ULTRASONIC NOZZLE
Vortex Nozzle
The Vortex Ultrasonic Nozzle integrates ultrasonic atomization with a spiral gas stream to generate a stable, controllable cyclone spray. Whether applied to uniform thin-film deposition or ceramic spray drying, this configuration disperses ultra-fine droplets over wide areas for superior coating uniformity and process efficiency. By inducing rotational airflow at the nozzle outlet, the vortex head directs atomized particles into a stable, wide-angle cone. The combination of droplet size control (via frequency: 60 kHz or 120 kHz) and gas-driven ultrasonic spray shaping significantly enhances uniformity on planar, curved, or recessed surfaces. Compatible with nanoparticle suspensions, sol-gels, enzymes, conductive inks, and bio-reagents.
How This Ultrasonic Spray Nozzle Works
The vortex nozzle uses a spiral gas stream to create a stable, wide-angle cone of atomized droplets. A rotational airflow at the nozzle outlet disperses ultra-fine droplets over wide areas, optimizing coating uniformity and efficiency. Gas pressure adjusts spray angle and throw distance without disturbing droplet size, while the vortex-driven turbulence minimizes droplet coalescence and promotes lateral distribution. Wide spray coverage at fixed stand-off heights makes the vortex head ideal for wafers, tubes, and roll-to-roll systems. The nozzle integrates directly with robotic and gantry-type positioning systems for automated production environments.
Product Demos
Vortex Nozzle Spray Demo
Vortex Nozzle producing a wide-pattern conical spray using isopropyl alcohol for visibility. Footage slowed to 40%.
Zirconia Ceramic Vortex — 60 kHz
60 kHz zirconia ceramic Vortex Nozzle in operation, showcasing durability for high-wear coating applications.
6-Inch Wafer Coating
Vortex Nozzle depositing across a 6-inch wafer, demonstrating uniform coverage for semiconductor thin-film applications.
Spray Diameter
~15 cm (6 in) at 25 cm (10 in) stand-off
Droplet Size
15–40 µm (60 kHz), 10–25 µm (120 kHz)
Frequency
60 kHz or 120 kHz
Spray Pattern
Conical, vortex-stabilized
Air Sheath Pressure
0.1–2.0 bar (adjustable)
Fluid Viscosity
< 50 cP, water-based or alcohol-based
Vortex Spray Nozzle Features
Wide Spray Coverage at Fixed Heights
15 cm (6 in) spray diameter at 25 cm (10 in) stand-off distance for efficient large-area coating.
Micron-Size Droplet Control
10 µm (120 kHz) for ultra-thin, defect-free films.
Enhanced Mixing and Homogeneity
Vortex-driven turbulence minimizes coalescence and promotes uniform lateral distribution.
Air-Pressure Tunable
Gas pressure adjusts spray angle and throw without disturbing droplet size.
Broad Fluid Compatibility
Works with nanoparticle suspensions, sol-gels, enzymes, conductive inks, and bio-reagents.
Key Advantages
- Semiconductor wafer coatings: photoresist, ALD precursors, dielectrics on 100–300 mm wafers
- Biomedical device functionalization with inks or quantum dots on catheters, stents, and syringes
- Solar cell thin films: perovskites, quantum dots, and CIGS structures
- Catalyst deposition on porous substrates: foam and mesh in fuel cells or reactors
Ideal Applications
Supporting Research
Peer-reviewed publications and technical literature relevant to this application area. Links open the publisher's site.
- Numerical Investigations on the Ultrasonic Atomization of Catalyst Inks for Proton Exchange Membrane Fuel Cells
Li et al.
Journal of The Electrochemical Society ·
- Modeling thin film formation by Ultrasonic Spray method: A case of PEDOT:PSS thin films
Lonakar et al.
Organic Electronics ·
- Ultrasonic Spray Pyrolysis for Synthesis of Spherical Zirconia Particles
Song et al.
Journal of the American Ceramic Society ·
Open access · no paywall