Ultrasonic Coating Solutions for Advanced Battery Research and Emerging Production
Sono-Tek’s ultrasonic spray systems enable precision deposition of Advanced Battery Coatings for next-generation energy storage technologies — including lithium-ion (Li-ion) batteries, solid-state batteries, sodium-ion platforms, and emerging aluminum-ion battery (AIB) research. Our ultrasonic atomization process delivers exceptionally uniform, thin film coating layers across electrodes and separators, supporting breakthroughs in cell performance, battery safety, durability, and long cycle life.
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 coating uniformity, low waste, porosity control, and micron-level thickness repeatability 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
- Battery Separator Coating layers
- Polyimide and dielectric barrier coatings
- Anode and cathode coatings
- Porous carbon electrode coatings used in next-generation AIB research, where engineered pore morphology is explored to increase capacity and improve ion transport
Controlled Porosity for Ion Transport — Ultrasonic spray deposition promotes open pore structures, enhancing lithium-ion diffusion and electrolyte infiltration through the separator and electrode coating layer.
Uniform Material Distribution — Produces homogeneous coating morphology for stable capacity retention and reduced degradation.
Controlled Thickness — Enables application-specific control of coating thickness for high-energy or high-power rate performance designs.
Battery Separator Coating and Battery Separator Layer Performance
A uniform Battery Separator Coating improves battery safety, mechanical strength, and electrolyte wettability, contributing directly to long cycle life, compatibility with advanced electrolytes, and improved thermal resilience. Ceramic and polymer/oxide composite coatings applied via ultrasonic spray maintain separator structural integrity at elevated temperatures and help prevent shrinkage or meltdown events.
Thermal Stability and Safety — Ceramic and polymer separator coatings strengthen thermal shutdown response and prevent deformation under heat stress.
Coating Uniformity — Ultrasonic spray achieves thin, consistent separator coating layers without compromising separator porosity or ion transport pathways.
Customizable Coating Parameters — Control porosity, thickness, and composition of the Battery Separator Layer to meet specific electrochemical performance targets.
Low-Waste, Scalable Deposition — Efficient material utilization supports cost-effective separator coating with minimal overspray, ideal for pilot and emerging production.
Polyimide Coating Machine for Precision Insulating and Barrier Films
Sono-Tek provides a Polyimide Coating Machine approach for applying high-precision insulating and dielectric barrier coatings within modern battery stacks. Ultrasonic spray enables dense, defect-free polyimide coatings down to micron or sub-micron thickness for applications requiring reliable electrical isolation and surface modification.
High-Precision Insulating Layers — Uniform polyimide thin films for precise electrical isolation in cell stacks, tabs, and bus bars.
Non-Contact Deposition — Gentle coating across sensitive foils, nanofiber membranes, and polymer films preserves substrate integrity.
Surface Reliability — Dense, consistent films mitigate shorts, leakage, and arcing in high-voltage assemblies.
Compatibility with Advanced Architectures — Well suited to solid-state and hybrid systems where uniform barrier layers and controlled morphology are critical.
Summary – Sono-Tek partners with leading research and pilot-scale developers worldwide to enable scalable, next-generation battery materials through precision ultrasonic spray coating. Whether your focus is electrode coatings for improved cathode/anode performance, a high-performance separator coating layer, porous carbon coatings for emerging aluminum-ion chemistries, or a polyimide dielectric barrier, ultrasonic spray provides controllable thin-film deposition with excellent uniformity, porosity retention, and low material waste.
Visit https://www.sono-tek.com/ultrasonic-coating/how-ultrasonic-nozzles-work/ to learn more about how ultrasonic spray is an effective method for applying thin film coatings for battery manufacturing applications.