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Ultrasonic Nozzle Overview

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Ultrasonic spray nozzle systems have replaced pressure nozzles in a wide range of industrial and R&D applications, and enabled spray processes that would otherwise be impossible. Concerns over the environment and unacceptable quantities of waste have influenced manufacturers to adopt ultrasonic spray nozzle systems as a technology that is more precise, more controllable, and a more environmentally friendly coating application.

Sono-Tek’s founder, Dr. Harvey Berger, was the inventor of ultrasonic spray technology, commercializing his patented invention in the late 1970s. Early applications were the development of ultrasonic nozzles for use in home heating oil burners and liquid fuel burners contracted by the US military for use in portable power generation equipment. Blood collection tube coating and printed circuit board fluxing applications soon followed. Today there are dozens of unique applications and industries utilizing Sono-Tek ultrasonic spray technology worldwide.

Sono-Tek ultrasonic nozzles, with their characteristic fine mist spray, dramatically reduce overspray, saving money and reducing atmospheric contamination. The nozzles are inherently non-clogging, self cleaning devices that atomize liquids using high frequency sound waves (beyond human hearing range) instead of forcing a liquid through a small orifice using high pressure. Ultrasonic nozzles open up a broad range of new application possibilities. The nozzles are ideal, for example, when extremely low flow rates are required. They offer unique benefits when spraying particles in suspension, keeping particles evenly suspended during the entire spray process through the ultrasonic action of the nozzle itself. This results in more uniform dispersion of functional particles in thinner layers. Sono-Tek’s ultrasonic spray nozzles are fabricated from Titanium for long life and excellent acoustical properties.

Spray Applications Overview

A sampling of modern spray applications using Sono-Tek ultrasonic coating technology. Click on the image to enlarge.

To learn more about how Sono-Tek’s patented ultrasonic nozzles work, go to: http://www.sono-tek.com/how-ultrasonic-nozzles-work/.

Sono-Tek ultrasonic nozzles systems reduce:

  • Material consumption by up to 80%
  • Wasteful overspray and wasteful contamination
  • Waste disposal
  • Servicing and downtime

Ultrasonic nozzle benefits:

  • Spray patterns are easily shaped for precise coating applications
  • Highly controllable spray produces reliable, consistent results
  • Corrosion-resistant titanium and stainless steel construction
  • Ultra-low flow rate capabilities, intermittent or continuous
  • No moving parts to wear out
  • Non-clogging
  • Drops sizes as small as 13 microns, depending upon nozzle frequency
  • reduce downtime in critical manufacturing processes

Ultrasonic spray technology is used to coat practically any substrate shape, size or surface with uniform micron thick coatings, and even nanocoating thicknesses. In addition, ultrasonic technology is used for:

  • Moisturizing
  • Spray drying
  • Continuous web coating
  • Fine-line spraying
  • Dots
  • Nanosuspension dispersion
  • Aerosol generation


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