Characteristic Analysis Of The RPS-SONIC Full Series Of Atomizing Nozzles

Based on the core principle of ultrasonic atomization, RPS-SONIC has developed four core series of atomizing nozzles to meet the application needs of different industries and scenarios: wide-area coating type, focused coating type, flux type, and high-temperature type. Customization services are also available. Each series has been specifically optimized in terms of structural design and performance parameters, retaining the general advantages of ultrasonic atomization while possessing unique core characteristics. The following analysis, based on their working mechanisms, examines the unique features of each series.

 

2.1 Wide-Area Coating Type Ultrasonic Atomizing Nozzle (RPS-SONIC Core Series)

The wide-area coating type nozzle is RPS-SONIC's most widely used series. Its core positioning is "large-area, uniform coating." Its working characteristics revolve around "expanding the atomization range and ensuring coating uniformity," perfectly adapting to the processing of large substrates such as float glass coating, non-woven fabric spraying, and metal/plastic sheet coating.

 

From a working principle perspective, this series of nozzles employs a "wide airflow channel" structure in its atomizing tip design, coupled with an auxiliary air inlet (guide air inlet), to significantly expand the atomization range. After droplets are generated from the atomizing tip, the auxiliary airflow (pressure 0.1-0.5MPa) is ejected at high speed (20-50m/s) from the airflow channel, creating a "shearing effect" on the droplets. This further refines the droplets (from 5-10μm in pure ultrasonic atomization to 1-5μm), preventing droplet aggregation. Simultaneously, the airflow provides directional thrust to the droplets, expanding the atomization range from less than 30cm in pure ultrasonic atomization to 0.5-2m, forming a uniform fan-shaped spray.

 

2.2 Focused Coating Type Ultrasonic Atomizing Nozzle (Specifically for Precision Applications)
The focused coating type nozzle is primarily designed for atomization needs requiring "high precision and small area," such as photoresist coating on semiconductor wafers, coating on drug-eluting stents, and spraying on blood collection tubes. Its operating characteristics revolve around "precise orientation, micro-droplets, and thin coating," making it a core product of RPS-SONIC in the precision manufacturing and biomedical fields.

 

From a working mechanism perspective, this series of nozzles employs a "conical focusing design" at the atomization tip, highly concentrating vibrational energy in a tiny area at the tip. This results in a thinner liquid film (5-50μm) and more uniform capillary standing wave wavelength, leading to smaller droplets (1-30μm, precisely controllable via frequency). Furthermore, the droplets exhibit extremely strong directionality, with the spray range controllable between a few millimeters and tens of millimeters, achieving precise "point-to-point" atomization.

 

Furthermore, this series of nozzles can be paired with XYZ three-axis or XYZ-rotary axis motion systems to achieve precise coating on complex curved surfaces, such as curved surface spraying for medical devices and uniform full-area coating for semiconductor wafers. The coating thickness can be controlled between 0.5-10μm, with no pinholes or drips, significantly improving product performance and yield. RPS-SONIC also offers customization services for this series, designing the atomizing tip size and spray angle according to the customer's specific application scenario to meet individual needs.

 

2.3 Flux-Type Ultrasonic Atomizing Nozzle (Electronics Industry Exclusive) The flux-type nozzle is an exclusive product from RPS-SONIC for the electronics industry (PCB circuit boards, semiconductor packaging). Its core requirement is "precise flux spraying to avoid bridging and cold solder joints." Its working characteristics revolve around "adapting to flux characteristics, preventing clogging, and precise positioning," solving the industry pain points of "severe overspray, frequent clogging, and inaccurate positioning" in traditional flux spraying.

 

From a working principle perspective, flux typically possesses a certain viscosity and corrosiveness, and contains a small amount of solid components. Traditional pressure nozzles with their small orifice diameters are prone to clogging. However, the RPS-SONIC flux-type nozzle employs a "large-diameter liquid channel (1-5mm) + high-frequency vibration self-cleaning" design, fundamentally solving the clogging problem. High-frequency vibration continuously cleans residual flux and solid particles from the inner wall of the channel, eliminating the need for frequent disassembly and cleaning even during prolonged continuous operation.

 

Furthermore, this series of nozzles supports both intermittent and continuous spray modes, allowing for flexible adjustments to match the production line's rhythm. Simultaneously, the nozzle's corrosion-resistant design (titanium alloy tip + fluororubber seals) effectively resists flux corrosion, extending equipment lifespan and meeting the continuous production needs of the electronics industry.

 

2.4 High-Temperature Ultrasonic Atomizing Nozzle (Suitable for Special Environments)

From a working mechanism perspective, high-temperature environments severely impact the performance of piezoelectric transducers and amplitude transformers-high temperatures weaken or even damage the piezoelectric effect of the piezoelectric ceramics, while also accelerating the oxidation and deformation of metal components. To address this, RPS-SONIC has comprehensively optimized its high-temperature nozzles for enhanced high-temperature resistance: the piezoelectric transducer utilizes high-temperature resistant piezoelectric ceramic material, enabling stable operation in environments ranging from -40℃ to 200℃; the amplitude transformer is made of high-temperature resistant titanium alloy with an anti-oxidation coating to prevent high-temperature oxidation; and the atomizing tip incorporates a cooling channel that circulates cooling media to reduce tip temperature and prevent liquid overheating and deterioration at the tip.

2.5 RPS-SONIC Customized Atomizing Nozzles (Personalized Fit)

In addition to its four standard series, RPS-SONIC offers comprehensive customization services, a core competitive advantage. Based on the business philosophy of "not blindly promoting products, but finding suitable products for customers," RPS-SONIC's technical team designs targeted nozzles according to the customer's specific application scenarios (such as liquid type, atomization requirements, environmental conditions, and flow rate requirements). Customization is available for everything from the shape of the atomizing tip, frequency range, and liquid channel size to the generator power and control mode.

 

For example, to meet the needs of nanomaterial spraying, high-frequency (120-180kHz) atomizing nozzles can be customized to achieve atomization of nano-sized droplets (5-10μm); for the atomization treatment of high-viscosity wastewater, high-flow-rate, low-frequency (20-40kHz) nozzles can be customized, combined with heating functions to reduce wastewater viscosity and improve atomization efficiency; for small laboratory scenarios, compact nozzles can be customized, with a small size for easy integration into experimental equipment. Furthermore, RPS-SONIC provides free solution design, sample testing, and technical guidance for customized products to ensure that the products are fully adapted to the customer's application needs.