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FlexiCoat FC

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FlexiCoat FC Fuel Cell Coating System


The FlexiCoat FC System is an inline programmable 3-axis small footprint platform designed for depositing catalyst suspensions containing carbon black inks, PTFE binder, ceramic slurries, platinum and other precious metals onto PEM fuel cells, GDLs, electrodes, various electrolyte membranes, and solid oxide fuel cells. Fuel cell coating processes using ultrasonic spray result in highly uniform dispersion of Pt throughout the coating, ensuring maximum surface area exposure of Platinum in Hydrogen fuel cell construction. Electrochemically active Pt surface area using ultrasonic atomization has been recorded as high as 71% of the total Pt particle surface area. Thin film coatings of catalyst inks are deposited onto Nafion fuel cells without deformation of the membrane.

Ideal for mid-to high volume fuel cell manufacturing, the FlexiCoat FC employs robust ball-screw slides driven by precision servo motors. Any Sono-Tek nozzle can be integrated. Spray patterns are easily shaped, ranging from 2 – 50 mm (0.08 – 2″) wide. Several integrated liquid delivery options are available, depending on the system configuration.

Ultrasonic nozzle benefits for fuel cell coating:

  • Up to 80% reduction in material consumption
  • Reduced wasteful overspray
  • Minimal servicing and downtime
  • Self-cleaning ultrasonic nozzle prevents clogging
  • Highly controllable spray produces reliable, consistent results
  • Low-velocity delivery will not damage components
  • Minimal floor space required
  • Controllable drop size customization

The FlexiCoat FC fuel cell coating system features:

  • Windows®-based programming software
  • Teach pendant with trackball for easy axis motion and programming
  • Offline programming capabilities
  • 500 mm x 500 mm x 100 mm (19.69” x19.69” x 3.94”) range of motion
  • Programmable 3-axes coordinated motion via stepper motor drive
  • Non-volatile memory for storage of up to 30 programs
  • Can be configured for spray up or spray down applications
  • Wide range of delivery rates from .02 ml/min and up
  • Exhaust Sensor

FlexiCoat FC Benefits:

  • High transfer efficiency
  • Up to 80% reduction in consumption of expensive catalyst suspensions
  • Controllable drop size allows the flexibility to influence coating porosity
  • Very durable, pinhole-free catalyst layer coatings (even on delicate electrolye substrates)
  • Low velocity atomized spray reduces overspray and atmospheric contamination
  • Minimal servicing and downtime
  • Self-cleaning ultrasonic nozzle prevents clogging
  • Highly controllable spray produces reliable, consistent results
  • Small footprint platform minimizes floor space required
  • Ultrasonic energy disperses agglomerated particles, resulting in homogenous coatings

Optional Equipment

  • IR Heat, Heat and/or Vacuum Plate
  • Ultrasonic Dispersion Pump
  • MicroFlow Recirculation Pump
  • Laser Pointer
  • 4th Axis (rotational)
  • Camera (Passive Vision)

Nozzles are typically integrated with AccuMist or Impact air shaping technologies, depending upon production needs.


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