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New TCO Spray Pyrolysis System Provides Cost Effective Alternative to Solar Manufacturers

Published April 30, 2012

Sono-Tek Corporation, Milton NY USA, announces a new TCO production volume ultrasonic spray pyrolysis system for thin film solar cell manufacturing. This new wet process spray system will be highlilghted at SNEC PV 2012, May 16-18 in Shanghai, China.

Using patented, proprietary ultrasonic nozzle technology, Sono-Tek’s Impact ARRAY system is designed to deposit uniform Transparent Conductive Oxide (TCO) layers in spray pyrolysis applications. Previously, these layers have been formed using CVD or sputtering deposition processes. This new inline ultrasonic spray pyrolysis system gives manufacturers a viable alternative to costly, complicated vacuum deposition techniques.

Spray pyrolysis deposition of TCO chemistries such as ITO and ZnO requires high temperature reactions spraying corrosive acid solutions, with heat tolerances of up to 600 degrees Celcius substrate temperatures. The IMPACT ARRAY coating system is able to meet the difficult corrosive and high temperature challenges of these spray applications for high volume manufacturing. High temperature protected construction with a unique cooling design protects ultrasonics and nozzle components from high temperatures.

Ultrasonic spray processes feature 95%+ effective use of chemistry, resulting in significant saving in expensive materials. The ultrasonic nozzle design provides an easily controllable atomized spray that cannot clog because of the large feed orifice and the self-cleaning ultrasonic vibration.

In a high temperature ultrasonic spray pyrolysis process, precursor solutions such as Zinc are sprayed onto a substrate heated to approximately 450-500o Celcius. The solvent is exaporated in transit and the ZnO cyrstalline film is grown on the substrate surface, often soda-lime or other glass. Substrate temperature often dictates the morphology characteristics of the film.

Sono-Tek has over 35 years of expertise in ultrasonic spray technology, with hundreds of patented spray systems installed worldwide for continuous glass manufacturing and advanced energy applications, including world class service and support. For more information, go to http://www.sono-tek.com/production-volume-tco/ or visit Sono-Tek at booth E3-802 for International Solar Cell Equipment
W1-816 & W1-817 for Thin Film SolarShow.

Posted in Corporate, Energy

Visit Sono-Tek at Hannover Messe 2012

Published April 20, 2012

Sono-Tek will be exhibiting at Hannover Messe 2012 H2 & FC Fair April 23-27 at the Hannover Exhibition Grounds in Hanover, Germany, booth C76/1 with Rubroder GmbH Factory Automation.

Ultrasonic nozzles produce highly durable, uniform, pinhole free coatings of carbon based catalyst inks onto fuel cell proton exchange membranes such as Nafion, without deformation of the membrane. Sono-Tek has become the industry’s leader in applying uniform homogeneous dispersion of carbon catalyst ink suspensions. Our unique technology allows greater control of layer thickness, dryness of the spray and uniformity across the surface area and depth of the coating. Ultrasonic vibrations continuously deagglomerate particles and keep them evenly dispersed, resulting in uniform dispersion of precious metal particles throughout the entire coating. This translates to the highest possible functional characteristics of the coating. Ultrasonic coatings are durable and highly repeatable.

For more information regarding the Hannover Messe Exhibition go to http://www.hannovermesse.de/home. For more information regarding Sono-Tek’s ultrasonic coating technology for fuel cells, go to http://www.sono-tek.com/fuel-cell-coating-overview/

Posted in Corporate, Energy

Thin Film Solar Article in Asian Solar Magazine

Published April 19, 2012


Steve Harshbarger, Direct of Electronics and Advanced Energy, recently had an article published regarding the cost effectiveness of scaling up thin film solar production for start up companies and the role ultrasonic wet process coating systems can play in making manufacturing profitable.

Companies may have difficulty finding funding for developing pilot lines for their new innovative products based on past failures of large thin film solar companies. Ultrasonic spray technology may enable significant reductions in manufacturing costs compared to CVD manufacturing equipment as well as savings in raw material for thin film solar startups, making it easier to bring new products to market profitably.

Read the full article in the April May 2012 issue of Asian Solar Magazine: Asian-Solar-April-May-2012 on pages 58-59.

For more information regarding Sono-Tek’s ultrasonic technology for thin film solar, go to http://www.sono-tek.com/cigs-czts-photovoltaic-modules/

Look for Sono-Tek at SNEC PV 2012 May 16-18 at the Shanghai New International Expo Center, booth:
E3-802 for International Solar Cell Equipment
W1-816 & W1-817 for Thin Film Solar Show

Posted in Corporate, Energy

Ultrasonic Spray for Fuel Cell Platinum Catalyst Coatings

Published February 15, 2012

Look for Sono-Tek’s Technical Brief article in this February 2012 issue of ASME’s Journal of Fuel Cell Science and technology. The article, entitled “Maximizing the Use of Platinum Catalyst by Ultrasonic Spray Application”, was written by Robb Engle, director of Engineering, and focuses on the advantages that Ultrasonic Spray processes offer in the deposition of carbon black catalyst suspensions onto fuel cell PEM membranes.

