Polyimide Spraying Micron-Level Coatings
In aerospace, electronics, and high-end equipment manufacturing, polyimide has become an indispensable high-performance material due to its excellent heat resistance, radiation resistance, and high strength. The quality of polyimide coatings directly impacts their performance. Traditional processes struggle to meet the high-precision requirements for spraying coatings as thin as 10 microns and covering large areas as large as 400 x 400 mm. Ultrasonic adhesive sprayers, with their innovative technology, offer a breakthrough in polyimide spraying.
Traditional polyimide spraying methods, such as brushing, roller coating, and conventional spraying, have numerous limitations when applying coatings as thick as 10 microns and covering large areas as large as 400 x 400 mm. Brush coating is inefficient and difficult to achieve uniform coating. When spraying large areas, uneven thickness and flow marks are common. Roller coating cannot precisely control coating thickness and struggles to achieve uniform coverage on complex surfaces. Conventional spraying suffers from poor atomization, leading to significant variations in coating thickness between the edges and the center during large-area spraying. This results in unstable polyimide coating performance and makes it unsuitable for high-end applications.
Ultrasonic adhesive sprayers utilize the cavitation effect of high-frequency ultrasound to atomize polyimide solution into uniform, fine nano-scale particles. Guided by precisely controlled airflow, these particles are evenly and stably deposited on the target surface, achieving a precise coating thickness of 10 microns. Compared to traditional processes, ultrasonic adhesive sprayers can strictly control coating thickness tolerances to within ±0.5 microns, achieving consistent, high-quality polyimide coatings across a large spray area of 400 x 400 mm, from the center to the edges and corners. Its unique nozzle design and motion control algorithm ensure uniform nozzle movement speed and stable paint output during large-area spraying, effectively preventing coating defects.
The advantages of ultrasonic adhesive sprayers have been fully demonstrated in practical applications. In the aerospace sector, spraying a 10-micron polyimide coating on the surface of a 400×400 mm aircraft component significantly improves its high-temperature resistance and fatigue strength, extending its service life in extreme environments by 50%. In electronic chip packaging, a uniform polyimide coating effectively improves the chip’s insulation and heat dissipation capabilities, reducing chip failure rates by 30%. Furthermore, the ultrasonic adhesive sprayer’s non-contact spraying method avoids physical damage to the substrate surface, making it suitable for a wide range of substrate materials.
In addition, ultrasonic adhesive sprayers offer high flexibility and adaptability. Parameters such as ultrasonic frequency, solution flow rate, and nozzle movement speed can be freely adjusted to suit the specific polyimide material properties, substrate type, and production requirements. Its modular design facilitates quick replacement of nozzles and accessories, adapting to different sizes and shapes of spray objects. Chifei continues to upgrade its ultrasonic adhesive spraying machines, optimizing their intelligence. The intelligent monitoring system monitors all parameters during the spraying process in real time and automatically adjusts them, ensuring stable and efficient completion of every 10-micron, 400x400mm polyimide spraying operation.
Ultrasonic spraying technology is an ideal solution for achieving micron level precision coating of polyimide (PI). Polyimide precursor solutions (such as polyamide acid PAA) usually have high viscosity, and traditional spraying is difficult to form uniform films. Ultrasonic spraying utilizes high-frequency sound waves to atomize the solution into uniformly sized and fine micrometer sized droplets, which are accurately and uniformly deposited on the substrate through non-contact methods.
This technology can effectively overcome defects such as wire drawing and orange peel, and easily prepare coatings with a thickness in the range of several micrometers and extremely high consistency. By precise control of parameters such as flow rate, spray speed, and concentration, fine control of coating thickness can be achieved. After spraying, the polyimide film with excellent performance can be obtained by high-temperature imidization treatment.
This high-quality coating is crucial in the field of microelectronics and is widely used in wafer level packaging, covering layers for flexible circuit boards (FPCs), chip passivation layers, and stress buffering layers in advanced packaging. Ultrasonic spraying not only ensures excellent insulation, heat resistance, and mechanical properties of the coating, but also greatly improves production yield and material utilization, meeting the stringent requirements of high-end electronic manufacturing for precision coating.
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.
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