Ultrasonic Spraying of High-Purity Whisker Carbon Nanotubes

Ultrasonic Spraying of High-Purity Whisker Carbon Nanotubes

High-purity whisker carbon nanotubes, also known as vapor-grown carbon fibers, are high-end one-dimensional carbon nanomaterials prepared through high-temperature graphitization purification and directional growth processes. As an important high-end branch of carbon nanotubes, they possess core advantages such as high purity, low specific surface area, easy dispersibility, and high conductivity, making them a core supporting material in fields such as lithium batteries and high-end composite materials. They appear as a fine black powder or uniformly dispersed liquid, with a purity exceeding 99% and extremely low metal impurity content. Their diameter is typically 8-50 nm, and their length 10-50 μm, exhibiting a linear whisker structure. They can be prepared by chemical vapor deposition. Compared to ordinary carbon nanotubes, they have higher crystallinity and a more stable structure, making them suitable for precision coating in various scenarios and the fabrication of high-end devices, demonstrating strong compatibility.

Although high-purity whisker carbon nanotubes have excellent performance and wide applications, their whisker-like structure, high aspect ratio, and high purity limit the achievement of high-quality film formation using traditional spraying processes. Its extremely high surface energy makes the whiskers prone to agglomeration and entanglement due to strong van der Waals forces. This not only disrupts its linear whisker structure, leading to decreased electrical and thermal conductivity, but also introduces defects such as porosity and uneven coating thickness. Furthermore, while its whisker structure is tough, the high-pressure impact and mechanical shearing forces of traditional air-pressure spraying and spin coating processes easily cause whisker breakage and introduce impurities, compromising its high-purity properties and affecting the final product performance. In addition, traditional processes suffer from uneven atomization, significant raw material loss, substantial waste of expensive high-purity whisker carbon nanotubes, and poor coating thickness consistency, failing to meet the stringent coating standards of lithium batteries and high-end composite materials, severely limiting its industrialization and large-scale application.

Chifei ultrasonic spraying machines, specifically designed for the material characteristics of high-purity whisker carbon nanotubes, offer a customized precision spraying process, completely resolving the various pain points of traditional processes. The equipment employs a 25kHz-120kHz high-frequency ultrasonic atomization principle, converting electrical energy into high-frequency mechanical vibration through a piezoelectric transducer. This uniformly atomizes a high-purity crystalline carbon nanotube dispersion into micron-sized fine droplets. The entire process involves low-pressure, gentle atomization, free from high-pressure impact and mechanical shearing, maximizing the protection of the whisker structure’s integrity and preventing whisker breakage and impurity introduction. Simultaneously, it effectively inhibits whisker aggregation, precisely preserving the core advantages of high purity, high conductivity, and easy dispersion, thus contributing to the construction of a highly efficient conductive network.

Compared to traditional spraying processes, Chifei’s ultrasonic spraying equipment offers significant advantages. The equipment boasts high atomization uniformity, with coating thickness uniformity consistently within a 5% deviation. It can achieve the preparation of nanoscale ultrathin continuous films, producing dense coatings free of pinholes and cracks, effectively preserving the intrinsic superior properties of high-purity crystalline carbon nanotubes, meeting the stringent requirements of high-end products. The non-contact directional deposition spraying method allows for a high utilization rate of over 90% for high-purity crystalline carbon nanotubes, a significant improvement over traditional processes, greatly reducing production costs and aligning with green production principles. The equipment boasts exceptional compatibility, adaptable to dispersions in various solvent systems, including water-based and alcohol-based solutions, and suitable for diverse substrates such as metals, ceramics, flexible films, and silicon wafers. It enables large-area uniform spraying and roll-to-roll continuous preparation, meeting the needs of both laboratory R&D and industrial mass production. The specially designed nozzle significantly reduces the risk of clogging and lowers maintenance costs.

In practical applications, high-purity whisker carbon nanotube films prepared by the Chifei ultrasonic spraying machine exhibit stable performance and excellent repeatability, making them widely applicable in various high-end fields. In the lithium battery field, as a novel conductive agent, it can significantly improve battery energy density, cycle life, and rate performance, meeting the needs of automotive fast-charging batteries and solid-state batteries. In the composite materials field, it can be used as a reinforcing filler in rubber-plastic and metal-based composite materials, improving material mechanical properties and thermal conductivity. In the electrothermal conversion field, it can be used in products such as heated down jackets and heated knee pads to achieve efficient electrothermal conversion. In the electromagnetic shielding field, it can be used as a shielding coating for electronic equipment and military products, ensuring stable equipment operation.

With the continuous iteration of new energy and high-end manufacturing technologies, the market application of high-purity whisker carbon nanotubes is becoming increasingly widespread, leading to ever-increasing demands on the precision and stability of spraying processes. Chifei Ultrasonic Equipment Co., Ltd. has been deeply involved in the field of nano-spraying for many years, focusing on solving the precision film formation challenges of various high-end nanomaterials. Relying on mature equipment technology and a complete process system, we provide efficient, stable, and cost-effective complete solutions for the preparation of high-purity whisker carbon nanotube thin films, helping various related enterprises achieve technological upgrades and mass production.

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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