Ultrasonic Spray Systems for Fuel Cell PEM and GDL Catalyst Coatings

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. Other metal alloys, including Platinum, nickel, Ir, and Ru-based catalyst inks and metal oxide suspensions can be sprayed using ultrasonics for manufacturing PEMs, GDLs and solide oxide fuel cells to create maximum load and high cell efficiency. Sono-Tek ultrasonic nozzles are used by some of the largest fuel cell manufacturers in the world for spraying uniform thin film layers of catalyst inks.

The uniform thin film coating achieved with ultrasonics retains the porosity of the electrode and does not impede the transport of reactants due to flooding of the electrode surface. Catalyst solutions will not clog the ultrasonic nozzle, allowing for uniform, homogeneous catalyst coatings with controlled droplet sizes at ultra-low flow rates.

Ultrasonic Nozzle benefits

• Up to 80% reduction in material consumption, conserving expensive inks
• Reduced wasteful overspray
• Spray patterns that are easily shaped for precise coating applications
• Highly controllable spray that produces reliable, consistent results
• Non-clogging
• Ultra-low flow rate capabilities, intermittent or continuous
• Ultrasonic vibrations continuously deagglomerate particles and keep them evenly dispersed

Sono-Tek is well known for our highly durable, pinhole-free ultrasonic catalyst coatings onto Nafion fuel cells, with ultrasonic technology systems installed in some of the largest alternative energy manufacturers in the world.

In addition, Sono-Tek ultrasonic nozzles are well suited to spraying polymer solutions such as PTFE binder onto GDLs to enhance hydrophilic or hydrophobic properties in electrolyzing processes.

Customized in-house laboratory testing is available to aid in determining the best technology solution for each customer’s unique process.

With over 30 years of industry leadership in ultrasonic spray technology, Sono-Tek has the experience to help you integrate our technology into your application. The expertise of our engineering staff gives us the ability to help customers solve process issues to develop systems that meet the needs of each unique application. From large-scale, automated turnkey systems to individual spray system components, Sono-Tek delivers the support you need to take full advantage of the benefits of ultrasonic spraying through state-of-the-art design and unsurpassed customer service.