it is often necessary to spray a special high temperature resistant and anti-oxidation coating on the surface of carbon felt, like a solid “protective armor” to protect the carbon felt from erosion by harsh environments.

In the field of energy storage, such as supercapacitors and lithium-ion batteries, carbon felt is often used as an electrode material. In order to improve the electrochemical reaction activity of the electrode, a specific catalyst coating needs to be sprayed on its surface. This is like equipping athletes with a more efficient “energy booster”, which can significantly improve the performance of the electrode during charging and discharging. Whether it is aerospace or energy storage, these coatings must not only be closely integrated with the surface of carbon felt, but also have uniform thickness and excellent quality, which puts forward almost demanding requirements on the spraying process.

3. Key points of ultrasonic spraying machine in carbon felt spraying
When using ultrasonic spraying machine to spray carbon felt, the preparation of coating can be called “opening prelude”. The coating formula needs to be tailored according to the specific application scenario and performance requirements of carbon felt. Taking carbon felt used in the field of heat dissipation of electronic equipment as an example, if the heat dissipation coating is to be sprayed, high thermal conductivity nanoparticles may need to be added to the coating, and the viscosity of the coating must be strictly controlled within an appropriate range. If the viscosity is too high, the coating is difficult to be effectively atomized under the action of ultrasound, just like thick syrup is difficult to be blown into fine droplets; if the viscosity is too low, even if it is successfully atomized, it is impossible to form a coating with sufficient thickness and adhesion on the surface of carbon felt, just like it is difficult for clear water to remain on the wall.

During the spraying process, it is crucial to control the distance between the nozzle and the surface of carbon felt. This distance is like the “golden ratio” in artistic creation. If it is too close, the local coating of the carbon felt will be too thick, resulting in a “drooping” phenomenon similar to the rain flowing under the eaves, which seriously affects the coating quality; if it is too far, the droplets may not be evenly covered on the surface of the carbon felt due to volatilization or uneven dispersion during the long “trek”, resulting in mottled coating and uneven thickness.

In addition, the spraying speed and scanning method should not be ignored. A reasonable scanning path should ensure that every inch of the carbon felt can be accurately “visited”, just like a gardener carefully watering every corner of the garden. The spraying speed must be closely coordinated with the ultrasonic atomization frequency and the paint supply speed to form an efficient and stable “collaborative system”. If the spraying speed is too fast and the paint supply is not enough, the coating thickness will be insufficient; if the speed is too slow, the production efficiency will be reduced and the production cost will be increased.

4. The advantages and significance of ultrasonic spraying machine spraying carbon felt
From the quality dimension, the ultrasonic sprayer has a clear advantage in carbon felt spraying. It can create high-quality coatings, which fully meet the stringent performance requirements of carbon felt in different high-end fields. Whether it is the requirements for coating uniformity, adhesion, or the fineness of the coating microstructure, ultrasonic spraying can complete the task excellently and greatly increase the added value of carbon felt products. Taking carbon felt parts used in high-end medical equipment as an example, high-quality coatings can ensure the stable performance of carbon felt in long-term complex use environments and ensure the accuracy and reliability of medical equipment.

In terms of production efficiency, ultrasonic sprayers effectively reduce defective products and rework with their precise control capabilities. In traditional spraying processes, it is difficult to accurately control the thickness and uniformity of the coating, and a large number of products that do not meet quality standards often appear, requiring a lot of time and cost for rework. The precise operation of ultrasonic sprayers has greatly improved production efficiency, saving valuable time and economic costs for enterprises, allowing them to seize the initiative in the fierce market competition.

The environmental protection level is also remarkable. Ultrasonic spraying can accurately control the amount of paint, reduce paint waste, and reduce pollution to the environment. In traditional spraying methods, a large amount of paint is scattered into the air under the action of high-pressure airflow, which not only causes waste of resources, but also poses a pollution threat to the environment. The application of ultrasonic spraying machines has paved a solid road for the green and sustainable development of the carbon felt industry. It not only helps carbon felt to continuously optimize its performance in traditional fields, but also expands its application in emerging fields such as quantum communication equipment, and effectively promotes the innovation and upgrading of the entire related industrial chain.

In summary, the application of ultrasonic spraying machines in the field of carbon felt spraying is undoubtedly a technological innovation. With its excellent performance and advantages, it plays a key role in improving the quality of carbon felt products, production efficiency and environmental protection level. It is bound to make a bold and colorful contribution to the grand blueprint of future industrial development and continue to promote related industries to new heights.

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.

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