Stepped Plate Resonator: Intense Acoustic Waves in Air

Ultrasonic Thawing of Foods

Air-borne ultrasound provides an effective solution to address these challenges during thawing. By producing high-intensity ultrasound waves in air, it improves heat and mass transfer at the surface of the food, facilitating more uniform and controlled thawing. This method considerably shortens thawing time, reducing exposure to oxygen and oxidative stress, which helps safeguard proteins and lipids from degradation. Additionally, the faster process preserves the meat’s natural water-holding capacity by limiting structural damage, ensuring a juicier and more visually appealing product. Read more about the Hielscher Stepped Plate Sonicator for the Thawing of Frozen Foods!

Aerosol Generation

The high-intensity sound waves can disrupt liquid surfaces to produce aerosols. This capability is particularly useful in:

• Pharmaceutical manufacturing (e.g., inhalable drug formulations)
• Thin film deposition
• Humidification and fine mist applications

Aerosol Formation on Stepped Plate Transducer

Acoustic Defoaming

In processes where foam interferes with operations, the resonator effectively collapses bubbles through airborne ultrasonic energy. This application is particularly valuable in:

• Chemical processing
• Food and beverage production
• Coating and painting systems

Stepped Plate Resonator: Acoustic Defoaming

Non-contact Precision Cleaning of Surfaces

The Hielscher SPR excels at removing fine particles from surfaces in sensitive manufacturing processes. Its ultrasonic waves dislodge contaminants without using harsh chemicals or abrasive methods, making it ideal for cleaning:

• Precision electronics
• Optical components
• Medical devices

Acoustic Removal of Particles From Surfaces

Acoustic Levitation

The intense acoustic field can be used to levitate objects for non-contact transportation.

• Non-Contact transportation of wafers
• Non-Contact transportation of glass, e.g. for displays

Acoustic levitation using a stepped plate resonator.

Integration and Usability

The Hielscher stepped plate resonator is designed for seamless integration into industrial systems. Its robust construction ensures reliable performance in demanding environments, while its compact size allows for easy installation. Suitable for both existing workflows and new process designs, this technology offers a practical, scalable solution for airborne ultrasonic applications.

Why Choose the Stepped Plate Resonator?

This special resonator provides a non-invasive, energy-efficient alternative to traditional cleaning, drying, and aerosol-generation methods. By minimizing chemical usage and mechanical wear, it supports sustainable, high-precision production practices.

Stepped Plate Transducers – FAQ

1. What is a stepped plate transducer, and how does it work?

Stepped plate transducers are specialized ultrasonic devices that generate high-intensity airborne ultrasound through their unique stepped geometry. Each “step” in the plate design amplifies and directs ultrasonic waves, creating a robust and unified sound field. This high-intensity, non-contact energy is ideal for processes where traditional mechanical or thermal methods may cause damage or contamination. The vibrations travel through the stepped plate, which amplifies the sound intensity due to the geometry of the resonator. The precise, controllable energy delivery makes them an efficient choice for applications like drying, cleaning, and particle manipulation.

2. What are the primary applications of stepped plate resonators?

Stepped plate resonators find use wherever non-contact processing is essential. They accelerate drying in heat-sensitive materials such as thin films, textiles, or delicate coatings, and provide non-contact cleaning in electronics or optics manufacturing. By eliminating the need for harsh chemicals and abrasive methods, these transducers reduce contamination risks and extend the lifespan of sensitive components. Beyond drying and cleaning, they excel in particle manipulation, acoustic streaming, and aerosol generation. In pharmaceutical and materials science, for instance, they can move or separate powders and droplets mid-air, ensuring sterility and maintaining product integrity. They also enhance gas-flow efficiency in chemical reactors, supporting advanced research and specialized production processes.

3. What distinguishes stepped plate transducers from traditional ultrasonic transducers?

Their defining feature is the stepped plate design, which provides stronger wave amplification and a wider acoustic field compared to probe type resonators. This makes them better suited for high-intensity, targeted applications in airborne ultrasound, a domain where traditional ultrasonic devices are less effective.
Additionally, many conventional ultrasonic transducers are optimized for use in liquids, whereas stepped plate transducers specialize in transmitting sound in air. This specialization opens a broader range of industrial uses, such as gentle drying or sensitive cleaning, where immersion in a liquid might be unfeasible or risky for the product.

4. How energy-efficient are stepped plate sonicators?

Hielscher stepped plate sonicators are designed for high efficiency, delivering focused energy directly to the target while minimizing energy loss. They often require fewer additional resources, such as heat or chemical agents. Their high reliability and sustained performance delivers elevated power levels for challenging processes.

5. Which materials and environments are suitable for stepped plate transducers?

Their non-contact nature makes stepped plate transducers ideal for handling sensitive or delicate materials without risking surface damage or contamination. Textiles, thin films, food, electronics, and optical components all benefit from ultrasonic processing that doesn’t involve mechanical stress or high temperatures.
Hielscher stepped plate transducers are designed for industrial settings, such as cleanrooms in semiconductor or pharmaceutical manufacturing. Their robust construction withstands extended operation, temperature fluctuations, and chemical exposure, ensuring they remain a durable and versatile choice in various production lines.

6. What about maintenance and system integration?

All Hielscher sonicators feature durable materials and straightforward designs that keep maintenance needs to a minimum. Routine checks for dust or surface residue are generally sufficient to maintain their performance. Their reliable operation over extended periods reduces downtime and enhances overall process efficiency.
Integration into existing systems is usually seamless. Hielscher sonicators are compact and adaptable, making it easy to install them as retrofits or to include them in newly designed setups. This flexibility allows manufacturers to upgrade or transform their production lines without significant reengineering or costly modifications.