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USI Expands Installed Base of Precision Coating Technology at Fuel Cell Companies in Asia

Haverhill, MA – Ultrasonic Systems, Inc. (USI), a leader in ultrasonic spray coating systems, announced it has expanded its installed base of fuel cell coating systems in Asia. Companies in Shanghai, Chengdu, and Shenzhen, China, as well as Hyderabad, India have recently implemented USI’s PRISM systems for their fuel cell manufacturing processes.

USI products deliver superior performance in coating deposition for fuel cell manufacturing, with an advanced technology that provides precise control of coating pattern and film thickness. Numerous coatings are used in the construction of fuel cells, many of which are precious metal or ceramic based slurries containing suspended particles. The ability to apply these coatings uniformly and keep the suspended particles properly mixed during the coating process is critical to the quality and performance of the fuel cell.

USI’s automated method for the precise application of fuel cell coating materials utilizes USI’s proprietary ultra-Thin Coating Application Technology (tCAT), combining ultrasonic “nozzle-less” spray with a high-performance programmable motion and control platform with advanced material handling capabilities. Ultrasonic energy breaks liquids into small drops to form the spray and directed air streams are used to shape the ultrasonically produced spray, providing a rectangular, uniform spray pattern. USI’s advanced liquid delivery components ensure the coating liquid properties remain consistent during the coating process.

“USI systems meet the demand for thin, uniform thickness down to sub-micron level required by modern fuel cell manufacturers,” said Larry Sirois, Senior Applications Engineer for USI. “Process repeatability is another area where USI products lead the industry.”

USI offers a full line of coating systems for fuel cell coating from the PRISM-400 for lab-scale and R&D applications to the PRISIM-800 for high-volume production and large size substrates.

About Ultrasonic Systems, Inc.
Ultrasonic Systems, Inc. (USI) has developed, engineered, and manufactured high-performance spray coating equipment based on proprietary, nozzle-less ultrasonic spray head technology for over twenty years. With thousands of installations worldwide, USI serves customers in multiple markets spanning solar, fuel cell, semiconductor, implantable medical devices and other industries. USI supports customers with worldwide distribution and comprehensive technical service and support.

Ultrasonic Systems’ PRISM-400 Spray Coating Platform Receives Range of Enhancements

Haverhill, MA – Ultrasonic Systems, Inc. (USI) announced today, a number of enhancements to its PRISM-400 nozzle-less spray coating platform. Enhancements that improve and expand the system’s current capabilities include new Ultra-Coat software, a metal framed glass front door, internal mini system controller for the Ultra-Coat software, an LED light to illuminate the coating area, as well as a sensor on the Z-axis which limits the travel of the spray head to prevent accidental crashes. There are also several new options that include electronic head air flow control, a 590 ml reservoir with stirring capability, and tilt and rotate for the spray head.

USI’s proprietary, nozzle-less ultrasonic spray head technology is designed for the thin, uniform application of a variety of low viscosity aqueous and solvent based coatings to glass panels and other flat substrates. With coating transfer efficiency of up to 99% and finished film thicknesses down to the sub-micron level, PRISM platforms are designed for high-precision applications depositing uniform spray coatings.

An advanced graphical Windows-based control interface drives the liquid delivery system, which features a positive displacement liquid metering pump for precise flow rate control as well as automatic data logging.

These enhancements extend the PRISM-400 BT Benchtop Coating System advantage as a platform for a wide variety of coatings in R&D and lab applications. USI coating systems have been chosen by thousands of organizations across dozens of industries who demand the most precise coating deposition control solutions.

USI’s PRISM-1200 Raises Coating Performance while Slashing Cost at Touch Panel Device Manufacturer

Haverhill, MA – Ultrasonic Systems, Inc. (USI) announced today the installation of a PRISM-1200 system at major touch panel manufacturer. The PRISM system is being used to apply anti-smudge (anti-fingerprint) coatings to touch panel displays such as ATMs, point-of-sale kiosks, and more. Compared with conventional coating technologies, USI’s patented nozzle-less ultrasonic spray system delivers a thinner, uniform, defect-free coating to a variety of materials substrates.

