Intelligent Ultrasonic Spray Nozzle Pyrolysis Coating Machine System

Model: TMAX-FS03I-Intelligent Ultrasonic Spray Coater

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1. Introduction

Ultrasonic spraying is a unique spray technology based on ultrasonic atomization nozzle technology. The sprayed material is initially in a liquid state (solution, sol, suspension, etc.), which is atomized into fine particles by an ultrasonic atomization device and uniformly coated onto the substrate surface with a carrier gas to form a thin film or coating.

Advantages over Traditional Spraying:

· Superior uniformity

· Thinner coating thickness

· Higher precision

· Reduced paint splashing

· Material utilization rate is over 4x higher than traditional methods

Applications: Qualitative experiments in scientific research laboratories, small-scale production, and thin-film fabrication.

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2. Principle

The ultrasonic nozzle converts electrical energy into high-frequency mechanical energy via the piezoelectric effect, creating a standing wave that atomizes the liquid into uniform micron-sized droplets.

Key Features:

· Precise control of droplet size and distribution

· Rapid evaporation for high-surface-area particles and thin-film coatings

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3. Structure and Power Control of Ultrasonic Atomization Nozzle

Structure:

· Nozzle body: Titanium (excellent acoustic properties, high tensile strength, corrosion resistance)

· Protective casing: 304 stainless steel (titanium optional)

Power Control:

· Vibration amplitude must be carefully controlled:

o Too low: Insufficient energy for atomization

o Too high: Liquid is torn and ejected unevenly

· Optimal input power: 1–15 watts

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4. Droplet Size Distribution and Flow Rate

Droplet Size:

· Determined by nozzle frequency, liquid surface tension, and density (frequency is primary factor).

· Higher frequency → Smaller median droplet diameter.

· Distribution follows a normal curve (median, number-average, and volume-average diameters).

Flow Rate:

· Depends on liquid arrival speed (not pressure).

· Adjustment ratios:

o Large apertures: 5:1

o Small apertures: 10:1

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5. Advantages

· High Stability: Titanium alloy and stainless steel construction; no wear, clogging, or noise.

· Material Saving: Minimal splashing; paint utilization >4x traditional methods.

· High Controllability: Precise flow rate and spray pattern control.

· Easy Maintenance: Self-cleaning; no moving parts or cooling required.

· Wide Applications: Fuel cells, solar cells, glass coatings, electronic circuits, chemical liquids, etc.

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6. Parameters

Parameter	Specification	Parameter	Specification
Product Type	TMAX-FS03I	Motion System	XYZ three-axis, programmable (300×300 mm, max 400×400 mm)
Nozzle Frequency	20–200 kHz	Control Method	PLC with touch screen and buttons
Nozzle Power	10–100 W	Control Content	Ultrasonic spraying, liquid supply, heating, ultrasonic dispersion
Max Continuous Spray Rate	20–1200 ml/h/pcs (expandable)	Liquid Supply Method	Precision syringe pump
Effective Spray Width	2–260 mm/pcs (expandable)	Ultrasonic Dispersion (Optional)	50 ml, 40 kHz, bio-grade sampler
Spray Uniformity	<5%	Dispersion System Power	200 W
Solution Conversion Rate	≥95%	Heating/Drying (Optional)	Up to 200°C
Dry Film Thickness	20 nm–100 μm	Vacuum Adsorption (Optional)	Multi-zone, with vacuum generator
Solution Viscosity	≤50 cps	Ultrasonic Generator	Fully digital, intelligent frequency tracking
Temperature Range	1–60°C	Exhaust Vent	Included
Atomized Particle Size (Median)	10–45 μm (distilled water, frequency-dependent)	Total Weight	~180 kg
Max Carrier Gas Pressure	≤0.15 MPa	Accessory Material	Sheet metal, powder-coated
Input Voltage	220 V ±10%, 50–60 Hz	Nozzle Core Material	Piezoelectric ceramic, titanium alloy