The following is a brief excerpt from the article:

“By using a technology that is self cleaning, the atomizers are able to run processes without the risk of clogging. The core detriment of processing with nozzles that will clog is not when they fail, but in the event of slowly clogging, the spray characteristics are changing. Ultrasonic atomizers do not clog and therefore do not vary.

In addition, the delivery means to the atomizers are from closed volumes using precision metering pumps. The accuracy of and repeatability of material delivered to the substrate can be related to the fidelity of a quality pump. Moreover, keeping the material in a closed reservoir prevents loss of solvent by evaporation to atmosphere and subsequent changes during the process.

The net effect is that a properly run ultrasonic coating process maximizes stability and repeatability, thus maximizing efficient exposure of platinum.”

The full article can be found here: http://asmedl.org/dbt/dbt.jsp?KEY=JFCSAU&Volume=CURVOL&Issue=CURISS

For more information regarding Sono-Tek’s spray systems for fuel cell manufacturing, go to http://www.sono-tek.com/fuel-cell-coating-overview/ or email info@sono-tek.com.

Posted in Corporate, Energy, Nanotechnology

The Proof is in the PEM!

Published October 13, 2011

Visit Sono-Tek at the 2011 Fuel Cell Seminar and Exposition, October 31st  - Nov 3 in Orlando, FL, booth 627 to see what we mean. Sono-Tek’s precision ultrasonic coating technology is being used by some of the largest Fuel Cell manufacturers in the world to spray uniform thin film coatings of carbon black inks, ceramic slurries, or other catalyst suspensions onto fuel cell membranes such as Nafion and solid oxide fuel cell rods.

Sono-Tek ultrasonic coating systems provide highly durable, pinhole free catalyst coatings, with homogenous dispersion of platinum particles, creating the most effective surface area for maximum transport of reactants. This in turn has a direct effect on cell efficiency. Electrochemically active Pt surface area using ultrasonic atomization has been recorded as high as 71% of the total Pt particle surface area.

Turnkey systems for R&D tabletop coating applications and standalone fully automated spraying systems are available from Sono-Tek. For more information, go to http://www.sono-tek.com/energy/page/overview or go to http://www.sono-tek.com/energy/page/overview to see a video of Sono-Tek systems in action. Contact us by email at info@sono-tek.com.

Ultrasonic Fuel Cell Catalyst Coating

SEM detail of catalyst coating applied with Sono-Tek ultrasonic nozzle

Posted in Corporate, Electronics, Energy

Sono-Tek Celebrates 35th Anniversary Milestone

Published September 29, 2011

2011 marks the 35th anniversary of the founding of Sono-Tek Corporation, Milton, NY USA. The Company was started in 1975 by Dr. Harvey Berger, inventor of the ultrasonic nozzle. From modest beginnings during the oil crisis of the 1970s, we have continually developed our unique technologies and grown from being a company that only provided ultrasonic nozzles to a full coating solutions company.  Our initial developments included fuel efficient nozzles for oil burners, but we quickly realized the unique capabilities of our ultrasonic nozzles would benefit manufacturers in a wide variety of industries. Our current worldwide offerings include spray fluxing systems for PCB manufacturing, XYZ coating platforms used in Solar and fuel cell manufacturing, precision medical device coating equipment, and various other industrial coating machines for glass, textile, and food applications.

The Company’s diversification plan into several industries has allowed steady growth for the past 6 years and counting. Sono-Tek has delivered over 10,000 ultrasonic coating systems around the world through the company’s history.

Dr. Christopher Coccio, Sono-Tek’s CEO, made the following statement regarding this historic milestone for the company, “Having worked with Sono-Tek for the past decade, I have seen the company and many of our products develop into industry standard methods for coating in several industries. The opportunities we find for implementation of our ultrasonic spray coating equipment continues to expand, and we see exciting potential in the years ahead”.

Posted in Corporate, Electronics, Energy, Food, Industrial, Medical, Nanotechnology

Save the Date: PV Taiwan 2011 Photovoltaic Forum & Expo Starts October 5

Published September 29, 2011

Sono-Tek plans to exhibit ultrasonic coating technology for thin film solar cell manufacturing at PV Taiwan 2011, October 5-7, at the Taipei World Trade Center in Taiwan.

Ultrasonic wet process equipment continues to gain momentum in the thin film solar manufacturing world as a viable, cost effective alternative to costly vacuum deposition processes. Sono-Tek offers a full line of equipment, from research and development to pilot line and high volume production equipment for applying active and buffer layer coatings onto CIGS and CdTe solar panels.  Sono-Tek ultrasonic coating systems have also proven successful for depositing TCO layer chemistries in R&D and pilot line manufacturing.

Since ultrasonic coating systems all utilize the same core nozzle technology, scaling up from R&D to pilot line and high volume manufacturing is accomplished seamlessly. Proving process at the R&D level allows customers to optimize coating parameters at little cost, with the assurance that the same quality coatings will be achievable at high volume.

