Customizing the Perfect Coating Solution for PEM Electrolyzers

Dialogue with Cheersonic Application Engineers – Customizing the Perfect Coating Solution for PEM Electrolyzers

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

Once 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 are the core execution units 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 perfluorinated sulfonic 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 Pt/C 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 Methods
Stable delivery of catalyst inks directly determines coating uniformity and repeatability. Cheersonic provides various solution delivery options: 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—settling tendency, particle size, shear sensitivity—and desired spraying cycle time. 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-process stability from the storage tank to the nozzle outlet, free from clogging or flow drift caused by complex inks.

3. Customization of Catalyst Deposition Strategies
The catalyst layer of PEM electrolyzers must simultaneously provide high electrochemical active area, excellent proton/electron conduction pathways, and appropriate porous structure. Cheersonic offers diverse deposition strategies for different electrolyzer designs (traditional flat-plate, 3D porous transport layer, 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 path, overlap ratio, spraying height, and substrate temperature. For 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 loading (e.g., iridium loading below 0.2 mg/cm² on the anode) while maintaining excellent electrolysis performance.

4. Overall Configuration of the Membrane Coating System
Cheersonic delivers not isolated spraying equipment, but complete membrane coating systems, flexibly configurable for laboratory, pilot, or fully automatic mass production. Based on your production throughput requirements (coating area per minute or membrane electrode pieces 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 lines, and roll-to-roll (R2R) continuous coating systems for large-scale production. The R2R system supports proton exchange membrane rolls with widths from 300 mm to over 1000 mm, integrated with online film thickness monitoring, defect detection, and closed-loop feedback adjustment. The system also includes exhaust emission, solvent recovery, heating/drying modules (infrared or hot air), and explosion-proof design to ensure safety, environmental compliance, and 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 proofing services) and provide detailed process reports, including film thickness distribution profiles, sheet resistance tests, electrochemical polarization curves, and long-term operational stability data. Whether you aim to control film thickness tolerance 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 work with you to find the most reliable engineering solution.
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.

Chinese Website: Cheersonic Provides Professional Coating Solutions