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USI's patented "nozzle-less" Ultra-Spray ultrasonic technology is revolutionizing the coating market by providing a superior alternative to conventional air-atomizing spray nozzle, film coating and dispensing technology for conformal coating, semiconductor coating, fuel cell coating, medical coating and solar cell coating applications.
How it Works
Ultra-Spray ultrasonic technology has three components: an ultrasonic transducer with a spray forming head, an ultrasonic generator and an independent fluid applicator.
Ultrasonic Transducer with Spray Forming Head
The ultrasonic transducer operates at a fixed frequency and produces vibrations with maximum amplitude at the tip of the spray forming head. The transducer converts electrical energy to mechanical energy at the operating frequency of the spray head. The body of the spray forming head is shaped to concentrate the ultrasonic vibrations at the tip.
Ultrasonic Generator
The ultrasonic generator provides the electrical energy to the ultrasonic transducer. The amplitude of this sinusoidal voltage is adjustable so that the amplitude of the vibrating tip can be optimized for the liquid being sprayed. A microprocessor monitors these dynamic conditions and adjusts the generator to maintain optimum transducer operation.
Fluid Applicator
The fluid applicator delivers liquid to the atomizing tip and directs airflow to shape and add momentum to the ultrasonically produced spray. The fluid applicator is comprised of a liquid applicator and an air detector. In this case the liquid and air delivery components are integrated into a single applicator called the Integrated Liquid Deliver System (ILDS).
The liquid applicator supplies liquid to the atomizing tip in an even flow to match the width of the spray forming head. The output surface of the liquid applicator is positioned adjacent to the spray forming tip so that the liquid flows easily onto the atomizing tip. At that point the liquid forms a film over the tip area and is disintegrated into micro drops by the ultrasonic energy. The ultrasonic energy propels the spray from the atomizing tip.
The air director is used to shape and accelerate the ultrasonically produced spray. The air director can be configured either to focus or expand the spray pattern width to spray in a narrow mode or wide mode.
For narrow mode operation, the air director is in the form of an air-shaping ring contained in the ILDS applicator. The air-shaping ring contains small holes arranged in a circle at a predetermined angle relative to the axis of the ring. The angle of the holes in the air-shaping ring can be set to achieve a specific "focal point" of the sprayed liquid, thus producing the desired spray pattern size.
For wide mode operation, the air director impinges a jet of air onto the face of the spray forming tip on the ultrasonic transducer. Air is impinged on the opposite side of the liquid feed on the spray forming tip to expand the spray pattern width. A similar air director configuration is used with the blade heads to expand the width of the spray pattern. | 