For more information about Sono-Tek thin film solar manufacturing equipment, go to http://www.sono-tek.com/energy/page/thin_film_overview or email info@sono-tek.com.

CIGs coating

Ultrasonic wet process spray system manufacturing CIGs solar panels

Posted in Corporate, Electronics, Energy

Sono-Tek to Exhibit at the 2011 Fuel Cell Seminar & Exposition

Published September 20, 2011

Sono-Tek Corporation – Milton, NY, will be exhibiting at the 2011 Fuel Cell Seminar & Exposition in Orlando, Fl, November 1st – November 3rd, in booth 627. Visitors can get a hands-on view of Sono-Tek’s ultrasonic nozzle technology and learn about our fully enclosed coating systems such as ExactaCoat FC for depositing carbon black suspensions onto PEMs, GDLs and SOFC fuel cells or other electrolyte substrates in fuel cell manufacturing processes.

The ExactaCoatFC  is a 3 axis programmable ultrasonic spray coating system specially designed for depositing carbon platinum catalyst ink and precious metal suspensions. With state-of-the-art customizable options including integrated heat and/or vacuum plate, camera/laser pointer, rod spinner/coater, ultrasonic dispersion pump and dual nozzle configurations, the ExactaCoatFC is a complete R&D and small volume production solution. Sono-Tek precision coating systems are known to provide significantly higher platinum utilization and active surface area coverage of catalyst inks due to the unique nature of ultrasonic atomization. Highly uniform, repeatable thin films have proven to be among the best quality fuel cell industry coatings. For more information regarding the ExactaCoat FC coating system, go to http://www.sono-tek.com/energy/page/exactacoat_fc or email info@sono-tek.com.

Posted in Corporate, Electronics, Energy

Sono-Tek to Exhibit Ultrasonic Spray Coating Systems for CIGs Solar Cells Coating at EU PVSEC

Published August 16, 2011

Sono-Tek Coporation, Milton, NY, USA, plans to exhibit ultrasonic coating technology for spraying CIGs solutions and CdTe layer chemistries in thin film solar cell manufacturing at the 26th European Photovoltaic Solar Energy Conference (EU PVSEC) September 5-8, in Hall A4/B27b, in Hamburg, Germany.

As ultrasonic wet process spray gains popularity for use in thin film solar manufacturing, Sono-Tek remains at the forefront of companies offering these cost effective spray solutions. In particular, Sono-Tek has developed the ExactaCoat spray system for R&D applications, and the WideTrack system for pilot line and full production scale applications, both of which provide uniform thin film coatings of suspensions used in thin film solar manufacturing, and are easily integrated with existing lines.

Capital equipment costs for manufacturers using wet process ultrasonic spray technology are a fraction ofCVDand other vacuum deposition process equipment costs, making investment into new lines more feasible for emerging companies.

Further manufacturing cost savings achieved with ultrasonic spray include: seamless integration with inline high volume production lines versus slow batch processing, and high effective material transfer of very expensive rare elements used in CIGS and CdTe suspensions (up to 95%). The targeted, low velocity ultrasonic spray produces very little overspray. Independent control of process parameters such as drop size, flow rate, and deposition contributes to the highest possible uniformity with the flexibility to optimize morphology characteristics.

Sono-Tek’s patented ultrasonic nozzles, the core of all of the company’s coating equipment, are non-clogging precision atomizing devices, whose high frequency vibrations break up any agglomerations in solution throughout the entire coating process. This is particularly valuable when depositing cadmium-based suspensions where agglomerations can result in non-uniform distribution of particles and lower cell efficiency.  Ultrasonic atomization creates a very stable process with highly repeatable thin films, and uniformities as low as +/-2%.

Sono-Tek ultrasonic spray systems are proven and currently in use at some of the largest solar cell manufacturers in the world. For more information on Sono-Tek’s ultrasonic coating systems for thin film solar manufacturing, visit http://www.sono-tek.com/energy/page/r&d_thin_filmor email info@sono-tek.com.

Posted in Corporate, Electronics, Energy, Nanotechnology

Sono-Tek Prepares for Washington, DC Fuel Cell Technology Conference

Published July 11, 2011

Sono-Tek’s Technical Services Director, Robb Engle, plans to present his paper “Maximizing The Use Of Platinum Catalyst  By Ultrasonic Spray Application”, at the ASME 9th Fuel Cell Science, Engineering and Technology Conference on Wednesday, August 10th, in Washington, DC, in Track 2-4-6 Modeling PEM Fuel Cells and Related Processes. Mr. Engle’s paper discusses the benefits of ultrasonic deposition of Carbon black catalyst ink in order to optimize available surface area and maximize catalyst exposure. Ultrasonic nozzle theory, coating durability and experimental results of PEM coatings are discussed.

For more information regarding Sono-Tek’s ultrasonic technology for applying catalyst coatings onto fuel cells, go to http://www.sono-tek.com/energy/page/overview.

Posted in Corporate, Electronics, Energy