Ultrasonic Systems, Inc. (USI) is a leading developer and manufacturer of advanced ultrasonic coating systems with 25+ years of innovation and expertise in precision engineering and hundreds of installations in multiple industries all over the world. USI’s ultrasonic coating systems are based on their patented ‘nozzle-less’ ultrasonic spray head technology which provides exclusive benefits over traditional air-atomizing or nozzle-based coating systems for a variety of coating applications.
The PRISM series of coating systems utilise USI’s proprietary nozzle-less Ultra-Thin Coating Application Technology (tCAT) to deliver the thinnest, uniform, defect-free coatings for lab-scale and industry applications ranging from solar panels, semiconductors, fuel cells, medical devices and electronics assembly markets.
Nano Technology Solutions is the exclusive distributor of USI’s PRISM coating systems in Australia and New Zealand, offering installation, service and technical support for instruments used in the whole range of applications. USI’s Ultrasonic Coating systems have been chosen by leading Australian universities and industry.
Product lines for coating processes:
- PRISM-400 BT: Ideal for lab-scale applications
- PRISM-500: R&D and industrial applications
- PRISM-800: High-volume, high-throughput manufacturing
Industrial-scale Ultrasonic Coating Systems
The PRISM-500 is a highly flexible pilot-scale coating system with a programmable X-Y-Z motion control platform and advanced material handling capabilities. This small-footprint platform is designed for automated R&D and small to mid-volume production operations to achieve thin, highly uniform, durable applications of a wide variety of coatings from pure solutions to high-solids suspensions and slurries, including flammable solvents. It is ideal for labs and industries that are experimenting with production methods or proof-of-concept manufacturing
The PRISM-800 is a large format, high-throughput automated coating system engineered to meet a wide variety of coating requirements in commercial-scale manufacturing lines. The blade head gantry has a high speed capability of coating up to 700 mm/sec. These systems have seen a huge increase in shipments over the last 5 years with rising demand for state-of-the-art coating methods in biomedical and fuel cell research and production.
System Features and Benefits
All PRISM systems employ a Precision Coating Application System consisting of the following components which together provide superior advantages in coating applications:
- A nozzle-less ultrasonic spray-coating head
- A precision liquid delivery system with advanced material handling capabilities
- A sophisticated X-Y-Z-θ-Ø head motion and positioning platform
Apart from these common features, the PRISM-500 and 800 systems also have the following benefits for industrial use cases:
- Safety – all electrical enclosures are mounted above the coating chamber, and they meet applicable safety codes.
- Stability – air flow inside the coating chamber comes in from the top and goes out through the bottom, ensuring a controlled spray coating process
- Ease of use – state-of-the-art Ethernet based control system and Ultra-Coat software with simple “point and click” functionality to create individual coating lines, area fills, circles, dots, etc. for easy coating recipe creation.
- Integrated – all system functions fully integrated into the control system.
- Robust – heavy duty welded steel frame construction; safety rated clear glass panels in steel framed doors; optional rugged conveyor
Ultra-Spray head with an Integrated Fluid Delivery System (IFDS)
The Ultra-Spray head with proprietary tCAT technology contains the following elements to produce a uniform and rectilinear spray pattern of thickness down to sub-micron:
- The atomising surface of the spray forming head
- The liquid applicator output surface
- Air director for control of spray pattern
Substrates are kept in an isolated and ventilated spray area for coating. The assembly can be configured with one or two coating heads based on the application requirements:
- An ILDS Head for coating patterns of width 3 mm to 30 mm on smaller substrates
- A Blade Head for coating patterns of width 25 mm to 150 mm on larger substrates
A precision liquid delivery system
- PRISM’s precision metering pump (PMP) uses a micro-stepping drive to control liquid flow rate and ensure precise, reliable, and repeatable delivery and coating process.
- Multiple PMP configurations are available with the system:
- 100 ml (PMP-100) or 200 ml (PMP-200) capacity glass syringe
- Single or dual pump system for higher throughput or simultaneous supply for two coating heads
- Automatic pump refill from coating reservoir
- Internal stirring of the coating within the syringe
- Different reservoir options
- The minimum requirement of liquid volume is only about 5-10 ml for the integrated syringe pump, making it perfect for small volume coating operations, suitable for both advanced research and training steps.
- Syringe pumps with automatic liquid stirring mechanisms (optional) to ensure coatings with suspended particles are kept agitated.
- The system is designed to spray flammable coatings also.
- PRISM Platform process logs:
- Records process logs of all test and live spray runs, including includes every parameter set by the operator
- Ensures post-process verification and repeatability.
Fully programmable X-Y-Z motion control system
USI’s PRISM series of ultrasonic coating systems consist of an automated programmable position control platform that provides coordinated electronic control over spray head motion, airflow, liquid flow rate and flow activation/deactivation.
- 3- or 4-axis of motion: additional rotational axis for tubular substrates
- Servo drive ball screw actuators for precise motion of head
- Mini Internal PC with Windows GUI to provide operators with easy, precise control of system functions and parameters:
- motion path and head speed
- head rotation and tilt angle
- air flow rate
- liquid flow rate
- controllable laser pointer for teaching mode, programming
Additional options for specific applications:
- Batch or in-line conveyor configurations
- Dual substrate lift station
- Automatic spray head clean and purge
- Substrate heating with vacuum hotplate
- 90 degree pneumatic head rotation, head tilt
- Optional powered HEPA Filtration
- Optional tandem spray heads for increased throughput (PRISM-800)
- Substrate rotational axis for tubular substrate
The PRISM-500 and 800 systems can be installed and configured according to specific production requirements in each of the following markets:
- Semiconductor packaging
- Fuel cell coatings
- Medical and biomedical devices
- Lens and display coatings
Contact us for support and additional information regarding the product and applications.