Ultrasonic Spray Coating

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Ultrasonic Spray Coating

Ultrasonic atomization equipment uses piezoelectric transducers to convert electrical energy into longitudinal high-frequency vibrations, generating standing waves in the liquid at the tip of the nozzle. When the amplitude of the standing wave reaches a certain level, the liquid separates from the nozzle tip into uniformly sized droplets, achieving atomization. This precision spraying equipment utilizes ultrasonic energy to atomize liquids and coat them evenly onto substrate surfaces, enabling highly uniform and precise thin film coating. Compared to traditional pneumatic spraying, material utilization is several times higher, and coating uniformity is superior.

Advantages

Uniform Coating

Utilizes ultrasonic high-frequency vibration atomization technology, producing uniformly sized droplets. Spraying onto the substrate results in a coating with even thickness.

High Controllability

Enables precise control of liquid flow rate, with a minimum flow rate of 0.01 ml/min. Allows accurate control of coating thickness, capable of producing coatings from tens of nanometers to tens of micrometers.

High Efficiency & Energy Saving

Low-velocity spray ensures precise droplet placement, drastically reducing overspray. Achieve over 4x higher material utilization than traditional two-fluid spraying, minimizing waste and environmental impact.

Reduced Splashing

Can operate without or with minimal use of air supply, fundamentally eliminating splashing contamination associated with pressure spraying.

Applications

Ultrasonic spraying is widely applied across multiple industries, including electronics, energy (fuel/solar cells), semiconductors, medical devices, and industrial coatings (photovoltaics, glass, textiles). It delivers exceptional precision, high material efficiency, low pressure atomization, and excellent adaptability to complex geometries.

Application-1

Proton Exchange Membrane (PEM)
Gas Diffusion Layer (GDL)
Hydrogen Electrolysis
Batteries & Electrodes
Transparent Conductive Films (TCF)

Application-2

Medical Devices
Drug-eluting stents
Blood collection tubes, balloon catheters
Microneedle patches
Biosensors

Application-3

Glass Industry
Float Glass
Functional Coating Vacuum Chamber

Application-4

Photoresist coating
Flux spraying
Compound nanoparticle coating

Types Of Atomizing Nozzles

• Divergent • Micro-spray • Direct-spray

• Convergent

• Ring-shaped

Frequency	40 kHz	60 kHz	100 kHz	120 kHz
Generator Model	RPS-HF010
Input Voltage	220V/50Hz
Nozzle Material	Titanium Alloy
Housing Material	Stainless Steel
Communication	RS485
Coating Width	10~50 mm	10~35 mm	2~10 mm	2~8 mm
Droplet Size	10~40 μm	10~20 μm	5~15 μm	1~10 μm
Material Viscosity	<100 cps	<80 cps	<50 cps	<50 cps
Solid Content	<10%
Ultrasonic Power	100W, 10~90% adjustable
Atomization Rate	<40 ml/min	<15 ml/min	<7 ml/min	<5 ml/min
Nozzle Orifice ID	0.3~1.5 mm	0.3~1 mm	0.3~0.8 mm	0.3~0.5 mm

Material Information We Must Know:

Material viscosity
Whether the material is corrosive
Whether the material has solid content, the percentage and size of solid particles
Required atomization flow rate
Required atomized particle size and uniformity requirements

Product Recommendations

Frequently Questions & Answers About Ultrasonic Homogenizer

1.Why can't ultrasonic homgenizer achieve the desired effect?

The ultrasonic homogenizer is an auxiliary/replacement equipment based on the basic production process. It can accelerate or enhance the speed and efficiency of reactions. It needs to be combined with other processes and equipment to complete the entire production process and obtain the final product. For example, in herbal plant extraction, the ultrasonic homgenizer is one part of the process that can accelerate reaction speed and increase extraction efficiency. The entire extraction process requires many pieces of equipment and processes; it is not possible to obtain the final product directly with just one set of ultrasonic homogenizer.
Each material has different characteristics, requiring different numbers and powers of homogenizers. For example, for tea polyphenol extraction and olive oil extraction, for the former, a processing volume of 200L can be processed with one set of ultrasonic equipment for 1 hour to see results. However, for olive oil extraction, the same processing volume requires more than one set of ultrasonic homegnizer, needing multiple sets to process for several hours. The desired effect the customer needs only can be determined after testing.
Therefore, we recommend using our pilot-scale equipment before large-scale use of ultrasonic equipment, testing with small batches of materials, and then proceeding to mass production based on the results obtained.
2.Does the ultrasonic generator alarm during operation? What is the alarm prompt?

