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Nozzle-less Difference
USI’s core technology is called tCAT, a proprietary nozzle-less ultra-Thin Coating Application Technology for the thin, uniform application of a variety of low viscosity materials.

How it Works
The Ultra-Spray head consists of an ultrasonic transducer with a spray forming tip, an ultrasonic generator, an external liquid applicator, a precision liquid delivery system, and air directors. The ultrasonic transducer contains a spray-forming tip that vibrates at an ultrasonic frequency (> 20 kHz). The ultrasonic transducer is resonant at a particular ultrasonic frequency of 35 kHz, 45 kHz, or 60 kHz, and is driven by an ultrasonic generator with a corresponding frequency. The particular ultrasonic frequency is selected based upon the material to be sprayed and the coating application requirements. The amplitude of vibration of the spray-forming tip is also set with the ultrasonic generator.

The coating liquid is delivered to the spray-forming tip on the ultrasonic transducer with an external liquid applicator. The liquid is stored in a reservoir and fed to the liquid applicator with a precision liquid delivery system. The ultrasonic vibrations of the spray-forming tip break up the liquid into small drops and propel them from the tip in the form of a spray. The width of the spray pattern produced is equal to the width of the spray-forming tip (2mm to 20mm depending on head type).

Air directors are used to shape and accelerate the ultrasonically produced spray. The air director impinges a jet of air on the tip of the spray head opposite the liquid feed side. The resulting airflow entrains and expands the spray to produce a flat (rectilinear) pattern up to five (5) times the width of the pattern produced by the ultrasonic energy alone

CAT ILDS Head and Blade Head
Two ultrasonic spray head types are available: the CAT ILDS Head and the Blade Head. The ILDS head produces a spray pattern width in the range of 3mm to 25mm, while the Blade head produces a spray pattern width up to 300mm. The ILDS head is typically used for smaller substrates and the blade head for larger substrates.

Since the spray is produced with ultrasonic energy rather than pressure, and because a low-velocity air stream is used only to shape the spray, very little coating is wasted due to overspray with a transfer efficiency of 97% to 99%.

All process parameters for the Ultra-Spray head are set electronically for maximum control and flexibility, including:

  • Liquid flow rate
  • Air pressure
  • Head height
  • Head speed
Coating Head Selected & Optimized for Your Application
Model Spray Width Typical Liquids
CAT ILDS 2 to 25mm
  • Fuel Cell Coatings
  • Conductive Coatings (EMI Shield)
  • Fluxes
  • Photoresists
  • Polyimides
  • Conformal Coatings – Acrylic & Urethane
  • Other low viscosity solutions and suspensions
  • Available in 35kHz & 60kHz frequencies

Blade 25 to 300mm
  • Fuel Cell Coatings
  • Anti-reflective Coatings
  • Cadmium Chloride
  • Dopants
  • Fluxes
  • Photoresists
  • Hard Coat Coatings
  • Other low viscosity solutions and suspensions
  • Available in 35kHz, 45kHz & 60kHz frequencies

Micro-Line 1 to 3mm
  • Low viscosity Conformal Coatings
USI Spray Valve- Dual Mode 10 to 25mm
  • Silicone Coatings
  • Conformal Coatings
  • Higher Viscosity Coatings
USI Dispensing Valve 1 to 4mm
  • Silicone Coatings
  • Conformal Coatings
  • Higher Viscosity Coatings
USI Download Center

To download technical articles and product brochures, please click the following link:
USI Technical Library