In the world of nanomaterials, carbon nanotubes are known as "star materials" for their mechanical, electrical, and thermal properties. However, how to efficiently and accurately convert this microscale performance into actual functionality in macroscopic devices has always been a bottleneck that restricts its large-scale application. Traditional coating techniques, such as spin coating, scraping coating, or conventional spraying, often struggle to overcome obstacles such as uniformity, material waste, and structural damage. It is in this context that ultrasonic spraying technology has emerged as a precise process for weaving carbon nanotube networks, opening new doors for the manufacturing of high-performance devices.

01 Technical bottleneck, difficult application of carbon nanotubes

Carbon nanotubes face the problems of uneven dispersion and easy aggregation in composite material applications, which has become a research hotspot in the field of materials science. Even at extremely low concentrations (0.01~0.05wt%), carbon nanotubes can significantly improve the mechanical properties of the matrix material, but the prerequisite for all of this is that they must achieve uniform dispersion. Carbon nanotubes have inherent hydrophobicity and high surface energy, leading them to tend to form aggregates through van der Waals forces, which not only reduces their effective specific surface area but also seriously affects their performance. When used as sprayable coatings, these materials tend to aggregate or clump due to their cohesive properties. The traditional air spray atomization method is prone to exacerbating agglomeration phenomena and cannot achieve uniform dispersion at the nanoscale.

02 Ultrasonic spraying, precise dispersion principle

Ultrasonic spraying technology utilizes high-frequency vibration energy (50-120kHz) to convert liquid into uniform fine droplets; The core technology also lies in the cavitation effect generated by pre ultrasonic waves, achieving uniform dispersion of carbon nanotubes in solvents. When sound waves propagate in liquid media, the formed microbubbles instantly collapse, producing local high temperature, high pressure, and strong shock waves. This physical condition can effectively separate carbon nanotube aggregates, just like using a precise "nano surgical knife" to untangle their entanglement. FUNSONIC has developed various automated precision spraying equipment by combining professional ultrasonic application technology, providing new solutions for the coating of carbon nanotubes. Unlike traditional atomization spraying methods that require high temperature or high pressure conditions, ultrasonic atomization equipment does not require additional high temperature or high pressure during the spraying process, which can avoid the agglomeration of the tubular structure and surface of carbon nanotubes. The atomized droplets generated by it are milder, more uniform, and reduce the fracture and deformation of carbon nanotubes caused by mechanical shear forces.

03 Five advantages, showcasing technological competitiveness

Ultrasonic spraying technology has multiple significant advantages in carbon nanotube coating, making it widely applicable in many fields.

Maintaining the integrity of carbon nanotube structure is one of the key advantages. Ultrasonic atomization avoids the fracture and deformation of carbon nanotubes caused by mechanical shear forces, maintaining their inherent excellent performance.

High uniformity and controllability are another major advantage. Ultrasonic waves can disperse solutions into nanoscale droplets, forming uniform films or coatings. By precisely adjusting the atomization parameters (frequency, flow rate, distance), different spraying effects can be achieved to meet various application needs.

The high utilization rate of materials significantly reduces production costs, especially for expensive carbon nanotube materials. The material utilization rate of ultrasonic spraying can reach over 90%, significantly reducing waste.

This technology is also applicable to complex substrates and patterns, capable of achieving uniform coating on multiple substrate materials, and can be combined with other production equipment, expanding its application fields.

The strong adhesion of the coating is attributed to the high specific surface area and excellent mechanical properties of carbon nanotubes. By introducing carbon nanotubes through ultrasonic spraying, a more dense and robust coating structure can be formed, thereby improving the durability and corrosion resistance of the coating.

Ultrasonic spraying technology provides an efficient and precise path for the application of carbon nanotubes. As researchers have stated, by using the ultrasonic cavitation effect to prepare a uniform solution, and then generating liquid atomization through high-frequency ultrasonic vibration, carbon nanotubes can be uniformly distributed on the substrate, constructing a 3D conductive network comparable to a "neural network". In the future, with the continuous optimization and innovation of ultrasonic spraying technology, carbon nanotubes are expected to demonstrate their extraordinary potential in more fields such as energy, electronics, and healthcare, injecting new vitality into technological progress and industrial development.

FUNSONICFansuoneng Ultrasound has accumulated rich practical experience and data over the years, and has an open ultrasound application laboratory that provides free sampling activities to a wide range of users. For the demand of large-scale, large-area, and continuous automated production lines, we can also design and provide one-stop solutions according to the specific needs and process of users, to meet the preparation of automated precision spraying and high-grade coatings.