Ultrasonic Spraying Machine For PTC Circuits

Ultrasonic Spraying Machine For PTC Circuits – Cheersonic

As electronic devices upgrade towards safety, miniaturization, and high reliability, PTC circuits, built upon the core characteristics of PTC thermistors, have become a core foundational circuit in electronics, new energy, and communications due to their overcurrent protection, overheat protection, and automatic recovery advantages. They are widely used in digital batteries, automotive electronics, small appliances, and communication equipment. PTC (Positive Temperature Coefficient) generally refers to semiconductor materials or components with a large positive temperature coefficient. The core of a PTC circuit is the PTC thermistor, which is divided into two main categories: ceramic PTC and polymer PTC. Its circuit performance, stability, and lifespan directly depend on the high-precision spraying quality of the electrode conductive layer and insulating protective layer. Chifei ultrasonic spraying machines, with their core advantages of high precision, low damage, and high adaptability, perfectly meet the precision spraying needs of various PTC circuits, solving the pain points of traditional spraying processes. They provide core equipment support for the large-scale, high-quality mass production of PTC circuits, contributing to the upgrading and improvement of my country’s electronic component industry.

The core characteristic of PTC circuits is the use of the temperature sensitivity of PTC thermistors for circuit protection. Their precise structure and diverse application scenarios place extremely high standards on the spraying process. When a PTC thermistor exceeds a certain temperature (Curie temperature), its resistance increases abruptly with increasing temperature. Ceramic PTCs, mainly composed of barium titanate, can withstand frequent overcurrent surges and are suitable for constant temperature heating and overheat protection scenarios. Polymer PTCs, also known as resettable fuses, automatically return to a low-resistance state after a fault is cleared and are widely used in overcurrent protection scenarios. The coating process for PTC circuits primarily involves applying coatings to the conductive electrode layer and the insulating protective layer. The core requirements focus on three main aspects: First, high uniformity coating, ensuring a uniform, dense, and gapless coating thickness to guarantee stable electrode conductivity and prevent localized resistance anomalies from affecting the temperature response sensitivity of the PTC thermistor. Second, low-damage adaptation, as PTC circuits have delicate structures; ceramic PTCs are brittle, and polymer PTCs are easily damaged. The coating process requires low pressure and temperature control throughout to avoid high-pressure impacts or high temperatures that could damage the circuit structure and thermistor characteristics. Third, high compatibility, adapting to different types of PTC circuits, including ceramic and polymer PTCs, and accommodating the tiny electrode gaps of different circuit specifications to meet the coating requirements of miniaturized and high-density layouts in electronic devices.

Currently, in the field of PTC circuit coating, traditional coating processes (brush coating, high-pressure gas atomization spraying, and manual coating) have many shortcomings, making it difficult to adapt to their precision structure and the demands of large-scale mass production, thus becoming a bottleneck restricting the industry’s quality and efficiency improvement. Brush coating requires highly skilled operators, suffers from poor coating uniformity, and is prone to defects such as missed areas and runs, leading to poor contact of PTC circuit electrodes and affecting overcurrent protection. High-pressure gas atomization spraying is prone to uneven droplet size and large coating thickness deviations. High-pressure airflow can damage the thermal characteristics of PTC thermistors, introduce micro-dust impurities, and reduce circuit insulation performance, resulting in material utilization of only 25%-35%, which is insufficient to meet the coating requirements of miniaturized PTC circuits. Manual coating is inefficient, produces poor coating consistency, and is prone to contamination, making it unsuitable for large-scale mass production. Furthermore, it is difficult to control coating thickness, leading to inconsistent temperature response sensitivity of PTC circuits and increasing the trial-and-error costs of process optimization for enterprises.

Chifei Ultrasonic Spray Coating Machine addresses the characteristics, diverse needs, and pain points of traditional spraying methods for PTC circuits. Leveraging its core high-frequency ultrasonic atomization technology and combining key aspects of PTC circuit manufacturing processes, it creates customized solutions that completely break through the bottlenecks of traditional processes. The equipment converts industrial frequency electricity into a 40-150kHz high-frequency electrical signal using an ultrasonic generator. This signal is then converted into high-frequency mechanical vibration by a piezoelectric ceramic transducer. Utilizing the ultrasonic cavitation effect, conductive and insulating slurries are atomized into fine droplets of 0.01-2 microns. This effectively deagglomerates particle clusters in the slurry, precisely controls the solvent evaporation rate, and ensures a uniform, fine, dense, and void-free coating. This perfectly matches the coating requirements of the conductive and insulating protective layers of PTC circuit electrodes, guaranteeing stable conductivity and insulation performance without affecting the temperature response sensitivity of the PTC thermistor.

The atomization process is conducted under low pressure and temperature control throughout. The droplets are gently deposited on the surface and tiny gaps of the PTC circuit, guided only by a small amount of carrier gas. There is no mechanical contact or high-pressure impact, which does not damage the structural integrity of the ceramic PTC or the thermosensitive properties of the polymer PTC. Spraying parameters can be flexibly adjusted to adapt to different types of PTC circuits, including ceramic and polymer PTCs. It provides seamless coating for circuits of different specifications, allowing for seamless integration into automated, large-scale production lines. For the coating needs of PTC circuits, Chifei ultrasonic spray coating machines demonstrate four core advantages, helping enterprises achieve large-scale, high-quality mass production.

Firstly, ultra-precise and uniform coating, with a coating uniformity of over 99% and a thickness deviation of ≤±1%, effectively avoids defects such as missed coating and sagging, ensuring good contact of PTC circuit electrodes and ensuring sensitive temperature response of thermistors, solving the pain point of uneven coating in traditional processes.
Secondly, low-damage protection, low-pressure gentle atomization technology avoids damage to PTC thermistors and circuit structure, balancing coating adhesion and circuit integrity, significantly improving product yield.
Thirdly, high material utilization, reaching over 95%, significantly reduces waste of expensive conductive and insulating pastes, lowers PTC circuit manufacturing costs, and meets the economic needs of large-scale industrial production.
Fourthly, excellent mass production adaptability, supporting automated continuous spraying and compatibility with Class 100 cleanrooms, seamlessly integrating into large-scale PTC circuit production lines, adapting to the coating of different types and specifications of PTC circuits without dead angles, solving the problems of low efficiency, high loss, and poor consistency of traditional processes.

Currently, Chifei ultrasonic spraying machines are widely used in various PTC circuit spraying scenarios, covering core products such as ceramic PTC heating circuits and polymer PTC overcurrent protection circuits. They are compatible with applications in digital battery packs, automotive electronics, small home appliances, and communication equipment, helping domestic electronics companies solve problems such as circuit damage, low yield, and material waste caused by traditional spraying processes, achieving breakthroughs in high-quality PTC circuit manufacturing and large-scale mass production. As a leading company in the field of ultrasonic electronic equipment, Chifei Ultrasonic has been deeply involved in PTC circuit spraying for many years, closely following the trend of PTC circuits towards miniaturization and high reliability. Combined with the technological iteration needs of PTC thermistors, it can provide customized spraying solutions, covering the entire process from equipment selection and process parameter optimization to slurry adaptation.

In the future, Chifei Ultrasonic will continue to optimize equipment performance, further improve atomization accuracy and compatibility with diverse PTC circuits, helping my country’s PTC circuit industry break through technological bottlenecks and injecting strong momentum into the high-quality development of electronics, new energy, and other fields.

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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