Ultrasonic Coating Solutions for Advanced Battery Research and Emerging Production
Sono-Tek’s ultrasonic spray systems enable precision deposition of advanced functional materials for next-generation energy storage technologies — including lithium-ion, solid-state, and sodium-ion batteries.
Our ultrasonic atomization process delivers exceptionally uniform, thin coatings across electrodes and separators, supporting breakthroughs in performance, safety, and longevity.
Sono-Tek systems are designed for precision thin-film and alternative-material coating — not for conventional thick slurry processes. Our technology excels in R&D and emerging production where uniformity, low waste, and control at the micron level are essential.
Sono-Tek’s experience includes:
- Graphite, Graphite-Sulfur, Carbon Nanotubes
- Lithium Iron Phosphate (LiFePO₄, LFP), Lithium Cobalt Oxide (LiCoO₂), Lithium Manganese Oxide (LiMn₂O₄)
- Nickel Manganese Cobalt (NMC) Oxides
- Ceramic separator coatings
- Polyimide and dielectric barrier coatings
Anode and Cathode Coatings
- Controlled Porosity for Ion Transport — Ultrasonic spray deposition promotes open pore structures, enhancing lithium-ion diffusion and electrolyte infiltration.
- Uniform Material Distribution — Produces homogeneous coatings for stable capacity retention and reduced degradation.
- Controlled Thickness — Enables application-specific control of layer thickness for high-energy or high-power designs.
Separator Coatings
Separator coating enhances safety, mechanical integrity, and electrolyte wetting, contributing directly to longer cell life and improved thermal resilience. Ceramic layers applied via ultrasonic spray maintain separator structure at elevated temperatures and prevent shrinkage or meltdown events.
- Thermal Stability and Safety — Ceramic and polymer composites strengthen thermal shutdown response and prevent deformation under heat stress.
- Coating Uniformity — Ultrasonic spray achieves thin, consistent coverage without compromising separator porosity.
- Customizable Coating Parameters — Control porosity, thickness, and composition to meet specific performance targets.
- Low-Waste, Scalable Deposition — Efficient material utilization enables cost-effective, high-volume separator coating with minimal overspray.
Polyimide Coatings
- High-Precision Insulating Layers — Uniform dielectric films down to micron or sub-micron thicknesses for precise electrical isolation in cell stacks, tabs, and bus bars.
- Non-Contact Deposition — Gentle application across sensitive foils and polymer films preserves substrate integrity.
- Surface Reliability — Dense, defect-free coatings mitigate electrical shorts, leakage, and arcing in high-voltage assemblies.
Summary
Sono-Tek partners with leading research and pilot-scale developers worldwide to enable scalable, next-generation battery materials through precision ultrasonic spray coating.
Visit https://www.sono-tek.com/ultrasonic-coating/ultrasonic-spray-benefits/ to learn more about how ultrasonic spray is an effective method for applying thin film coatings for battery manufacturing applications.