Sonobond Ultrasonics' Welding Equipment Sets the Standard for Fast, Reliable, Environmentally-Friendly Battery Assembly

This ultrasonic technology is highly effective in welding multiple layers and/or delicate foils to tabs or terminals.

WEST CHESTER, Pennsylvania, April 2, 2009-Sonobond Ultrasonics announced today that more and more manufacturers are relying on its SonoWeld® 1600 Digital Metal Spot Welder and its Dual Head SpliceRite(TM) ultrasonic unit for ultra-dependable battery assembly. According to Melissa Alleman, Sonobond's vice president, "Our technology is especially important to companies that produce rechargeable lithium-ion batteries. These types of batteries are in high demand today because they are used in everything from laptops to cell phones and power tools to hybrid electric cars. However, manufacturing lithium-ion, as well NiMH batteries, often requires the welding of multiple layers and/or delicate foils to tabs or terminals. The SonoWeld® 1600 has the capability of welding up to 20 layers of foil. And our Dual Head SpliceRite(TM) unit extends the range to up to 80 layers of foil. It's no wonder that these two units are in heavy demand from battery manufacturers."

Superior to Conductive Adhesives

Sonobond's ultrasonic welding technology creates a fast, durable bond without using heat, current, fluxes, or fillers. As a result, there are no costs related to consumables and no post-assembly cleaning requirements. Instead, the patented Wedge-Reed coupling system directs high frequency ultrasonic energy to the metals being welded. The energy disperses the oxides and surface films between the work pieces to create a true metallurgical bond without melting the materials. The process is completed in a single operation and takes only seconds. There is no damage to foils or mesh.

The SonoWeld® 1600 Digital Metal Spot Welder-which is available in 1500 and 2500 power levels-is highly effective in welding dissimilar metals to tabs or terminals. It confidently accommodates copper, aluminum, lithium, nickel, and other non-ferrous materials. The resulting bonds have greater electrical conductivity and weld strength than those created by conductive adhesives. In addition to lithium-ion and NiMH batteries, the SonoWeld® 1600 can be used to assemble pouch cells and for a variety of other terminal-joining operations.

At the same time, the Dual Head SpliceRite(TM) ultrasonic unit-which comes with a 3500 watt power supply-is also ideal for use by battery assemblers. That's because of its unique technology. Like the SonoWeld® 1600, this unit uses the patented Wedge Reed System. But, as the name suggests, the Dual Head SpliceRite(TM) has two welding heads, one on each side of the weld area. This increases its welding capacity, enabling the unit to confidently process up to 80 levels of foil.

Up to 250 Weld Protocols

Both units are capable of storing and recalling up to 250 weld protocols with their microprocessor controllers. Weld parameters can be set by time, total energy, or final weld thickness. And both units have taper lock tips that can perform up to 100,000 or more welds prior to easy removal and replacement.

In commenting on this technology, Vice President Alleman says, "We work closely with our customers to customize our units to their needs. We also offer a free Ultrasonic Welding Viability Test so battery assemblers and others can be confident that our technology is right for their specific applications. Sonobond units are easy to operate with only minimal training. Equally important, we back our technology with superior technical support and excellent customer service."

A Leader in Ultrasonic Welding Technology

Sonobond is a worldwide leader in the application of ultrasonic welding and bonding technology. In 1960, Sonobond-then known as Aeroprojects-received the first patent ever awarded for ultrasonic metal welding. During the intervening 49 years, Sonobond has earned an outstanding reputation for its pioneering work and quality-engineered products. Today, Sonobond manufactures a complete line of ultrasonic bonding and welding equipment for a wide variety of customers in the automotive, appliance, electrical, HVAC, aerospace, filtration, medical, and apparel industries.

Additional Information

Additional information about Sonobond's products and its free, no obligation Ultrasonic Welding Viability Test is available by visiting the company's website at or by calling 800-323-1269.

The Sonobond SonoWeld® 1600 Digital Ultrasonic Spot Welder is ideal for use by battery assemblers. It is also very effective in welding dissimilar metals to tabs or terminals.

The SonoWeld® 1600 and the Dual Head SpliceRite(TM) can weld multiple and/or delicate foils. Both units create durable bonds without using heat, fluxes, or fillers.

1191 McDermott Drive,
West Chester,
PA 19380
Phone: 610-696-4710
Fax: 610-692-0674

Melissa Alleman
Vice President

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