Ultrasonic Spraying Machine Application in MLCC Slurry Coating Process

As a core passive electronic component in the modern electronics industry, Multi-Layer Ceramic Capacitors (MLCC) are widely adopted in consumer electronics, new energy equipment, industrial control systems and other fields. With the continuous miniaturization, high-precision and high-stability upgrading of terminal electronic products, the manufacturing requirements for MLCC have become increasingly stringent. Traditional slurry coating processes can no longer meet the production demands of ultra-thin, high-density and high-precision MLCC products. Ultrasonic spraying technology, with its unique advantages of uniform atomization, controllable coating thickness and high material utilization, has become an advanced and mainstream solution for precision MLCC slurry coating, effectively solving the technical bottlenecks of traditional coating processes.

The working principle of ultrasonic spraying machines relies on piezoelectric energy conversion technology. The built-in piezoelectric transducer converts high-frequency electrical energy into stable mechanical vibration with a frequency range of 20kHz to 120kHz. The professional feeding system delivers MLCC ceramic slurry and electrode slurry evenly to the nozzle atomization surface. Driven by high-frequency vibration, a stable standing wave is formed on the slurry liquid film, and the liquid is decomposed into uniform micron-sized fine droplets without high-pressure airflow assistance. Guided by low-pressure carrier gas, the droplets deposit gently on the ceramic substrate surface at a low speed, forming a dense, flat and uniform coating layer. This soft landing atomization mode fundamentally avoids common defects such as slurry splashing, coating accumulation and pinholes in traditional spraying.

Ultrasonic spraying has significant technical advantages over conventional processes in MLCC slurry coating. Traditional pneumatic spraying uses high-pressure airflow for atomization, resulting in high-velocity droplets that easily rebound and splash. Its material utilization rate is less than 50%, and the finished coating suffers from uneven thickness and edge overflow, making it unsuitable for ultra-thin coating production. Screen printing, another traditional process, has obvious limitations including serious slurry waste, frequent screen clogging and poor process flexibility, which cannot adapt to the manufacturing of micro and high-precision MLCC components.

In contrast, ultrasonic spraying droplets fly at a low speed of 0.1 to 0.5 m/s, realizing gentle and precise deposition. The material utilization rate can reach 80% to 95%, greatly reducing the production cost of high-value MLCC slurry materials. In addition, the highly consistent droplet size ensures ultra-thin and uniform coating, with no pinholes or wrinkles. The coated layer features strong adhesion and stable performance, fully complying with the strict quality standards of MLCC precision manufacturing.

In mass production, targeted parameter optimization is required for different types of MLCC slurries. According to the solid content, viscosity and particle size characteristics of ceramic slurry and metal electrode slurry, manufacturers can adjust core parameters such as ultrasonic vibration frequency, slurry feeding flow rate, carrier gas pressure and nozzle movement distance. With precise parameter control, the coating thickness error can be controlled within ±1μm, meeting the ultra-precision coating requirements of high-end MLCC products. Equipped with an intelligent motion control system, the ultrasonic spraying machine supports full coverage uniform coating for large-area substrates and precise single-point coating for micro-components.

At present, ultrasonic spraying technology has been widely applied in MLCC mass production, effectively improving the compactness, voltage resistance and service life of MLCC components. Driven by the growing demand for miniaturized and high-end MLCC products, ultrasonic spraying will further replace traditional backward coating processes. It will serve as a core standardized process for MLCC slurry coating, promoting the intelligent and precise upgrading of the passive component manufacturing industry.

About Cheersonic

Cheersonic is the leading developer and manufacturer of ultrasonic coating systems for applying precise, thin film coatings to protect, strengthen or smooth surfaces on parts and components for the microelectronics/electronics, alternative energy, medical and industrial markets, including specialized glass applications in construction and automotive.

Our coating solutions are environmentally-friendly, efficient and highly reliable, and enable dramatic reductions in overspray, savings in raw material, water and energy usage and provide improved process repeatability, transfer efficiency, high uniformity and reduced emissions.

If you have any technical questions, customization demands, or procurement inquiries about ultrasonic atomization nozzles, feel free to contact our professional sales and technical team for detailed parameters, customized solutions, and industry application support.
Email: market2@cheersonic.com