Battery Layer Coatings

Ultrasonic Coating Solutions for Advanced Battery Research and Emerging Production

Ultrasonic atomization spraying technology enables high-precision coating preparation for next-generation energy storage devices, with applications covering lithium-ion batteries, solid-state batteries, sodium-ion batteries, and aluminum-ion battery systems still under development. Utilizing the ultrasonic atomization mechanism, highly uniform thin-film coatings can be prepared on electrode and separator surfaces, helping to improve the overall performance of the battery cell and enhance battery safety, service reliability, and cycle life.

This technology is more suitable for thin-film and low-solids-content composite slurry systems, unlike traditional high-solids-content thick slurry coating processes. It offers significant advantages in research and development and small-scale pilot production, achieving low material loss, controllable porosity, and stable reproduction of micron-level thicknesses.

Processable coating material systems include:

• Graphite, graphite-sulfur composites, carbon nanotubes;
• Lithium iron phosphate, lithium cobalt oxide, lithium manganese oxide;
• Nickel-manganese-cobalt ternary oxides;
• Ceramic-modified separator coatings;
• Various functional coatings for battery separators;
• Polyimide dielectric barrier coatings;
• Positive and negative electrode active material coatings;
• Porous carbon electrode coatings used in next-generation aluminum-ion battery research, which improve battery capacity and optimize ion transport efficiency by controlling the pore structure.

Controllable pore structure, optimized ion conduction: Ultrasonic spraying can form an open porous coating structure, promoting lithium-ion diffusion and facilitating full wetting of the separator and electrode coating by the electrolyte.

Highly uniform material distribution: Forming a coating with uniform morphology ensures stable battery capacity and slows down cell aging and degradation.

Precisely adjustable coating thickness: The coating thickness can be flexibly set according to the design goals of high energy density or high-rate discharge.

Battery Separator Coating and Its Performance Advantages

A uniform functional coating on the separator can enhance battery safety performance, improve separator mechanical strength, enhance electrolyte wetting ability, directly extend battery cycle life, adapt to new electrolyte systems, and enhance separator heat resistance. After preparing a ceramic-polymer-oxide composite coating through a spraying process, the separator can maintain its structural integrity under high-temperature environments, avoiding the risks of separator thermal shrinkage and melting failure.

– Thermal Stability and Safety Assurance: The ceramic-polymer composite separator coating enhances thermal shutdown capability and suppresses separator deformation under high-temperature stress.

– Coating Uniformity: It can prepare thin and uniform separator coatings without damaging the separator’s pores and ion transport channels.

– Customizable Process Parameters: Porosity, membrane thickness, and coating composition can all be adjusted as needed to meet different electrochemical performance indicators.

– Low Loss and Easy Scale-up: High raw material utilization and low overspray loss make it suitable for pilot lines and small-scale mass production projects.

Polyimide Precision Insulating Barrier Coating Preparation Equipment

Polyimide coating technology is used for the preparation of high-precision insulating and dielectric barrier films inside battery modules. Ultrasonic spraying can prepare dense, defect-free polyimide films with thicknesses reaching the micron or even sub-micron level, meeting the requirements for electrical isolation and surface modification.

– High-precision insulating film: Uniform polyimide thin layer for electrical isolation of cells, tabs, and busbars.

– Non-contact film formation: Friendly to fragile substrates such as metal foils, nanofiber films, and polymer films, without damaging the substrate.

– Stable surface properties: Dense, continuous film, reducing the risk of short circuits, leakage current, and arc discharge under high-voltage conditions.

– Adaptable to cutting-edge battery architectures: Ideal for solid-state and hybrid battery systems, meeting the requirements for uniform and controllable barrier layer morphology.

Ultrasonic Coating Equipment Solutions from R&D through high volume production. Choose a product to learn more.

All of Cheersonic’s ultrasonic coating systems integrate Cheersonic ultrasonic nozzles, liquid delivery, and full system controls. Machines range from R&D tabletop systems, standalone fully enclosed programmable systems, and wide area continuous production inline systems.

The UAM series are general-purpose coating equipment, and the equipment parameters are standard parameters. If you want to know the equipment and parameters that are more suitable for your industry, you can click on the specific industries.

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