ExactaCoat

Programmable Coater 

Automated, programmable benchtop coating system with coordinated XYZ motion control using Windows-based software and user-friendly teach pendant with trackball. Versatile R&D to mid-volume production thin film coatings.

Basic Specifications

DIMENSIONS: 944 mm W x 831 mm H x 794 mm D (37.2” W x 31.2” H x 32.7” D)
WORK AREA*:

400 x 400 x 100mm (15.75” x 15.75” x 3.94”)
*Note: Work area may be reduced depending upon system configuration

CONTROL: Windows-based (PC included)
POWER REQUIREMENTS: 120V, 220V, +/-10%, 50-60Hz
AIR: 551.6 kPa (80 PSI) dry unlubricated air
MOTORS: Brushless DC servo
CERTIFICATION: CE
ULTRASONIC NOZZLE DESIGNS: AccuMist, Impact, Vortex, MicroMist, or Propel

System Options

HEAT AND/OR VACUUM PLATE: 150, 250C heat/vac or 500C heat
HEAD CONFIGURATION: up to two heads (Ultrasonic or Vector)
COMMON OPTIONS:

Wire/rod coater, Ultrastatic ESC, Nozzle rotate and or tilt, 1 or 2 drawer load system, N2 Rich Environment, LEL Sensors, cleanroom upgrade, aggressive material upgrade

LIQUID DELIVERY:

Common Liquid Delivery: Syringe pump (standard, Sonic or stirring), gantry mounted syringe pump, MicroFlow, SonoFlow Fusion, HyperFlow catalyst pump

*Additional custom options may be available depending upon application requirements

FlexiCoat

Programmable Coater 

Fully automated, programmable standalone system with coordinated XYZ motion control. Versatile mid to high-volume or pilot scale production thin film coatings. Can be configured with standard SMEMA conveyor for inline coating solutions.

Basic Specifications

ENCLOSURE DIMENSIONS:

1021mm W x 1693mm H x 997mm D (40.2”W x 66.7”H x 39.2”D)

RANGE OF MOTION*: 420 mm x 490 mm x 85 mm (16.5” x 19.2” x 3.3”) *Note: Work area may be reduced depending upon system configuration
CONTROL: Windows-based programming software and on-screen teach device
POWER REQUIREMENTS: 100-240 VAC, 50/60 Hz, 4.5A max base system, 17A max with standard heat plate
AIR: 551.6 kPa (80 PSI) dry unlubricated air
MOTORS: Brushless DC servo
CERTIFICATION: CE
ULTRASONIC NOZZLE DESIGNS: AccuMist, Impact, Vortex, MicroMist, or Propel

System Options

COMMON OPTIONS:

Wire/rod coater, Ultrastatic ESC, glovebox enclosure with or without filtration, standard floor standing enclosure.

LIQUID DELIVERY:

Common Liquid Delivery: Syringe pump (standard, Sonic or stirring), MicroFlow, SonoFlow Fusion

Heat and/or Vacuum Plate: 150 degrees C heat and or vac

Head configuration: Up to two heads (Ultrasonic or Vector)

*Additional custom options may be available depending upon application requirements

What Makes Ultrasonic Nozzles Unique?

Ultrasonic nozzles operate by converting high frequency sound waves into mechanical energy that is transferred into a liquid, creating standing waves. As the liquid exits the atomizing surface of the nozzle, it is broken into a fine mist of uniform micron sized droplets.

Unlike pressure nozzles, ultrasonic nozzles do not force liquids through a small orifice using high pressure in order to produce a spray. Liquid is fed through the center of a nozzle with a relatively large orifice, without pressure, and is atomized due to ultrasonic vibrations in the nozzle. A Sono-Tek engineered proprietary precision ultrasonic generator provides the mechanical energy required to create the vibrations in the nozzle. The power required to operate ultrasonic nozzles generally varies between 1 and 8 Watts.

Every ultrasonic nozzle operates at a specific resonant frequency, which dictates the median droplet size. Droplet sizes have little variance, and can be mathematically calculated to fall within a tight predicted drop distribution. For example, a 120 kHz nozzle produces a median drop size of 18 microns (when spraying water). The higher the frequency, the smaller the median drop size.

Nozzles are fabricated from a very high-strength titanium alloy and other proprietary metals, making them exceptionally resistant to chemical attack and providing superior acoustical properties. The electrically active elements are contained within a sealed housing that protects the nozzle components from external contamination.

The low velocity mist created by the ultrasonic nozzle is typically accompanied by additional low velocity air shaping devices to entrain the spray and direct it toward a substrate. This allows precise control of the spray into fine lines, conical patterns, or wide flat fan shapes.

Spray patterns range from 0.015” (0.4mm) wide lines to virtually unlimited widths using multiple nozzles mounted in tandem.

Sono-Tek ultrasonic nozzles are integrated into full coating systems, incorporating liquid delivery, exhaust, motion control, and custom options. The photo shows an ExactaCoat system with dual AccuMist air shaping nozzles, allowing layering of different chemistries.