Demand Is Increasing for Assembling Batteries with Sonobond's Ultrasonic Metal Welders

The SonoWeld® 1600 Ultrasonic Digital Metal Spot Welder and Dual Head Ultrasonic Spot Welder are ideal for attaching multiple layers of foil to battery tabs and terminals. In fact, the Dual Head is the only ultrasonic spot welder capable of welding up to 80 layers of foil with just one pulse.

WEST CHESTER, Pennsylvania - Vice President Melissa Alleman announced today that battery assemblers will have an excellent opportunity to learn more about Sonobond's ultrasonic bonding equipment, November 13-15 in Novi, Michigan.

In commenting on her company's participation in the 2012 Battery Show, she
said, "This upcoming conference and exhibition will be a leading showcase for
advanced battery technology. Sonobond is looking forward to taking part because our
ultrasonic spot welders play a significant role in so many battery assembly applications."

"The worldwide demand for batteries is increasing rapidly and new developments
are taking place all the time. For example, there is an ever expanding use of lithium-ion and NiMH rechargeable batteries in consumer products such as laptops, cordless and
cell phones, video game controls, and toys. There is also a big demand for batteries
used in all-electric and hybrid automobiles. And, of course, there are growing
requirements for advanced energy storage solutions for utility and renewable energy
support, medical technology, military use, and telecommunications. Sonobond has the
equipment that is used so effectively to assemble many of these products."

Ultrasonic Spot Welding Equipment for Battery Assemblers

Vice President Alleman went on to say, "I invite those attending the 2012 Battery
Show to come to Booth #B768 to learn more about our fast, dependable,
environmentally-friendly equipment that has so much to offer battery assemblers."

"Sonobond has two ultrasonic spot welders that are of particular importance to the battery industry. Our SonoWeld® 1600 Digital Metal Spot Welder-which we will have on display at the show-is ideal for most battery assembly needs. It is used by leading battery assemblers to provide a practical, cost-effective way to weld multiple layers and/or delicate foils to tabs or terminals. A second Sonobond machine, the Dual Head
Ultrasonic Metal Spot Welder, is perfect for applications where a high number of layers need to be attached. The Dual Head can weld up to 80 layers of foil without tearing them. No other ultrasonic metal spot welder can do this with a single pulse."

Fast, Reliable Welds

Both the SonoWeld 1600 and the Dual Head Metal Spot Welder create durable
bonds in a single operation that takes only seconds. This is accomplished without using
heat, current, fluxes, or fillers. No arcs, sparks, or fumes are produced and there is no melting of the weldment.

Sonobond's SonoWeld 1600 Series is an easy-to-use, ultrasonic metal welding
system with multi-function capabilities. It uses outputs of 1,500 or 2,500 watts of power to weld non-ferrous similar or dissimilar assemblies, including copper to aluminum. The SonoWeld 1600 is perfect for welding multiple layers and/or delicate foils to tabs or terminals for lithium-ion and NiMH battery assembly. This equipment can confidently accommodate up to 20 layers of foil. It is also used in assembling pouch cells.

Sonobond's Dual Head Spot Welder features two ultrasonic welding heads, one
on either side of the welding area. This machine is ideal for advanced battery and
super capacitor applications that may require up to 80 layers of foil to be welded to tabs or terminals. The Dual Head Spot Welder is the only ultrasonic metal spot welder
that has this capability.

Both Sonobond machines have a power supply with a built-in microprocessor. This permits storage and recall of over 250 weld protocols and features automatic
frequency control and overload protection. A digital display also allows weld parameters to be selected by time, energy, or distance. In addition, both of these ultrasonic metal welders feature heat-treated Taper Lock Tips that can perform up to 100,000 welds. These tips are designed for fast, convenient removal and replacement. Like all Sonobond equipment, the SonoWeld 1600 and the Dual Head Spot Welder can be operated easily with only minimal training.

Sonobond's Wedge-Reed System Delivers Big Advantages

All of Sonobond's metal spot welders-including the SonoWeld 1600 and the
Dual Head-are made in the U.S.A. They feature the unique, patented Wedge-Reed
bonding system of high vibratory force and low amplitude coupling. Sheer mode
vibration, parallel to the welding surface, is utilized while the line of force is directly over the parts to be welded. This creates true metallurgical bonds that are precise and dependable. There is no bending stress or stalling. This is also the only ultrasonic system capable of providing one-pulse welding of most oxidized and tinned metals without pre-cleaning.

Free Ultrasonic Welding Viability Test

Vice President Alleman invites companies to take advantage of Sonobond's free
Ultrasonic Welding Viability Test for their specific application. She says, "This is a
convenient way for a manufacturer to confirm that our machine is right for their
particular requirements. All they need to do is provide their non-ferrous materials to us so we can make sample welds. There is no cost or obligation involved in utilizing this valuable Sonobond service"

"Once a decision is made to incorporate our equipment into their production
process, we will work closely with company personnel to ensure that the installation is
completed as seamlessly as possible. Customers can count on us for excellent service
and top-quality technical support-before, during, and after installation of our

Over a Half-Century of Industry Leadership

Sonobond is recognized worldwide for its application of ultrasonic welding and
bonding technology. In 1960, the company-then known as Aeroprojects-received the
first patent ever awarded for ultrasonic metal welding. In the 52 years since then,
Sonobond has established and maintained a well-earned reputation for its pioneering
work and quality-engineered products. Today the company manufactures a complete
line of ultrasonic welding and bonding equipment. Among Sonobond's many customers
are leading firms in the electrical, automotive, appliance, solar, aerospace, filtration, medical, and apparel industries.

Additional Information

In summarizing Sonobond's participation in the 2012 Battery Show, Ms. Alleman
says, "Exhibition attendees are encouraged to visit us at Booth #B768. We will have the
SonoWeld 1600 on hand for them to see. And we will be pleased to answer questions
about the ways this machine, as well as our Dual Head Metal Spot Welder, can provide
dependable, cost-effective solutions for their battery assembly requirements."

For additional information about Sonobond's products or to learn about its free,
no obligation Ultrasonic Welding Viability Test, visit the company's website at or call 800-323-1269. For immediate service, contact
Vice President Melissa Alleman at


Melissa Alleman

Vice President


All Topics