Elevate Your Electrolyzer Performance

Consult with Our Application Engineers – Elevate Your Electrolyzer Performance

During the manufacturing of proton exchange membrane (PEM) electrolyzers, the uniformity and adhesion of catalyst coatings, precise control of film thickness, and production efficiency are critical factors determining the performance and service life of electrolyzers. Cheersonic understands that each customer faces unique electrolyzer application scenarios: some require high-loading catalyst coatings to boost current density, others demand ultra-thin films to minimize proton transport resistance, while some focus on the consistency of large-area coatings or pursue continuous production at high throughput. For this reason, we strongly recommend you communicate directly with Cheersonic’s senior application engineers for one-on-one consultations, and share with us your specific electrolyzer application requirements, material systems, performance targets, and production line planning in full.

When you engage in dialogue with Cheersonic’s application engineers, we will systematically tailor coating solutions for you across four core technical dimensions:

1. Precise Selection of Ultrasonic Nozzles
Ultrasonic nozzles serve as the core execution unit of the spraying system. Cheersonic offers a wide range of nozzle models with diverse atomization characteristics, including wide spray width, narrow spray width, focused, and diffused types. For PEM electrolyzer proton exchange membranes – typically Nafion series or other perfluorosulfonic acid membranes – we recommend the most suitable nozzle based on your catalyst ink viscosity, solid content, and solvent type (aqueous, alcohol-based, or mixed solvents). For instance, for low-solid-content, easily sedimentary iridium-based anode inks, we suggest high-frequency, fine-atomization nozzles to achieve more uniform droplet distribution; for high-viscosity platinum-carbon cathode inks, low-frequency, high-flow nozzles may be selected to ensure deposition efficiency and film integrity. Through proper nozzle matching, Cheersonic helps you eliminate the “coffee ring effect”, coating cracking, or pinhole defects at the source.

2. Design of Coating Solution Delivery Systems
Stable delivery of catalyst inks directly determines coating uniformity and repeatability. Cheersonic provides diverse solution delivery options, ranging from basic gravity feed and peristaltic pump constant-flow delivery to advanced closed-loop pressure tank control and mass flow meter closed-loop feedback systems. We design the most reliable delivery path based on your ink properties – including sedimentation tendency, particle size, and shear sensitivity – as well as your desired spraying cycle. For continuous roll-to-roll production, Cheersonic can integrate pulsed or continuous supply modules to eliminate film thickness deviations caused by fluid supply fluctuations. Our engineers optimize parameters and pipeline design to ensure full-chain stability from the storage tank to the nozzle outlet, eliminating concerns over clogging or flow drift caused by complex inks.

3. Customized Catalyst Deposition Strategies
Catalyst layers in PEM electrolyzers must balance high electrochemical active surface area, favorable proton/electron conduction pathways, and appropriate porous structures. Cheersonic provides versatile deposition strategies for various electrolyzer designs (conventional flat-plate, 3D porous transport layer structures, or novel microporous thin films), including static scanning deposition, multi-axis robotic dynamic deposition, and masked selective area deposition. We also assist in optimizing spraying paths, overlap ratios, spraying heights, and substrate temperatures. For scenarios requiring layered deposition of different catalyst formulations (e.g., IrO₂/TiO₂ composite catalysts on the anode side and Pt/C on the cathode side), Cheersonic supports multi-layer co-spraying or intermittent spraying processes to form gradient catalyst layers, significantly reducing interfacial contact resistance. With rational deposition strategies, you can achieve lower catalyst loadings (e.g., iridium loading below 0.2 mg/cm² on the anode) while maintaining outstanding electrolysis performance.

4. Integrated Membrane Coating System Configuration
Cheersonic delivers not standalone spraying equipment, but complete membrane coating systems flexibly configurable for laboratory, pilot, or fully automatic mass production. Based on your production throughput requirements (e.g., square meters coated per minute or membrane electrodes processed per day), we recommend corresponding substrate transport methods: single-piece vacuum chuck platforms for R&D and small-batch production, linear module reciprocating platforms for pilot trials, and roll-to-roll (R2R) continuous coating systems for large-scale manufacturing. These R2R systems support proton exchange membrane webs with widths from 300 mm to over 1000 mm, integrated with online film thickness monitoring, defect detection, and closed-loop feedback regulation. System configurations also include exhaust emission, solvent recovery, heating/drying modules (infrared or hot air), and explosion-proof designs to ensure safety, environmental compliance, and adherence to industrial standards.

Ultimately, all Cheersonic recommendations are closely aligned with your specific goals for PEM electrolyzer performance, film thickness, surface area, and production throughput. We verify parameters through preliminary experiments (sample submission or proof-of-concept services) and provide detailed process reports, including film thickness distribution profiles, surface resistance tests, electrochemical polarization curves, and long-term operational stability data. Whether you aim to control film thickness tolerances within ±0.5 μm, achieve a single-piece spraying cycle under 3 seconds, or increase active surface area by over 30%, Cheersonic’s application engineers will collaborate with you to develop the most reliable engineering solutions.

Contact Cheersonic’s application engineers today. Share your electrolyzer applications, and leave the rest to Cheersonic.

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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