Ultrasonic Atomization Slurry Coating

Ultrasonic Atomization Slurry Coating | Accurately Coating the Anode and Cathode Slurry onto the Current Collector (foil)

Against the backdrop of rapid development in the new energy industry, improving battery performance has become a core research and development direction, and electrode manufacturing technology, as a key link in battery production, directly determines the energy density, charging efficiency, and cycle life of batteries. Among them, the ultrasonic spraying machine, with its unique technical principle, has demonstrated significant advantages in the electrode slurry coating process, providing important support for the mass production of high-performance batteries.

The core structure of an electrode consists of a current collector and an active slurry. The current collector is usually made of lightweight metal foil – aluminum foil is commonly used for the cathode, and copper foil is mainly used for the anode. Its function is to carry the active substance and conduct current, so there are strict requirements for surface flatness and conductivity stability. The traditional spraying process relies heavily on high-pressure airflow to atomize the slurry, which can easily lead to uneven atomization particles due to pressure fluctuations, resulting in local accumulation or leakage during coating. This not only makes it difficult to control the coating thickness, but also causes waste of active materials, ultimately affecting the consistency of electrodes and battery performance.

Ultrasonic spraying machine achieves slurry atomization through high-frequency vibration. Its working principle is to use a transducer to convert electrical energy into high-frequency mechanical vibration (usually above 20kHz), causing the slurry at the nozzle to split into small and uniform droplets under the action of vibration. This atomization method does not rely on high-pressure airflow and can effectively avoid problems such as droplet aggregation and splashing in traditional processes, ensuring that the slurry is accurately and uniformly distributed on the surface of the current collector with precise flow rate and density. During the coating process, by precisely controlling the amplitude of ultrasonic waves, spraying speed, and nozzle distance, the thickness of the electrode coating can be controlled within the range of a few micrometers to tens of micrometers, achieving the “ultra-thin coating” effect that traditional processes cannot achieve.

A thinner electrode structure can significantly shorten the migration path of lithium ions in the active material. During the process of battery charging and discharging, lithium ions need to be inserted and removed back and forth between the cathode and anode. Shortening the migration distance can significantly reduce ion transport resistance, which can not only improve charging speed – experimental data shows that electrodes using ultrasonic spraying technology can shorten charging time by more than 30% compared to traditional processes, but also improve the utilization rate of active materials, thereby enhancing the energy density and discharge efficiency of the battery. At the same time, uniform coating thickness can avoid local current concentration, reduce side reactions caused by local overheating during charging and discharging, lower the risk of battery bulging, decay, and extend battery cycle life.

In addition, the precise coating ability of ultrasonic spraying machines can also reduce slurry waste. In traditional processes, the slurry loss rate caused by uneven atomization can reach over 15%, while the slurry utilization rate of ultrasonic spraying can be increased to over 90%, which can effectively reduce production costs in large-scale production. At present, this technology has been widely applied in fields such as power batteries and energy storage batteries, providing key process guarantees for the performance upgrade of products such as electric vehicles and portable electronic devices, and promoting the development of the new energy industry towards high efficiency, energy conservation, and long lifespan.

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.

If you have any technical questions, customization demands, or procurement inquiries about ultrasonic atomization nozzles, feel free to contact our professional sales and technical team for detailed parameters, customized solutions, and industry application support.
Email: market2@cheersonic.com