Graphene Sheet Spraying

Graphene Sheet Spraying – Nanomaterial Coating Systems – Cheersonic

In new material composite processes, functional encapsulation of graphene sheets has always faced the dual challenges of adhesive uniformity and substrate integrity. Ultrasonic sprayers, with their unique atomization principle, provide an innovative approach for applying adhesive to graphene sheets while balancing precision and protection, becoming a key process breakthrough in promoting the large-scale application of graphene.

The core advantage of ultrasonic sprayers lies in their use of high-frequency vibrations to achieve micron-scale atomization of the adhesive. Unlike traditional pressure spraying, ultrasonic sprayers use a transducer to convert electrical energy into high-frequency mechanical vibrations, creating a uniformly dispersed droplet mist at the nozzle with a particle size deviation of less than 5%. This pressure-free atomization mode avoids damage to the graphene sheet caused by high-speed airflow impact, making it particularly suitable for single-layer graphene substrates as thin as 0.34 nanometers, and eliminating the edge curling and surface scratching issues that are common with traditional processes.

At the process control level, this technology enables precise three-dimensional control of the adhesive spraying process. By adjusting the ultrasonic frequency (typically 20-180kHz), droplet size can be controlled. Combined with a programmable motion platform, this technology can form a uniform adhesive layer with a thickness of 0.1-10 microns on the graphene sheet surface. Stable spraying is achieved by adjusting the amplitude and feed rate for adhesives of varying viscosities, addressing the stringing and buildup issues often associated with high-viscosity adhesives and the problem of excessive spreading with low-viscosity adhesives. In flexible electronics applications, this process has achieved seamless bonding of graphene electrodes to substrates, with adhesive layer coverage exceeding 99.5%.

Ultrasonic spraying also significantly improves the economic and environmental performance of the adhesive spraying process. Its droplet utilization rate can reach over 85%, saving 30-50% in adhesive consumption compared to traditional spraying. The airless spraying mode eliminates the release of volatile organic compounds, meeting green manufacturing standards. In the graphene coating process for power batteries, this technology precisely controls the thickness of the adhesive layer, increasing electrode conductivity by 20% while reducing adhesive usage by 30%, effectively boosting battery energy density.

As graphene applications expand into flexible displays, sensors, energy storage, and other fields, the precise adhesive application capabilities of ultrasonic sprayers will become a key supporting technology. In the future, integration with online inspection systems will enable real-time monitoring and closed-loop control of adhesive application quality, further promoting the industrialized mass production of graphene composites and providing reliable process assurance for the transformation of new material technologies.

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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