Depending on the different alarm prompts, solutions corresponding to the product manual can be used to resolve them.
3.Does the ultrasonic probe come into contact with the bottom or sides of the container during operation?

The ultrasonic probe should not touch the bottom or sides of the container as it can damage the horn and affect its operation.
4.Is the viscosity of the processed liquid too high?

The viscosity of the solution to be processed should be less than 2000cps/pa.s. Solutions that are too viscous cannot be processed and will trigger an alarm.
5.Does prolonged operation lead to increased temperature, causing damage to the transducer?

Use cooling air or a fan to reduce the temperature of the ultrasonic transducer. Replace the transducer if necessary.
6.Is the solution corrosive? Does it corrode the ultrasonic probe, affecting the frequency?

Corrosive solutions can corrode the horn, reducing its lifespan. It is advisable to regularly replace the horn.

Solution Of Ultrasonic Homogenizer

Beverage Sterilization

Ultrasonic is an effective auxiliary sterilization method, has been successfully used in wastewater treatment, drinking water disinfection and other fields, in the application of liquid food sterilization has also been more research, such as beer, orange juice, soy sauce and so on.Ultrasonic sterilization technology is a new technology that uses the physical effect of ultrasonic wave to kill bacterial colonies. Its basic principle and application can be summarized as follows:

1. How it works

When the ultrasonic wave propagates in the liquid, the cavitation phenomenon will be generated due to the periodic change of pressure, forming tens of thousands to hundreds of thousands of tiny liquid vacuoles. When these cavities oscillate, enlarge and collapse under the action of ultrasonic waves, high-speed microjets and strong liquid micronoisy streams are generated. This powerful physical effect can tear the cell membranes of bacteria and viruses, thus achieving the purpose of sterilization.

2. Application field

Aseptic treatment of liquid foods such as fruit juices and alcoholic beverages in the food industry. Water treatment sterilization, such as drinking water, industrial circulating water, etc

Shrimp culture - sterilization of aquaculture water

Customer

GLOBAL ARTEMIA DIRECT -India Using ultrasonic inactivation, the aquaculture water is extracted by external circulation, and the algae killing effect is achieved through ultrasonic treatment Excessive microbial growth is not conducive to the retention of oxygen in Marine water. Instead of chemical algal destruction, ozone algal destruction and artificial algal fishing The principle of ultrasonic sterilization involves the use of high-frequency sound waves, typically above the range of human hearing, to disrupt and destroy microorganisms.

Cavitation

Ultrasonic waves create a phenomenon known as cavitation in liquids. Cavitation involves the formation, growth, and implosive collapse of bubbles in the liquid. During the collapse of these bubbles, intense localized heating and pressure are generated, leading to the physical destruction of microorganisms.

Cell Membrane Disruption

The intense pressure changes and shear forces caused by cavitation and microstreaming can disrupt the cell membranes of microorganisms, leading to cell lysis and ultimately cell death.

Anti-scaling of oil condensate pipe - descaling

Customer: REMAL ADVANCED -Saudi Arabia

Using ultrasound for descaling and homogenizing, reducing the viscosity of oil in pipelines, preventing oil pipeline scaling blockages, replacing demulsifiers, and extending the pipeline's service life. We also provide customized integrated screens for convenient simultaneous monitoring of multiple sets of equipment.

Principle

Ultrasonic declogging technology utilizes the high-frequency vibration of ultrasound on the surface of blockages, inducing micro-vibrations and displacements, thereby disrupting the structure of the blockage, causing it to loosen or break apart, ultimately achieving the goal of unclogging. This technology offers advantages such as non-contact, non-damaging, high efficiency, and environmental friendliness, suitable for various types of blockages such as oil scale, deposits, water scale, and sediments.

Cavitation Effect

The energy of ultrasound directly generates numerous voids and bubbles in the treated fluid medium. When these voids and bubbles rupture and compress, they create strong pressure peaks within a certain range, with local pressure peaks reaching over a thousand atmospheres. Under the effect of these pressure peaks, scaling substances are pulverized and suspended in water, causing the existing scale layer to shatter and become easy to dislodge, thereby achieving the purpose of ultrasound descaling.

Activation Effect

Ultrasound induces cavitation in the fluid, enhancing the activity of flowing fluid and scaling substances, disrupting the conditions for scale formation and deposition on the heat exchanger tube walls. This process leads scaling substances to form dispersed sediment in the fluid rather than hard scale on the tube walls, thereby achieving the goal of ultrasound anti-scaling.