“We are happy that our PRISM-1200 system was chosen for its ability to handle high-precision applications,” said Drew Erickson, CEO of USI. “It delivers tight process control and a selectable finished film thickness in the sub-micron range for this process.”

The touch panel manufacturer is using USI’s PRISM-1200 system to automate processes and enhance performance, throughput, quality, and cost effectiveness of their display coating stage. The PRISM-1200 system provides the capability to apply their proprietary coatings at the required thickness reliably.

USI’s PRISM systems provide greater process control and uniformity than other spray systems on the market. The product line includes PRISM-400, PRISM-500, PRISM-800, and the recently introduced PRISM-1200 for larger format coating applications.

USI Increases Medical Applications Install Base

Haverhill, MA – Ultrasonic Systems, Inc. (USI), a leading manufacturer of high-performance ultrasonic spray coating equipment has increased its presence in the medical devices market with the sale of a PRISM-500 system to a European medical company.

USI’s PRISM-500 Programmable Coating System features proprietary nozzle-less ultrasonic technology with programmable X-Y-Z motion and positioning that is designed for production medical device coating applications such as drug eluting coatings for implantable devices, catheters, and surgical textiles, as well as coatings for diagnostic devices. The PRISM-500 delivers thin, sub-micron level defect-free coatings with at 95-99% transfer efficiency, and a 500x500mm X-Y range of motion. The system precisely controls all critical process parameters such as liquid flow rate, head motion path, and head speed, to prevent “process drift”, and logs the exact amount of coating used for each recipe.

“We’re happy to add a new installation to our global base of medical customers,” said Drew Erickson, CEO of Ultrasonic Systems. “Therapeutic coatings play a crucial role in enhancing device performance and creating positive patient outcomes. The PRISM-500 is a powerful tool to ensure coating performance matches the mission of these crucial devices.

USI Optimizes Silver EMI Shield Coating Cost and Effectiveness

Haverhill, MA – USI, a leader in high performance coating application equipment, announced today that its proprietary spray coating systems reduce the overall cost in package-level Electromagnetic Interference (EMI) shielding processes compared to sputtering-based coating equipment. USI’s PRISM systems employ a nozzle-less ultrasonic spray technology that reliably achieves a thin, uniform coating in high-volume production environments such as mobile device manufacturing and others. USI’s capability enables the latest generation of silver EMI coating materials to be applied at the component level in a cost effective process.

Today’s silver EMI coatings are capable of achieving EMI shield effectiveness equivalent to sputtering when applied in ultra-thin layers in the 1 to 10 micrometer range. When applied uniformly at the required minimum thickness, these latest generation silver materials deliver high performance at a much lower process cost.

“For companies, such as device manufacturers, EMI shielding is moving from the board level to the package level,” said Larry Sirois, Senior Sales Engineer at USI. “For smart devices and other applications, silver coatings applied by PRISM systems can provide the same EMI shield effectiveness at a lower cost than sputtering. The PRISM system applies exactly enough coating to attain the required shield effectiveness, with minimal waste. This new level of efficiency in the EMI process drives a lower overall process cost.”

According to Sirois, factors contributing to the PRISM system’s superiority in silver EMI shield coating applications include the ability to work with the new higher solids material formulations, software control of all key process parameters, and the efficiency of USI’s nozzle-less ultrasonic spray technology.

Electromagnetic Interference (EMI) is a process by which disruptive electromagnetic energy is transmitted from one electronic device to another via radiated or conducted paths, or both. In electronic components, devices and systems, EMI can adversely affect performance of today’s faster, smaller, electronic device that contains digital circuits. EMI shielding helps designers obtain the highest possible operating and processing speeds from the smallest possible physical package without performance-degrading interference.