Sonobond Ultrasonics Equipment Continues to be a Popular Choice of Battery Assemblers

The SonoWeld® 1600 Digital Metal Spot Welder and the Dual Head Spot Welder help
assure fast, dependable, environmentally-friendly assembly of batteries and capacitors.

WEST CHESTER, Pennsylvania, - Sonobond Ultrasonics announced today that demand for its ultrasonic welding equipment continues to increase among battery and capacitor assemblers. In making the announcement, Melissa Alleman, Sonobond's Vice President, said, "Our ultrasonic technology is ideal for battery applications. For example, our SonoWeld® 1600 Digital Metal Spot Welder is important in the production of lithium-ion and NiMH rechargeable batteries. And our Dual Head Spot Welder is of particular significance in applications that involve welding up to 80 layers of foil to terminals without tearing the delicate foils. Both units complete these functions ultrasonically in one fast, cost-effective step. So it's not surprising that there is
such demand for these welders from battery assemblers."

Multiple Battery Assembly Applications

Various configurations of lithium-ion and NiMH rechargeable batteries are used
today in the production of laptops, cell phones, power tools, hybrid electric cars, and
other technology. The manufacturing process for these batteries often requires that
multiple layers and/or delicate foils be welded to tabs or terminals. The SonoWeld®
1600 and the Dual Head Spot Welder help assemblers accomplish these tasks quickly and

Sonobond's SonoWeld® 1600 is able to weld up to 20 layers of foil, while the
Dual Head Spot Welder can confidently process as many as 80 layers. Everything is
accomplished in a single operation that takes only seconds. In addition, the power
supplies for these units feature a built-in microprocessor which permits storage and recall of over 250 weld protocols. A digital display allows selection of weld parameters by time, energy, or distance and features automatic frequency control and overload protection. The units have heat-treated tool steel Taper Lock Tips that are capable of performing up to 100,000 welds and are designed for easy removal and replacement.

SonoWeld® 1600 Digital Metal Spot Welder

The SonoWeld® 1600 Digital Metal Spot Welder uses outputs of 1,500 or 2,500 watts of power to weld non-ferrous similar or dissimilar metal assemblies, including copper to
aluminum. In addition to lithium-ion and NiMH batteries, this ultrasonic welder is frequently used in the assembly of pouch cells and for a variety of other terminal-joining operations. Manufacturers especially like the way the unit can be easily incorporated into automated assembly equipment.

Sonobond's Dual Head Ultrasonic Metal Spot Welder

True to its name, the Dual Head Metal Spot Welder has two ultrasonic welding heads-one on each side of the welding area. The microprocessor-controlled, 3,500-watt unit produces an ultrareliable, solid-state metallurgical bond. This is accomplished in one step without arcs, sparks, or fumes and without melting the weldment.

More and more companies in the battery and capacitor industry rely on the Dual
Head Metal Spot Welder as a fast, cost-effective way to weld multiple layers of foil. The unit has been successful in welding together up to 80 layers of delicate foil-as well as foil to terminal-without tearing. By means of special tooling, the unit is able to extend the range for welding even lightly tinned or oxidized wires to terminals.

Patented "Wedge-Reed" System Creates True Metallurgical Bonds

Both the SonoWeld® 1600 Digital Metal Spot Welder and the Dual Head Ultrasonic Metal Spot Welder create durable bonds without using heat, current, fluxes, or fillers. So there are no costs for consumables or for post-assembly cleaning. Instead, the patented Wedge-Reed coupling system directs high-frequency ultrasonic energy to the
metals being welded via a welding tip. The applied vibratory energy disperses the oxides and surface films at the weld. The resulting metallurgical bond is very reliable, has high conductivity, and is created without damage to foils or mesh.

Free Ultrasonic Viability Test

In further discussing the advantages of the two units, Vice President Alleman
says, "We are proud of our Sonobond technology and the important role these two
ultrasonic welders play in the battery and capacitor field. But that is only part of the story. Sonobond works closely with its customers to deliver the very finest technical support and customer service before, during, and after installation. We gladly provide a free Ultrasonic Welding Viability Test to assure that our technology is right for a company's specific application. And we work with manufacturers to customize our units to their individual requirements."

Like other Sonobond units, both the SonoWeld® 1600 Spot Welder and the Dual Head Spot Welder are easy to operate with only minimal training.

50 Years of Technological Leadership

Sonobond is a worldwide leader in the 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. Over the intervening 50 years,
Sonobond has established and maintained a well-earned reputation for its pioneering
work and quality-engineered products. Today Sonobond manufactures a complete line of
ultrasonic welding and bonding equipment. Among the company's many customers are leading firms in the electrical, automotive, appliance, solar, aerospace, filtration, medical, and apparel industries.

Additional Information

For additional information about Sonobond's products or to learn about their 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

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