Sono-Tek Flexicoat

The FlexiCoat FC is an inline 3-axis programmable coating system designed for applying precision coatings in fuel cell manufacturing processes, including coatings for PEMs, GDLs, electrodes, various electrolyte materials, and solid oxide fuel cells (SOFCs) with suspensions containing catalyst inks, PTFE binder, ceramic slurries, platinum and other precious metal catalysts. Ultrasonic spraying systems maximize the use of expensive carbon based inks with homogenous deposition of nanosuspensions, requiring less load of platinum to produce much higher cell efficiencies than knife coating or paste processing.

The FlexiCoat FC System is an inline programmable 3-axis small footprint platform designed for depositing catalyst coatings onto PEM fuel cells, GDLs, electrodes, various electrolyte membranes, and solid oxide fuel cells with suspensions containing carbon black inks, PTFE binder, ceramic slurries, platinum and other precious metals.

Uniform thin film coatings of catalyst inks are deposited onto Nafion fuel cells without deformation of the membrane. The high degree of uniformity achieved with ultrasonic spray ensures the maximum surface area exposure of Platinum in Hydrogen fuel cell construction.

Ideal for mid-level production volume, the FlexiCoat FC employs robust ball-screw slides driven by precision stepping motors. Any Sono-Tek nozzle can be integrated. Spray patterns are easily shaped, ranging from 2 - 50 mm (0.08 - 2") wide. Several integrated liquid delivery options are available, depending on the system configuration.

The FlexiCoat system has many benefits and integrated features:

BENEFITS:
• High transfer efficiency
• Up to 80% reduction in consumption of expensive catalyst suspensions
• Controllable drop size allows the flexibility to influence coating porosity
• Very durable, pinhole-free catalyst layer coatings (even on delicate electrolye substrates)
• Low velocity atomized spray reduces overspray and atmospheric contamination
• Minimal servicing and downtime
• Self-cleaning ultrasonic nozzle prevents clogging
• Highly controllable spray produces reliable, consistent results
• Small footprint platform minimizes floor space required
• Ultrasonic energy disperses agglomerated particles, resulting in homogenous coatings

FEATURES:
• Windows®-based programming software
• Teach pendant with trackball for easy axis motion and programming
• Offline programming capabilities
• Front panel LCD screen with function keys
• 500 x 500 x 100 mm (19.69 x 19.69 x 3.94") range of motion
• Three axes of continuous motion (programmable three-axis coordinated motion) via stepper motor drive
• Non-volatile memory for storage of up to 30 programs
• Can be configured for spray up or spray down applications
• Nozzles can be easily interchanged to produce spray patterns ranging from 2 - 50 mm (0.08 - 2" ) wide
• Wide range of delivery rates from .02 ml/min and up
• Ideal for flat or odd-shaped substrates
• Exhaust sensor/alarm

*FlexiCoat FC systems incorporate either Accumist, or Impact nozzle air shaping technologies.

Typical Options Include:

• IR Heat, Heat Plate and/or Vacuum Plate
• Ultrasonic Dispersion Pump - for keeping suspensions evenly dispersed during coating process
• MicroFlow Recirculation Pump - for precise dispense of suspensions at very low flow rates
• Camera - Passive or Active Vision
• Laser Pointer
• 4th Axis - Rotational