Dispersion of Coatings

Customer: Foshan Organic New Materials -China

Utilizing the principle of ultrasonic dispersion to disperse coatings, replacing mechanical stirring to achieve finer and more uniform coatings.
Adopting an external circulation method, facilitating the addition or removal of equipment, allowing for real-time adjustment of equipment usage based on production needs.
The dispersed particles are finer, reaching the nanometer level, resulting in more stable coatings without reverse demulsification.
The principle of dispersion involves the process of breaking down and distributing particles or substances evenly within a medium. In the context of materials such as coatings, paints, or pigments, dispersion is crucial for achieving uniformity and stability. Here are the key principles of dispersion:

Ultrasonic Dispersion

Ultrasonic dispersion utilizes high-frequency sound waves to create cavitation in the liquid medium. Cavitation causes the formation and collapse of bubbles, generating intense local forces that break apart agglomerates and disperse particles uniformly. This method is efficient and can achieve finer dispersion down to the nanometer level.

Stabilization

Proper dispersion is essential for stabilizing suspensions or emulsions. Well-dispersed particles are less likely to settle or agglomerate over time, leading to stable and consistent properties in the material.

Ageing

The application of power ultrasound in wine offers many beneficial effects. The most important applications include enhancing the flavor and aroma of wine by extracting flavor-rich components (such as phenols and aromatic compounds), aging in oak barrels, and accelerating maturation and aging. The mechanical action of ultrasound supports solvent diffusion into tissues for extracting aromatic and phenolic compounds from grapes. When ultrasound mechanically disrupts cell walls through cavitation shear forces, it aids in transferring substances from cells into the solvent. By reducing particle size through ultrasound cavitation, the contact surface area between solid and liquid phases is increased.

Applications

Aging of fruit wines such as red wine, brandy, etc.
Aging of vinegar condiments
Aging of preserved foods like salted duck eggs
Aging of grain-based liquors like white spirits
Extraction of effective substances in various medicinal wines
Time savings - The cell disruption function of ultrasound allows flavonoids, anthocyanins, tannins, resveratrol, and other aromatic components in grapes to be rapidly and effectively released. Scientific experiments have shown that after just three days of ultrasound treatment, they produce spirits similar to brandy aged for many years, reducing the aging time required.
Improved taste - In addition to the effective aromatic substances in grapes, ultrasound fully extracts aromatic components contained in oak chips, chestnut trees, and durable oaks and transfers them into the wine. This process takes only a few minutes and the resulting product is very stable over time, significantly enhancing the taste of the wine.

Ultrasonic Extraction of Tea Polyphenols

Ultrasound-assisted extraction is a method that uses the vibrational effect of ultrasound to increase the rate of chemical reactions in materials to achieve rapid extraction. By inputting ultrasound energy, the reaction liquid is atomized, increasing the liquid surface area, diffusing the reactants to their respective positions, and accelerating the reaction to achieve the extraction purpose. Currently, ultrasound-assisted extraction is widely used in the fields of food, cosmetics, pharmaceuticals, market research, medicine, environmental protection, and more.

Applications

Tea, as a common beverage, has various extraction methods. Traditional tea extraction methods typically involve steeping in hot water and allowing the tea to sit for a period, gradually dissolving the active ingredients into the water. However, this method has some drawbacks such as requiring a long time and not being highly efficient. Therefore, scholars have attempted to use ultrasound-assisted extraction technology to improve the efficiency of tea extraction. Applying ultrasound-assisted extraction technology in tea can reduce extraction time, increase tea extraction efficiency, and obtain higher levels of tea polyphenols and catechins. Additionally, ultrasound-assisted extraction technology can address issues such as fluctuations in acidity and alkalinity in tea. Therefore, ultrasound-assisted extraction has become a potential optimized method for tea extraction.

Advantages

Combining ultrasound with low-temperature extraction reduces the astringency of tea.
Shortens the extraction time required.
Greatly enhances the taste of tea beverages.
Increases the extraction rate.

FAQ for RPS-SONIC ultrasonic homogenizer

If you will test all machines before delivery?

Yes, we have 100% test before delivery.
Can you produce according to the samples?

Yes, we can customize the product according to your samples or 3D drawings.
How long is the Warranty period?

12 months limited warranty starting from date of shipping excluding wear parts.
How about the delivery time?

Normally, 10-30 days after receipt of advance payment and confirmed drawings. The specific delivery time depends on the items and the quantity of your order.
What is your terms of delivery?

EXW, FOB, CIF.
What is your terms of payment?

100% advance payment by T/T upon signing the contract.
Other payment terms can also be negotiated.

Famous Customers

Ultrasonic Spray Coating